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Slide 1

SS DES-05Design and Operational Study of a300 Km LPG-Pipeline System

Design and Simulation ClosingSession

José Luis Zaragoza y GutiérrezAlexander Bruce MacDonald10/16/13

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Design and Simulation ClosingSession

José Luis Zaragoza y GutiérrezAlexander Bruce MacDonald10/16/13

Supporting the Industryin Mexico

Consultoría Empresarial Ejecutiva, S.A. de C.V. (CEE)

• Engineering Consulting Firm based in Mexico City

• Founded in 1995 by chemical engineering experts in different fieldswith a solid background working at PEMEX

• CEE provides its expertise on a variety of projects in the Oil, Gas,Energy, and Petrochemical industries

• Projects range from the conceptual business development,engineering studies, planning, economic analysis, basic and detailedengineering, pre-commissioning, training, start-up, performancetests, and computer simulation, among others.

Slide 3

Consultoría Empresarial Ejecutiva, S.A. de C.V. (CEE)

• Engineering Consulting Firm based in Mexico City

• Founded in 1995 by chemical engineering experts in different fieldswith a solid background working at PEMEX

• CEE provides its expertise on a variety of projects in the Oil, Gas,Energy, and Petrochemical industries

• Projects range from the conceptual business development,engineering studies, planning, economic analysis, basic and detailedengineering, pre-commissioning, training, start-up, performancetests, and computer simulation, among others.

Outline

1. Overall Challenges and Drivers

2. Case Study Overview

3. Scope of Work

4. Simulation

a) Stage 1 – EXCEL

b) Stage 2 – PIPEPHASE + SIM4ME PORTAL

c) Stage 3 – DYNSIM

5. Benefits and Conclusions

Slide 4

1. Overall Challenges and Drivers

2. Case Study Overview

3. Scope of Work

4. Simulation

a) Stage 1 – EXCEL

b) Stage 2 – PIPEPHASE + SIM4ME PORTAL

c) Stage 3 – DYNSIM

5. Benefits and Conclusions

Overall challenges and drivers• Satisfy Mexico’s growing

LPG fuel demand;

• Historically, all existingpipeline systems havebeen owned andoperated by PEMEX

• New injection to themain LPG backbone wasthe first system to beoperated by a privatecompany

• Lack of experience tooperate a LPG-pipelineby the new owner!

• Change in the originaldesign – validate safetyand environmentalcompliance

Tuxpan

Slide 5

• Satisfy Mexico’s growingLPG fuel demand;

• Historically, all existingpipeline systems havebeen owned andoperated by PEMEX

• New injection to themain LPG backbone wasthe first system to beoperated by a privatecompany

• Lack of experience tooperate a LPG-pipelineby the new owner!

• Change in the originaldesign – validate safetyand environmentalcompliance

Image taken fromsener.gob.mx and modified

©

Poza Rica-Atotonilco LPG Pipeline

Cactus-Guadalajara LPG Pipeline

Refinery

Gas Processing Complex

Tuxpan

Case Study OverviewKey objectives:• Analyze normal, maximum and critical operating conditions to:

• Validate design

• Minimize Capital Expenditure

• Validate a Safe Operation

• Future: Design control philosophy and define start-up procedures

SteadyState andDynamic

SimulationTools Better capital

expendituredecisions

(up to $20M)Increase safetyon the operation

and more…

Slide 6

Key objectives:• Analyze normal, maximum and critical operating conditions to:

• Validate design

• Minimize Capital Expenditure

• Validate a Safe Operation

• Future: Design control philosophy and define start-up procedures

Expertiseand

ConsultingServices

Better capitalexpenditure

decisions(up to $20M)

Increase safetyon the operation

and more…

MecapalapaIntersection,

Puebla(km 34)

IRGEAtotonilco,

Hidalgo(km 232)

Tlautla,Hidalgo

(km 251)

San Agustín,Puebla(km 72)

