2-phase Flow Technology - Introduction

Session Objectives

Marine Pipelines - Hydraulics - 2

Understand the potential of Multi-phase Transport Systems

& the associated complexity

2-phase Flow Technology - Introduction

Topics

Gert van Spronsen - Pipelines

Status Multiphase flow

Shell Global Solutions International (SGSI) - Rijswijk

Email :
Tel :

Two-phase parameters
Models and validation

Dynamic simulation: when to use it

Gert.vanSpronsen@shell.com
+31 70 447 3427

2009 Shell Global Solutions International B.V. All rights reserved. Do not distribute without consent of copyright owner

2-phase Flow - Introduction

Multiphase Applications in Production Systems

Two-phase Flow Definition

Simultaneous Flow of Hydrocarbon Liquid & Gas
through a Single Conduit

Crude oil - below bubble point

Natural gas below dew point (Retrograde condensation)

Increase Application range

Production system modelling
Transient simulations
Transport untreated wellstream

3-Phase flow - HC Liquid, Water & Gas

Reduce costs
3

2-phase Flow - Introduction

Improve integrity / safety

Den Helder Slugcatcher 1000 m3

Two-phase Flow - the Key issues

Two-phase flow
Simultaneous flow of Hydrocarbon Gas & Liquid
Why bother
Centralize /reduce processing facilities
Key problem
Liquid arrival pattern (rate & quantity)
Technical Objective
Minimise liquid storage capacity at minimum operational constraints
5

2-phase Flow - Introduction

Slugcatcher - 5000 m3

Nigeria Slugcatcher, 1100 m3

2-phase Flow - Introduction

Multiphase Flow Calculations

Phase Diagram - Typical

Dense Phase
Region

Include:

Critical Point

Criconden Bar

Thermodynamics

Liquid
Region

Phase behaviour of HC Liquid & Gas

10

0%

P/L Inlet
60

80

iq
ui
d
nt
L

Criconden
Therm
20

ol
a

Pressure drop & liquid Hold-up

er
ce

Multiphase Correlations

Vapour
Region

i nt

rP

Pressure

Po

and

bl e
ub

40

P/L Outlet

%
0%

w
De

Po

t
in

B
Temperature
9

10

2-phase Flow - Introduction

2-phase Flow - Introduction

Phase Envelope - Example (2)

Phase Envelope - Example (3)

0 % Liquid

Liquid percentages

0 % Liquid

1 % Liquid

150

2 % Liquid

2 % Liquid

3 % Liquid
5 % Liquid
10 % Liquid
100

20 % Liquid
50 % Liquid

5%

3%

100 % Liquid

3 % Liquid
5 % Liquid
100

10 % Liquid
20 % Liquid
50 % Liquid

P&T - 6 mmNm3/d

50

1 % Liquid

150

Pressure (bar)

Pressure (bar)

Hydrate Curve

200

200

50

100 % Liquid

P&T - 4 mmNm3/d

Hydrate Curve

P&T - 2 mmNm3/d

- all in Mol %

- all in Mol %
0

0
-1 0 0

-5 0

50

100

-1 0 0

150

-5 0

50

100

150

Temperature (DegC)

Temperature (DegC)
11

2-phase Flow - Introduction

12

2-phase Flow - Introduction

Two-Phase Parameters Total Pipeline Hold-up

Multiphase Transport Concept

Annular dispersed

Gas is normally the demand variable

Gas flow

Liquid flows - as result of gas/liquid

interface forces

Less gas flow

Total hold-up

Total liquid contained in the pipeline at any given time

- determined by pressure drop

Stratified wavy

more liquid stays behind in pipeline

increase in hold-up

HL = Total Pipeline Hold-up (m3)

Note:
Normally calculated at steady state, but takes time to accumulate

Slug / Intermittent flow

13

14

2-phase Flow - Introduction

2-phase Flow - Introduction

Two-Phase Parameters - HL

Two-Phase Parameters -

Liquid hold-up (fraction) HL (Area of pipe segment filled with liquid)

Fractional

Due to liquid friction losses & elevation effects (on top of P & T)

