Documente Academic
Documente Profesional
Documente Cultură
thickness 7
7.1 Choosing a line size
7.1.1 General considerations
The fluid flow equations presented in Chapter 6 enable the engineer to initiate the
design of a piping or pipeline system, where the pressure drop available governs
the selection of the pipe size. When choosing a line size, it is necessary to evaluate
both pressure drop and flow velocity for expected maximum and minimum flow rates
anticipated during the life of the facility. It is usually advisable to add surge factors to
the expected flow rates to ensure there is sufficient pressure available to force the fluid
through the piping system. Surges can be a function of line length and elevation
changes. Table 7.1, based on data originally included in API RP 14E, presents some
typical surge factors that may be used if more definite information is not available.
The line diameter must be large enough so that the available pressure is sufficient
to drive the fluid through the line from point 1 to point 2. Therefore, its important
the operating pressures at the various points of the facility must be known. In most
cases, the pressure drop is not the governing criterion in production facility piping
system design since most of the pressure drop occurs across control valves. The pres-
sure drop in the line is relatively small compared with the pressure available in the
system.
Consideration should also be given to maximum and minimum velocities. The line
should be sized such that the maximum velocity of the fluid does not cause erosion,
excess noise, or water hammer. The line should be sized such that the minimum veloc-
ity of the fluid prevents surging and keeps the line swept clear of entrained solids and
liquids.
Ce
Ve 1:22 1
(7.1a)
2
Surface Production Operations. http://dx.doi.org/10.1016/B978-1-85617-808-2.00007-9
Copyright 2016 Elsevier Inc. All rights reserved.
472 Surface Production Operations
SI units:
Ce
Ve 1
(7.1b)
2
where
Ve erosional flow velocity (ft./s (m3/s)),
density of liquid (lb/ft.3 (kg/m3)),
Ce empirical constant, dimensionless.
Where solids and/or corrosive contaminants are present or where C values higher
than 100 for continuous service are used, periodic surveys to assess pipe wall thickness
should be considered. The design of any piping system where solids are anticipated
should consider the installation of sand probes, cushion flow tees, and a minimum
of three feet of straight piping downstream of choke outlets.
SI units:
2
3 KW Vp
vol 9:806 10 (7.2b)
gPh
where
vol volume of metal eroded (in.3 (mm3)),
Vp particle velocity (ft./s (m/s)),
Ph penetration hardness of the material (psi (kPa)),
a value between 0.5 and 1.0 depending upon the impingement angle of the particle,
K erosive wear coefficient, dimensionless,
W total weight of impinging solid particles (lbs (kg)),
g acceleration of gravity (32.2 ft./s2 (9.81 m/s2)).
The form of this equation indicates that there is no threshold below which erosion does
not occur. Instead, erosion can occur even at small velocities, and the amount of ero-
sion increases with the square of the velocity. It can be seen from Equation 7.2 that the
velocity for a given erosion rate is a function of 1/W. Since the percent of solids
impinging on any surface is inversely proportional to the density of the fluid, the ero-
sional velocity can be expected to be proportional to the fluid density. This is contrary
to the form of Equation 7.1. Thus, it is not correct to use Equation 7.1 with low C
value when solids are present.
The rate of erosion depends on both the concentration of solids in the flow stream
and the way in which these particles impinge on the wall. At an ell, one would expect
centrifugal force to cause a high percentage of the particles to impinge on the wall in a
concentrated area. It can be shown that with a solids concentration of 10 lbs/month
(4.5 kg/month) in the flow stream, the velocity for a 10 miles/year (0.25 mm/year)
erosion rate in an ell can be as low as 5 ft./s (1.5 m/s). At higher concentrations, the
erosional velocity would be even lower. For this reason, where sand production is
474 Surface Production Operations
Outlet
Bull plug or
weld cap
Inlet
7.1.3.2 Velocity
7.1.3.2.1 Maximum velocity
Maximum velocity: The maximum velocity is used in sizing liquid lines and depends
on service conditions, pipe materials, and economics. For example, API RP14E rec-
ommends that the maximum velocity not exceed 15 ft./s (4.5 m/s). Most companies
specify the following maximum velocities:
l
Cement-lined pipe: 8-10 ft./s (2.4-3.0 m/s)
l
Fiberglass pipe: 12-15 ft./s (3.7-4.5 m/s)
l
Where erosion corrosion is a problem: 10-15 ft./s (3.0-4.5 m/s)
Even lower maximum velocities may be used for cement-lined pipe, where erosion
corrosion is anticipated, or in water injection lines.