Cima de Togo,Hidalgo

(km 108)km 1.78

Poza Rica(produced LPG) Cactus-Guadalajara

LPG-Pipeline

Scope of Work

32 km 38 km 36 km 124 km 19 km

10’’ Pipeline with a total length of: 324 km

EB01 EB02 EB03 EB04

AtotonilcoHidalgo

Slide 7

km 0

Tuxpan,(imported LPG)

Tula RefineryEB01A

• 5 pump stations (cap.: 20,000 / 40,000 bpd)

• Pipeline burried 2 - 5 ft

• 25 sectioning + 10 check valves

• Minimum pressure limit: 14 kg/cm2g (200 psig)

• Maximum pressure limit: 100 kg/cm2g (1422 psig)

Poza RicaVeracruz

1,250 data points wereused to mirror the actual

pipeline profile

Specific Objectives 1st Phase

• Analyze…– Maximum/normal/minimum/critical operating conditions at different

scenarios (e.g.: temperature, flow, pressure).– System malfunctions (e.g.: pump failure, valve failure, pipeline rupture,

fluid hammer).– Abrupt flow, temperature and pressure variations.

… to• Confirm the need of an additional pipeline in segment EB01A-

Mecapalapa or propose an alternative solution• Validate the design and location of pumping stations• Validate the control strategy to protect the pumps and the entire

system

Slide 8

• Analyze…– Maximum/normal/minimum/critical operating conditions at different

scenarios (e.g.: temperature, flow, pressure).– System malfunctions (e.g.: pump failure, valve failure, pipeline rupture,

fluid hammer).– Abrupt flow, temperature and pressure variations.

… to• Confirm the need of an additional pipeline in segment EB01A-

Mecapalapa or propose an alternative solution• Validate the design and location of pumping stations• Validate the control strategy to protect the pumps and the entire

system

Simulation StagesStages

Assumptions/Simplifications

Advantages Disadvantages

1 – EXCEL • Steady-State

• Isothermal

• Readily available

• Simple to program

• (Almost) instantaneous

results

• Not rigorous (very

preliminary results)

• Limited by size of

the spreadsheet

2 – PIPEPHASE

+ SIM4ME

PORTAL

• Steady-State

• Non-Isothermal

• Rigorous

• Friendly interface


results

• Not in real time

• Cannot analyze the

control system

Slide 9

2 – PIPEPHASE

+ SIM4ME

PORTAL

• Steady-State

• Non-Isothermal

• Rigorous



results

• Not in real time

• Cannot analyze the

control system

3 – DYNSIM • Dynamic

• Non-isothermal

• More rigorous


• Control system analysis

in real time

• Malfunction analysis in

real time

• Speed of calculations

limted by computer’s

processing capacity

Every simulation stageget more and more

rigorous.

Excel

Simulation Stage 1Steady State – Isothermal


Steady-State, Isothermal Modeling

Slide 11

Screenshots of the Excel Simulator

Slide 12

The pressure drop of one segmentfor a given flow

Slide 13

Discharge Pressure Analysis

Minimum Pump Discharge Pressure (kg/cm2g)

FlowScenarios

(1000 BPD)EB01 EB01A EB02 EB03 EB04

Poza Rica:Tuxpan:

200 81.2 - 81.5 45.8 51.1

Slide 14

Poza Rica:Tuxpan:

020 - 86.3 81.5 45.8 51.1

Poza Rica:Tuxpan:

2020 90.2 95.3 90.0 74.8 52.2

Poza Rica:Tuxpan:

040 - 110.5 90.0 75.0 52.2

Pressure Drop vs Flow

Slide 15

PIPEPHASE + SIM4ME PORTALSimulation Stage 2:Steady State – Non-isothermal


PIPEPHASE considerations:

Pipe length, diameter, thickness, elevation change Fluid Composition Thermodynamics Pressure drop correlation Pump operating curves (flow rate, head, efficiency). Set point Exact location of devices Heat transfer Fluids Mixture

Slide 17

Pipe length, diameter, thickness, elevation change Fluid Composition Thermodynamics Pressure drop correlation Pump operating curves (flow rate, head, efficiency). Set point Exact location of devices Heat transfer Fluids Mixture

SIM4ME PORTAL

• Interface between Invensyssimulation software and EXCEL

• It has a lot of applications

• In our particular case, it wasused to create a simple,intuitive simulator built-inEXCEL for a non-experienceduser in PIPEPHASE.

