Nomenclature & abbreviations

Enhanced integrity and production of the KOC pipeline network operation through dynamic simulation

Farrukh Waheed (Process Specialist)
Kuwait Oil Company

Ray J. Davies (Head of Section) and
Tony D. Alfano (M.Sc., Project Engineer)
Asset Risk Management, Det Norske Veritas

ABSTRACT

Over the next few years production through the Kuwait Oil Company (KOC) pipeline network will be increased significantly. This means that the capacity and the integrity of the pipeline network have to be ensured. In order to do this, dynamic simulation models were built and case studies of various transient and maximum production cases were conducted.

The model scope included a vast underground network of pipelines, transporting five different hydrocarbon fluids, with a total length exceeding 3200 km. The models were implemented using a D-SPICE simulation environment. Physical pipeline data was used to parameterize the models and operational data was used to run the models to steady state. Relevant simulation scenarios, including transients, such as pump trips, shutdowns, valve closures and leakages and maximum production cases, were defined.

Based on the results from simulation case runs, the pipelines with integrity issues and pipeline network bottlenecks were identified. Actions to ensure that all the pipelines remain under maximum pressure and erosion velocity limits as well as actions solving the pipeline network bottlenecks were tested. Benefits of the simulation are illustrated with case examples of both integrity and operational issues.

It is shown that dynamic simulation is a powerful tool for planning of production changes. Through dynamic simulations, the actions required to meet the planned production targets, without sacrificing pipeline network integrity, can easily be tested and evaluated. The dynamic simulation models provide a further basis for enhancement of the pipeline integrity using a leak detection system.

Keywords: Dynamic simulation, pipeline integrity, oil and gas pipeline network, debottlenecking, industrial application.

NOMENCLATURE & ABBREVIATIONS

c	Empirical constant [ ]
pm	Fluid density [ ]
MAOP	Maximum allowed operating pressure [ ]
MAEV	Maximum allowed erosional velocity [ ]
BS	Booster Station
CMM	Central Mixing Manifold
DNV	Det Norske Veritas
D-SPACE	Kongsberg’s simulation software
GC	Gathering Center
HP	High Pressure
KOC	Kuwait Oil Company
LP	Low Pressure
NTF	North Tank Farm

INTRODUCTION

Kuwait oil company (KOC) owns and operates a vast network of hydrocarbon pipelines in the State of Kuwait. The network consists of underground pipelines with varying sizes, from 3-inch to 52-inch diameter, and the total length exceeds 3200 km. These pipelines, transferring crude oil, condensate, water, high pressure rich gas, low pressure rich gas and fuel gas, connect different Gathering Centers (GCs) and Booster Stations (BSs) through distribution manifolds to tank farms, refineries, consumers and export facilities. Due to the increasing global oil production demand, KOC is heavily expanding production. This means that ensuring sufficient transfer capacity, safety and integrity of the pipeline networks is of crucial importance. Monitoring of the fluid conditions in the pipelines is a challenge due to the limited number of measurements in the installed systems.

In continuation of KOC’s advanced efforts in the area of risk management, KOC intended to conduct an integrated risk assessment and simulation studies of their entire pipeline network. Det Norske Veritas (DNV) was awarded the contract and completed the risk assessment part of the project that consisted of data gathering, hazard identification, quantitative risk assessment and cost benefit analysis [1]. Kongsberg Oil and Gas Technologies completed the simulation study part of the project. This consisted of data gathering, dynamic modelling and simulation studies of the KOC pipeline network, and holding a simulator training course for the KOC personnel.

The overall objective of the simulation part of the project was to define the sensitivity of the KOC pipeline networks to sudden transients, such as pump trips, shutdowns, valve closures and leakages in the KOC pipeline networks. A further objective of this study was to identify areas of KOC’s pipeline networks that need debottlenecking and to determine if future production demands can be met.

METHODS

Дата добавления: 2015-10-29