Q1
V 0:012 (7.3a)
d2
SI units:
Q1
V 353:68 (7.3b)
d2
476 Surface Production Operations
)
4
61
Maximum
0.
=
(ID
Liquid flow velocity, ft. / s
7)
95
0.
)
8
=
27
)
(ID
23 )
)
1.
2.
= .125
)
)
)
50
6
=
(ID 39
0
3
1.
(ID
82
90
(ID = 2
9
=
3.
1.
2.
)
5
(ID
=
=
06
(ID
(ID
(ID
6.
)
1
=
98
(ID
)
7.
Minimum
.0
25 8 )
(ID
10
)
(ID = 1 .93
0
=
50 )
11
(ID
.2 0
3.
)
=
17 25
(ID
= 5.
1
(ID
(ID =
Liquid flow rate, barrels fluid per day
Figure 7.3 Liquid flow velocity as a function of liquid flow rate for different pipe sizes.
(Courtesy of API RP 14E)
where
V average velocity (ft./s (m/s)),
Ql liquid flow rate (BPD (m3/h)),
d pipe inside diameter (in. (mm)).
Derivation of Equation 7.3a (field units):
Converting velocity into oil field units,
Q
V
A
and
d 2
A
4144
5:61
Q QL
243600
substituting
Q1
V 0:012 (7.3a)
d2
Choosing a line size and wall thickness 477
where
V fluid velocity (ft./s),
QL liquid flow rate (BPD),
Q liquid flow rate (ft.3/s),
A pipe cross-sectional area (ft.2),
d pipe inside diameter (in.).
1260STfQ2g
d5 (7.4a)
PP=100ft:
SI units:
STfQ2g
d 5 8:186 105 (7.4b)
PP=100ft:
where
d pipe inside diameter (in. (mm)),
S specific gravity of gas relative to air,
478 Surface Production Operations
T temperature (R (K)),
fm Moody friction factor, dimensionless,
Qg gas flow rate (MMSCFD (m3/h)),
P pressure (psia (kPa)),
P/100 ft. desired pressure drop per 100 ft. (psi (kPa)).
7.1.4.2 Velocity
7.1.4.2.1 Maximum velocity
Maximum velocity: The gas velocity should be kept below 60-80 ft./s (18-24 m/s)
so as to minimize noise and to allow for corrosion inhibition. In systems with CO2
present in amounts as low as 1-2%, many operators limit the velocity to less than
30-50 ft./s (9-15 m/s). Field experience indicates that it is difficult to inhibit to inhibit
CO2 corrosion at higher velocities.
1
TZ 2
Ve 0:6 Ce (7.5a)
SP
SI units:
1
TZ 2
Ve 0:644 Ce (7.5b)
SP
where
Ve erosional velocity (ft./s (m/s)),
Ce empirical constant, dimensionless,
T temperature (R (K)),
S specific gravity of gas relative to air,
P pressure (psi (kPa)),
Z gas compressibility factor.
For most instances, with pressures less than 1000-2000 psi (7000-14,000 kPa), the
erosional velocity will be greater than 60 ft./s (18 m/s), and thus, the erosional criteria
will not govern. At high pressures, it may be necessary to check for erosional velocity
before sizing lines for 60 ft./s (18 m/s) maximum velocity.