• It brings the best of bothworlds together:

− The rigorousness ofPIPEPHASE

− The familiarity of EXCEL

Slide 18

• Interface between Invensyssimulation software and EXCEL

• It has a lot of applications

• In our particular case, it wasused to create a simple,intuitive simulator built-inEXCEL for a non-experienceduser in PIPEPHASE.

• It brings the best of bothworlds together:

− The rigorousness ofPIPEPHASE

− The familiarity of EXCEL

SIM4ME PORTAL SimulatorScreenshot of data input:

• Source flows

• Source temperatures

• Source pressures

• Source compositions

Slide 19

Screenshot of data output:

• Sink flows

• Sink temperatures

• Sink pressures

• Sink compositions

SIM4ME PORTAL SimulatorScreenshot of data input and output:

Pumpsuctionpressureanddischargepressure

Notes

Link to seepump curves

Slide 20

Pipelinesegmentpressuredrops

Convergenceindicator

Links to seepressureprofiles

SIM4ME PORTAL Simulator

0

200

400

600

800

1,000

1,200

1,400

0

500

1,000

1,500

2,000

2,500

3,000

0+214

2+768

5+089

6+536

8+435

9+769

11+806

13+649

14+997

16+971

18+856

20+504

22+252

24+423

26+311

28+036

30+249

32+940

37+025

40+761

42+853

46+378

50+064

52+551

55+225

57+172

59+269

60+991

61+649

62+513

63+220

64+319

67+318

69+391

70+736

72+917

74+998

77+146

79+042

80+883

81+646

82+829

86+191

88+816

91+455

93+519

96+006

99+705

102+654

104+371

105+989

110+285

116+857

122+001

126+847

133+274

143+898

151+618

161+454

173+896

179+482

183+394

188+570

197+178

209+064

219+487

223+725

228+297

235+659

243+159

Presión (psig)Elevación (m)

Perfil de Elevación y PresionesPoza Rica - Tlautla

EB-01

Poza Rica

EB-02

EB-03

EB-04

Presion

Elevación

Screenshot of data output:Pipeline elevation and pressure profiles

Slide 21

0

200

400

600

800

1,000

1,200

1,400

0

500

1,000

1,500

2,000

2,500

3,000

0+214

2+768

5+089

6+536

8+435

9+769

11+806

13+649

14+997

16+971

18+856

20+504

22+252

24+423

26+311

28+036

30+249

32+940

37+025

40+761

42+853

46+378

50+064

52+551

55+225

57+172

59+269

60+991

61+649

62+513

63+220

64+319

67+318

69+391

70+736

72+917

74+998

77+146

79+042

80+883

81+646

82+829

86+191

88+816

91+455

93+519

96+006

99+705

102+654

104+371

105+989

110+285

116+857

122+001

126+847

133+274

143+898

151+618

161+454

173+896

179+482

183+394

188+570

197+178

209+064

219+487

223+725

228+297

235+659

243+159

Presión (psig)Elevación (m)

Perfil de Elevación y PresionesPoza Rica - Tlautla

EB-01

Poza Rica

EB-02

EB-03

EB-04

Presion

Elevación

Comparison Between EXCEL andPIPEPHASE Steady-State Simulations

‘‘We need heuristic reasoning when we construct a strictproof as we need scaffolding when we erect a building…Heuristic reasoning is good in itself. What is bad is tomix up heuristic reasoning with rigorous proof. What isworse is to sell heuristic reasoning for rigorous proof’’.

