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Summary with a tube diameter of 15 cm. For more than 10 years, a viscous
crude oil has been produced in a water-lubricated flow regime.
Heavy oils represent a large quantity of hydrocarbon resources.
Since then, several studies have been dedicated to the CAF
Unfortunately, their high viscosities make it difficult to produce
regime, and different reviews of the published work have been
and transport them. Different industrial solutions have been devel-
written in Oliemans and Ooms (1986) and Joseph et al. (1997). It
oped to transport this specific type of oil in pipelines. The most
has been shown experimentally and theoretically that this particu-
spread-out way is to blend the crude oil with a light hydrocarbon
lar flow regime is stable for a specific range of velocity (Joseph
to decrease the viscosity. In this study, we investigate a technique
et al. 1997) and produces a very small pressure drop. Below a
based on two-phase flow: pipeline lubrication. A thin water film is
certain velocity limit, the capillary instability breaks the inner core
injected around the internal oil core, which leads to the core-/
into slugs, and at rest, stratification occurs in the system. So
annular-flow (CAF) regime. Water lubricates the heavy oil, and
it is necessary to reach a certain flow rate to transport oil in the
the longitudinal pressure gradient is then largely reduced.
CAF regime. The different flow configurations of oil and water
We experimentally investigated the flow, the stop and restart of
have been investigated, and flow charts are available (Joseph and
a viscous heavy oil with coinjection of water or brine as the lu-
Renardy 1993).
bricant fluid. The tests were conducted in steady laminar flow at
From an industrial point of view, a pipeline can be used in the
moderate flow rates. The results show a pressure-drop reduction of
CAF regime by using a coinjection of oil and water in the velocity
more than 90% compared with the same product without lubrica-
range of stability. However, when the flow stops in the line, the
tion. These results confirm the effectiveness of the lubricating
CAF regime cannot be maintained. The two phases evolve to
process for heavy-oil transport.
stratified flow, and the pressure drop in that configuration is very
We also measured restart pressure with different salts in the
high compared to the CAF. Then, the stop and restart mechanisms
water phase, and we show that in some cases, the restart pressure
have to be addressed. In this paper, we study experimentally the
can be limited.
restart pressure necessary to flow a CAF line. Specifically, we
show that with modification of the lubricating-layer nature, we can
Introduction decrease the restart pressure significantly.
First, the experimental setup is described, and then the pres-
Oil flow as a single phase in a pipeline is a spread-out way of
sure-drop measurement of the water and heavy oil is presented.
transporting hydrocarbon resources for very long distances. The
Then stop and restart experiments with modification of the nature
relatively low viscosity of conventional crude oil is a key issue for
of the lubricating layer are analyzed.
such a way of transport because of low resistance to flow. For
higher viscosity, the pipe diameter can be increased or, eventually,
the mean flow velocity can be decreased. But for very high vis- Experimental Setup
cosity, large pipe and small velocity lead to a noneconomical The installation used to perform the experiments is shown in
transport technique. Fig. 1. The setup consists of a flow loop with a tank for oil storage,
Multiphase flow is also widely used now because it allows the a 12-m (total length) stainless-steel pipe with a 25-mm internal
mixing of gas, water, and oil together in a single pipe. However, diameter, a fluid injector specifically designed for pipe-wall lubri-
flowing conditions are more difficult to predict because the phase cation, and a data-acquisition system.
configurations vary. CAF is one particular two-phase-flow regime The heavy oil, stored in a tank with a 450-L capacity, is trans-
in which the oil phase is in the center of the pipe and water is ferred with a screw-type positive-displacement pump to the center
flowing near the wall surface. A very interesting characteristic of of the injector (Fig. 2), located at the inlet of the pipe. The flow
this flow is that it is stable for an acceptable range of velocities. rate is varied and controlled by the rotation speed of the pump.
The pressure drop is also very small, with only a weak dependence Water (fluid of lubrication) is drawn from a 50-L stainless-steel
on the oil viscosity. Moreover, it is well suited for heavy oils. supply tank and pumped into the annulus of the injector with a
Indeed, in this case, densities are close to the water, so stratifica- volumetric pump, ensuring the internal-pipe-wall lubrication. The
tion of the phases is limited. Moreover, high viscosities slow down ratio between the water-flow rate and the oil-flow rate is kept
the core deformation and limit any modification of the flow regime. constant during the experiment.
Properties of CAF have been observed for a long time, and Pressure drop within the pipeline is measured across a test
industrial interest was first noticed approximately 100 years ago. A section, equipped with two 6-m-long pressure sensors. A data-
1904 patent of Isaacs and Speed (Isaacs and Speed 1904) in the U.S. acquisition system coupled to a computer allows recovery of the
first mentioned the ability to transport viscous products through pressure-sensor signal and control of the pressure evolution across
“water lubrication.” Despite this early concern, large-scale industrial the test section in real time.
pipelines for heavy oil are scarce; the first one was built only in the During the tests and to observe the behavior and the efficiency
1970s. The Shell line near Bakersfield, California, was 38 km long of the lubrication process along the conduit, the variation of the
pressure drop of the heavy oil with and without lubrication is
followed and recorded in real time.