Varies

Hold-up is normally more than the Liquid Volume Fraction

Liquid volume fraction -

Varies along the pipe with changing P & T

Liquid Volume Fraction is normally less than the fractional Hold-up

along the pipeline

Fluid dynamics in addition to Thermodynamics

(liquid fraction of total fluid flowing)

No liquid friction losses & elevation effects (on top of P & T)

Determined by Thermodynamic Equilibrium of the HC stream

- No influence from Fluid dynamics

A
L =H
L
A

AL

- In general Vl < Vg
- For homogeneous fluids (Vl = Vg) -> hold-up =
15

2-phase Flow - Introduction

QG =

Flowing volume, actual m3/s of gas

QL =

Flowing volume, actual m3/s of liquid

16

2-phase Flow - Introduction

Hold-up - Summary

Liquid flows mainly as a result of gas/liquid interface forces

Fractional Hold-up varies along the pipeline

Two-Phase Flow Regimes &

Flow pattern map

Thermodynamic effects (P&T) & Fluid Dynamics

Vertical
flow

Annular Dispersed / Mist

Forces to move liquid

Interfacial forces & gravity in down hill sections

Forces to slowdown liquid

Friction with pipewall & gravity for uphill sections

Stratified Wavy

Fg

Increased
gas loading

annular / mist

dispersed bubble

100

Slug (Intermittent)

Lower liquid velocity => increased liquid hold-up in the pipeline

10-1
FLOWLINES

10-2

Thus:

intermittent
(slug)

GAS TRUNKLINES

stratified wavy

Lower gas velocities

> higher liquid hold-up

Uphill sections

101

10-3

Dispersed Bubble

stratified smooth
GAS

> higher liquid hold-up

100

10-4
10-3

LIQUID

10-2

10-1

100

101

102

103

Increased
liquid loading

Horizontal flow
17

18

2-phase Flow - Introduction

2-phase Flow - Introduction

Two-phase Flow Pipeline

- Inlet Pressure - Outlet Pressure fixed at 65 bar

Two-phase Flow Pipeline

- Liquid Volume in Pipeline

- Steady Operation

140
14,000

36 inch
inch
36

36
36 inch
inch

38
38 inch
inch

Liquid Hold-up (m3)

Pressure (bar)

38
38 inch
inch

40
40 inch
inch

120

100

Liquid head
dominates the dP

80

At low flow
more liquid to
manage

12,000

40
40 inch
inch

10,000

8,000

Stability point, i.e. Minimum Flowrate

60
0

10

20

30

40

50

6,000

60

10

19

2-phase Flow - Introduction

20

30

40

50

60

Flowrate (mmsm3/d)

Flowrate (mmsm3/d)

20

2-phase Flow - Introduction

Pressure Loss - Model vs. Actual

Liquid Hold-up - Model vs. Actual

Pressure loss

Bar
27.6

Liquid volume
in line

L = 108 km

PSIA

D = 20 inch

400

~10 % liquid
20.7

L = 108 km

bbl/ x 10

6359

40

4769

30

D = 20 inch
~10 % liquid

300

Measured
13.8

Calculated KSLA

200

3180

Measured

20

Calculated

Calculated KSLA
6.9

Measured

100

3.5
1.3

100

200

300

2.7

5.4

8.1

1590

MMscf/d Gas
flow
m 3 x 10 rate
6

10

795
21

1.3

100

200

300

2.7

5.4

8.1

2-phase Flow - Introduction

2-phase Flow - Introduction

Bacton (UK) - Multi-Phase Testloop

Bacton (UK) - Multi-Phase Testloop

MMscf/d Gas
flow
6
m 3 x 10 rate

22

Dimensions:

8 inch, 150 m
0, 1, 3 & 5 inclination

Fluids

Gas & condensate

Flowrates:

Gas 0 - 10 m/s
Liquid 0 - 2 m/s

Pressure
Liquid

- 70 bar
fraction 0 - 1

Model verification
at
field conditions
24

2-phase Flow - Introduction

Scientific Instruments in Test Section

Bacton Testloop - Flow visualisation

Gas flow

Viewing Section

Wave Characteristics Meter

Video

low - 1 m/s

Hold-up Meter

8 Conductivity probes with different lengths

arranged radially under different angles

3 Neutron back
scattering probes.
Equally spaced over
the circumference Pressure

Neutron
Reflector

Glass Liner

Liquid flow

Tap
Temperature
(PT 100)

very low

low

0.1 m/s

0.3 m/s

Detector Neutron
Source

Gas flow
low

Reference
Probe

Pressure
Equalizer

Light
Source

Optical
Cable

high

2 m/s

Saphire
Pressure
Window

7 m/s
Liquid flow

medium ~1 m/s
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2-phase Flow - Introduction

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2-phase Flow - Introduction

Flow Visualisation a specific 450 km, 36 pipeline

Liquid

- KP 200
- 650 mmscf/d
- 58 barg @outlet

flowrate

- KP 320
-960 mmscf/d
- 47 barg @outlet

- KP 450
- 650 mmscf/d
- 58 barg @outlet

3 m/s

5 m/s

- KP 450
- 900 mmscf/d
- 58 barg @outlet
6 m/s

- KP 450
- 960 mmscf/d
- 47 barg @outlet
8.5 m/s

Bacton
Testloop
Flow
Visualisation

a specific operating window

Gas flowrate

10

Gas velocity (m/s)

27

2-phase Flow - Introduction

28

2-phase Flow - Introduction

Liquid Distribution in a Pipe - Bacton Testloop

Improvements in Two-Phase Modelling

Large scale Experiments

Accurate information on:

Friction losses

Liquid wetting - Corrosion

backed up by

Improved theory
10

Vsl=
1.0 m/s

0.2
0.07
0.02

0.4

old boundar
y
stratified

r + mis

0.5

intermittent
1

annula

Superficial liquid velocity, m/s

0.1

This removes conservatism and ensures:

Accurate Pressure drop & Hold-up prediction
Extended reach of multi-phase Pipelines

0.01
0.1

gas flow was constant at Vsg = 7.0 m/s

liquid flows Vsl were at different rates as indicated

10

Superficial gas velocity, m/s

Smaller slugcatcher & less constraints

29

30

2-phase Flow - Introduction

2-phase Flow - Introduction

Multiphase Modelling Aims

Steady State & Dynamic Simulation

- when to use what

To reduce cost and maximise revenue by:

Extending range of multiphase developments

Concentrating processing on one site

Minimising operational margins

Thorough understanding of Multiphase flow behaviour

- & developing modelling tools based on:

Steady state modelling always essential:

Allows rigorous checking of all options and concepts

Define operating window

Provide base case

Far simpler and quicker to use: cheaper

Use Dynamic Modelling to:

First principle mathematical / physical models

Check steady state & transients assumptions

Calibrating with experimental data

Develop operating envelopes

Validating with field data

Train operators on how the pipeline system will respond

Off / On line tool for operation optimisation

31

2-phase Flow - Introduction

32

2-phase Flow - Introduction

Dynamic Simulation - Applications & Predictions

Applications:

Dynamic Modelling in the Project Phases

Design

Sizing of pipeline & liquid handling facilities

Selection of thermal insulation

Operation

Development of operational strategies

Liquid management systems off-& online

Safety

Predictions:

Conceptual Design

Check key assumptions as made with steady state calculations

Detailed Design
Detailed Steady State & Transient Calculations
Pipeline System Principle Operational Modes Established

and contingency analysis

Training

Project Execution - before start-up

Liquid

production during a change of operation, depressurisation, etc

Cooling during shut-down, depressurisation, etc
Size of slugs (severe / hilly terrain)
Spillage of fluids during pipeline ruptures

Pipeline Operational Envelope & Procedures completed, Operator training

Dedicated Pipeline Operational Model (off-line) required?

Operational Assistance during operations

Maximise capacity, minimise start-up periods
On-line Operational Support should always be justified specifically

33

2-phase Flow - Introduction

34

2-phase Flow - Introduction

Point of Concern
Dont forget the basics

Use sophisticated simulations programs

only if justified by
standard calculation packages
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sometimes used for convenience where reference is made to these companies in general, or where no useful purpose is served by identifying a particular company.

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2-phase Flow - Introduction

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2-phase Flow - Introduction