- George Polya

How to Solve It (1945)

• The results obtained with EXCEL and PIPEPHASE are very similar inthis particular case.

So why bother?…

Slide 22

‘‘We need heuristic reasoning when we construct a strictproof as we need scaffolding when we erect a building…Heuristic reasoning is good in itself. What is bad is tomix up heuristic reasoning with rigorous proof. What isworse is to sell heuristic reasoning for rigorous proof’’.

- George Polya

How to Solve It (1945)

DYNAMIC SIMULATION - DYNSIMSimulation Stage 3:Dynamic – Non-isothermal


DYNSIM considers…

Everything PIPEPHASE takes into account plus…

• Time varying effect• Calculations performed every 0.25 seconds at every point

• Controllers (tuning constants, algorithm, limits)

• Control valves

• Equipment detailed data

• Operations constraints

• Malfunctions

Slide 24

Everything PIPEPHASE takes into account plus…

• Time varying effect• Calculations performed every 0.25 seconds at every point

• Controllers (tuning constants, algorithm, limits)

• Control valves

• Equipment detailed data

• Operations constraints

• Malfunctions

Cool Features

• Snapshots – Initial Conditions

• Trends

• Data Historian

• Cross Reference

Slide 25

• Snapshots – Initial Conditions

• Trends

• Data Historian

• Cross Reference

Visualizing the Results

Theinformationsaved via theDATAHISTORIANwas furtheranalyzed withMATLAB.

Videos wererecorded foreachsimulatedscenario.

Slide 26

Theinformationsaved via theDATAHISTORIANwas furtheranalyzed withMATLAB.

Videos wererecorded foreachsimulatedscenario.

Benefits and Conclusions


MecapalapaIntersection,

Puebla(km 34)

IRGEAtotonilco,

Hidalgo(km 232)

Tlautla,Hidalgo

(km 251)

San Agustín,Puebla(km 72)

Cima de Togo,Hidalgo

(km 108)km 1.78

Poza Rica(produced LPG) Cactus-Guadalajara

LPG-Pipeline

Benefits of using simulation

32 km 38 km 36 km 124 km 19 km

10’’ Pipeline with a total length of: 324 km

EB01 EB02 EB03 EB04

Slide 28

km 0

Tuxpan,(imported LPG)

Tula RefineryEB01A

• An additional pipeline was not needed

• Problem can be solved adding a pump station in

Mecapalapa

• Control valves at pump discharge were also

necessary

Benefits of Using PIPEPHASE

• Steady State Simulation - PIPEPHASE

− A parallel pipeline was not necessary, and the high pressureproblem can be solved by installing an intermediate pumpingstation in Mecapalapa… saved a huge capital investment… ≈20million USD!

− We were able to identify critical points at different operationconditions very easily and quickly

• Confirm that the selected pumps were adequate

• Evaluate the effects of changing T, P, F, and zi at the sources

• Select an adequate set point for the controllers so that the systemfunctions properly and safely.

• Allow other users with minimal or null experience in PIPEPHASE to runsimulations via the PIPEPHASE-EXCEL interface created with SIM4MEPORTAL.

Slide 29

• Steady State Simulation - PIPEPHASE

− A parallel pipeline was not necessary, and the high pressureproblem can be solved by installing an intermediate pumpingstation in Mecapalapa… saved a huge capital investment… ≈20million USD!

− We were able to identify critical points at different operationconditions very easily and quickly

• Confirm that the selected pumps were adequate

• Evaluate the effects of changing T, P, F, and zi at the sources

• Select an adequate set point for the controllers so that the systemfunctions properly and safely.

• Allow other users with minimal or null experience in PIPEPHASE to runsimulations via the PIPEPHASE-EXCEL interface created with SIM4MEPORTAL.