Gas velocity can be determined from Equation 7.6:
Field units:
Qg TZ
Ve 60 (7.6a)
d2 P
SI units:
Qg TZ
Vg 122:7 (7.6b)
d2 P
where
Qg gas flow rate (MMSCFD (std m3/h)),
T temperature (R (K)),
d pipe inside diameter (in. (mm)),
P pressure (psia (kPa)),
Vg gas velocity (ft./s (m/s)),
Z gas compressibility factor.
480 Surface Production Operations
d 2
A
4144
1 106 SCF day h 14:7 TZ
Q Qg
MMSCF 24h 3600s P 520
substituting
60Qg TZ
V (7.6a)
d2 P
where
Qg gas flow rate (MMSCFD),
Q gas flow rate (ft.3/s),
A pipe cross-sectional area (ft.2),
V gas velocity (ft./s),
Z gas compressibility factor, dimensionless,
P pressure (psia),
T temperature (R),
d pipe inside diameter (in.).
7.1.5.2 Velocity
7.1.5.2.1 Minimum velocity
Minimum velocity: A minimum velocity of 10-15 ft./s (3-4.5 m/s) is recommended so
as to keep liquids moving in the line and to minimize slugging of separator or other
process equipment. This is very important in long lines with elevation changes.
Ce
Ve 1
(7.7a)
m 2
SI units:
Ce
Ve 1:22 1
(7.7b)
m 2
where
Ve erosional flow velocity (ft./s (m/s)),
C empirical constant, dimensionless,
m mixture density (lb/ft.3 (kg/m3)).
It can be shown that the minimum cross-sectional area of pipe for a maximum allow-
able velocity can be expressed as
Field units:
2 3
ZRT
9:35 +
6 21:25P7
a4 5Q1 (7.8a)
1000Vmax
482 Surface Production Operations
SI units:
2 3
ZRT
9:35 + 3:24
6 P 7
a 29:694 5Q1 (7.8b)
Vmax
where
a minimum required cross-sectional area (in.2 (mm2)),
Ql liquid flow rate (BPD (m3/h)),
Vmax maximum allowable velocity (ft./s (m/s)),
Z gas compressibility factor,
R gas/liquid ratio (std ft.3/bbl (std m3/m3)),
P pressure (psi (kPa)),
T temperature (oR (K)).
Equation 7.8 can be rearranged and solved for pipe inside diameter:
Field units:
2 312
ZRT
6 11:9 + 16:7P Q1 7
6 7
d6 7 (7.9a)
4 1000Vmax 5
SI units:
2 312
ZRT
6 11:9 + 4:13 Q1 7
6 16:7P 7
d 5:4486 7 (7.9b)
4 Vmax 5
Figure 7.5 is a chart developed to minimize the calculation procedure. One must be
careful when using this chart as it is based on the assumptions listed in the chart. It is
better to use Equations 7.7 and 7.9 directly as follows:
(1) Determine m.
(2) Determine the erosional velocity, Ve, from Equation 7.7.
(3) For the design, use the smaller of Ve or that velocity required by the noise or CO2 inhibition
criteria.
(4) Determine the minimum ID from Equation 7.9.
(5) Check pressure drop, if applicable, to make certain there is enough driving force available.
Derivation of Equations 7.8a and 7.9a (field units)
From previous derivations,
Q a
A and A
V 144
and
Qg TZ
Q 6:49 105 QL + 0:327
P
Choosing a line size and wall thickness 483
Figure 7.5 Gas/liquid ratio as a function of pipe cross-sectional area for different operating
pressures.
1 106 Qg
R
QL
substituting
5 RTZQL
6:49 10 QL + 0:327
106
A
V
Substituting and factoring out QL, then multiply top and bottom by 1000:
2 3
ZRT
9:35 +
6 21:25P7
a4 5Q1 (7.8a)
1000Vmax
2 32
1
ZRT
6 11:9 + Q1 7
6 16:7P 7
6
d6 7 (7.9a)
7
4 1000Vmax 5