Copyright © 2007 Society of Petroleum Engineers
Fluid Characterization. For this study, a 16°API Venezuelan
This paper (SPE 97764) was first presented at the 2005 SPE International Thermal Op- heavy crude oil of moderate viscosity (4.75 Pa·s at 19°C) was used.
erations and Heavy Oil Symposium, Calgary, 1–3 November, and revised for publication.
Original manuscript received for review 29 August 2005. Revised manuscript received 26
The choice of the oil is based on two limits. First, we want a high
May 2006. Paper peer approved 1 June 2006. viscosity so that CAF is possible, but we also need to limit the
viscosity to be able to measure the pressure drop of the oil as a An example of data acquisition is given in Fig. 4 and shows the
single phase in our experimental setup. This crude oil is quite influence of the injection of water as a lubricant during the trans-
convenient for experimental studies because its viscosity is in our port of the heavy oil. The first plateau corresponds to the pumping
expected range. It should be emphasized that crude oil with a lower pressure resulting from heavy-oil flow before injection of water in
density range (less than 16°API) would be more efficient for the the pipe (9 bar). Approximately 150 seconds after the beginning of
CAF regime. A higher density and viscosity are favorable for the the test, the lubrication fluid is injected. A rapid decreasing of the
stability of CAF. pumping pressure is observed and stabilized at approximately 0.2
The rheological characterization of the oil was determined with bar after 200 seconds. The flow is then lubricated along the entire
the rotary viscometer Rheometrics RFS II.* pipe, which is a characteristic of the CAF regime. The injection of
The crude oil presents a Newtonian behavior as confirmed by the lubrication fluid is stopped after 430 seconds from the begin-
rheometric and loop measurement. Fig. 3 shows the evolution of the ning of the tests. Then, the pumping pressure increased and
shear stress vs. shear rate in a Couette viscometer and in the flow loop reached its initial value of 9 bar.
when pressure drop and mean velocity are normalized as follows: To evaluate the lubrication efficiency, we introduce the pres-
sure-drop reduction ⌬P* (%), calculated according to the follow-
D ⌬P ing relations:
= . : shear stress 共Pa兲 . . . . . . . . . . . . . . . . . . . . . . . . . . . (1)
冉 冊 冉 冊
4 L
⌬P ⌬P
.
and ␥ = 冉 冊冉 冊
32Q
=
8V
: shear rate 共s−1兲, . . . . . . . . . . . . . . . . . . (2)
L
−
L
冉 冊
1 2
⌬P* = × 100, . . . . . . . . . . . . . . . . . . . . . . . . (3)
D3 D ⌬P
where ⌬P/L= linear pressure loss (Pa/m), D⳱diameter of the con- L 1
冉 冊
duit (m), Q⳱total volumetric flow rate (m3/s), and V⳱flow ve-
⌬P
locity (m/s). where is the pressure drop of the oil without lubrica-
冉 冊
Water is used as the fluid of lubrication. The density is 1000 L 1
kg/m3, and the viscosity is 10−3 Pa·s. ⌬P
tion (bar/m) and is the pressure drop of the lubricated
L 2
Experimental Results flow (bar/m).
Pressure-Drop Reduction. The experimental procedure consists The evolution of the pressure-drop reduction ⌬P* is measured
in the measurement, in real time, of the pressure drop of the heavy- for two oil-flow rates and two water-/oil-flow-rate ratios and rep-
oil flow alone and the effect of the water addition that yields a resented in Fig. 5.
lubricated flow. The results obtained from the tests realized on the oil lubrica-
tion with water, using oil flow rates ranging from 220 to 450 L/h and
two water-/oil-flow-rate ratios of 4 and 6%, showed a pressure-drop
reduction larger than 80% and up to 98% in the best case.
* Mark of Reologica Instruments Inc., Bordentown, New Jersey. We notice that the flow loop used for these tests presents two
vertical sections and four bends, but despite these irregularities, the
CAF remains stable during the total experiment duration. So, the
Interpretation
We try in this section to give some insight concerning the different
mechanisms that have been observed experimentally.
References
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factor and holdup studies for lubricated pipelining—Experiments and
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dx.doi.org/10.1016/0301-9322(93)90078-9.
Bensakhria, A., Peysson, Y., and Antonini, G. 2004. Experimental study of
the pipeline lubrication for heavy oil transport. Oil & Gas Science and
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Huang, A., Christodoulou, C., and Joseph, D.D. 1994. Friction factor and
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http://dx.doi.org/10.1016/0301-9322(94)90022-1.
Isaacs, J.D. and Speed, J.B. 1904. Method of piping fluids. U.S. Patent No.
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