Benefits of using DYNSIM

• Identify that control valves at discharge were also necessary – avoiddamage to very critical and expensive equipment (justify theinvestment of the study)

• Preliminary tuning of the controllers; it is better to find out potentialerrors on the simulator than in real life.

• Locate critical points for critical scenarios and estimate the availableresponse time before dangerous conditions are reached.

• The Operation Philosophy can be designed, tested, and re-designed(if necessary) so that it is quantitatively proven to be effective andefficient… We’re testing on the computer and not in the field.

• Ability to connect to an HMI (Excel), so the operators can be trainedon a software based solution instead of the real DCS; it is better tolearn from mistakes on a simulator than in real life.

Slide 30

• Identify that control valves at discharge were also necessary – avoiddamage to very critical and expensive equipment (justify theinvestment of the study)

• Preliminary tuning of the controllers; it is better to find out potentialerrors on the simulator than in real life.

• Locate critical points for critical scenarios and estimate the availableresponse time before dangerous conditions are reached.

• The Operation Philosophy can be designed, tested, and re-designed(if necessary) so that it is quantitatively proven to be effective andefficient… We’re testing on the computer and not in the field.

• Ability to connect to an HMI (Excel), so the operators can be trainedon a software based solution instead of the real DCS; it is better tolearn from mistakes on a simulator than in real life.

Conclusions• The less simplifications a user makes, the more accurate the

simulation becomes… but simplifications are necessary to get started.

• Computer simulation is not a task in itself; it’s a tool which allows youto properly complete a task… Computer simulation is just tooimportant to be isolated from other project tasks!

• Simulators help in identifying and understanding to a greater extentthe system’s critical variables; and in doing so, also help in optimizingthe system’s configuration, equipment and operating conditions.

• It’s better to learn from mistakes made in a simulator than mistakesmade in real life.

• Computer simulators complement an engineer’s sound judgement.

Slide 31

• The less simplifications a user makes, the more accurate thesimulation becomes… but simplifications are necessary to get started.

• Computer simulation is not a task in itself; it’s a tool which allows youto properly complete a task… Computer simulation is just tooimportant to be isolated from other project tasks!

• Simulators help in identifying and understanding to a greater extentthe system’s critical variables; and in doing so, also help in optimizingthe system’s configuration, equipment and operating conditions.

• It’s better to learn from mistakes made in a simulator than mistakesmade in real life.

• Computer simulators complement an engineer’s sound judgement.

Next Steps – 2nd Phase

In the future the simulation model can be used to:• Establish the start-up protocols.• Establish the Control Philosophy and Safety Philosophy that:

– Maintains optimum conditions.– Prevents and fixes the malfunctions.

• Train and evaluate technical operators and process engineers.

Slide 32

In the future the simulation model can be used to:• Establish the start-up protocols.• Establish the Control Philosophy and Safety Philosophy that:

– Maintains optimum conditions.– Prevents and fixes the malfunctions.

• Train and evaluate technical operators and process engineers.

Teamwork!

Invensys

Simulation tools(PIPEPHASE,

SIM4ME PORTAL,DYNSIM)

CEE

Experience, background,operational expertise,

sound judgement

PEOPLE

Slide 33

Invensys

Training ,Technical Support

and Service

CEE

End user relationship(understanding the

client’s needs)

PEOPLE

Please Send Your Questions AndComments To:

Consultoría Empresarial Ejecutiva, S.A. de C.V.

José Luis Zaragoza y Gutiérrez [email protected]

Alexander Bruce MacDonald [email protected]

Invensys

Lourdes Reyes [email protected]

Gerardo Yañez [email protected]

Slide 34

Consultoría Empresarial Ejecutiva, S.A. de C.V.

José Luis Zaragoza y Gutiérrez [email protected]

Alexander Bruce MacDonald [email protected]

Invensys

Lourdes Reyes [email protected]

Gerardo Yañez [email protected]

Slide 35

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