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Economic Justification
to processing Fluid Flow Heat Transfer Fluid Properties Chemical Treatment Integrated Analysis
1
The Challenge of Flow Assurance
Design Objectives
10000 Adequate throughput capacity for life of field production
Pressure (psi)
6000 WELLBORE
Insulation
4000 Heating
PIPELINE
Asphaltene
Boosting
Bubble Point
2000
RISER
0
Platform
0 50 100 150 200 250
2
Temperature (°F)
Course Outline
3
A. Fluid Flow Fundamentals
4
Single Phase Flow
5
Momentum Balance
From the Law of Energy Conservation:
B
L
A
φ
6
Example A1 – Pipeline Pressure Gradients
Determine the pressure at B, when the pressure at A is 1000 psi
B
D = 12 inch L = 10,000 ft
A v = 25 ft/sec
Φ = 5 deg
ρ = 5 lb/ft3
f = 0.01
7
Friction Factor
8
Example A2 – Friction Factor
Find the friction factor in a 12-inch gas transmission pipeline, given the following
data: v = 25 ft/sec, D = 12 inch, Є = 0.0018 inch, ρ = 5 lb/ft3, μ = 0.01 cp
Determine the friction factor for a 12-inch heavy oil pipeline, given
the following :
v = 1 ft/sec, D = 12 inch, Є = 0.0018 inch, ρ = 60 lb/ft^3, μ = 30 cp
10
Terminology
Symbol Definition
f Friction factor
ρ Density (lb/ft^3)
v Velocity (ft/sec)
P Pressure (psi)
Re Reynolds number
11
B. Multiphase Flow Fundamentals
12
Basic Concepts of Two-Phase Flow
τwG
Gas Phase (with Liquid Entrainment) AG
VG τi
Diameter
VL τi
Liquid Phase (with Gas Bubbles) AL
hL
τwL
Slippage = vG - vL Holdup HL = AL / (AL + AG)
Extending Single Phase Flow:
New concept of holdup HL as the volumetric liquid phase fraction and HL ns as the no-slip
holdup
HL ns = qL / (qL + qG ) where qL and qG the phase volumetric flow rates at in situ conditions
Significant slippage between phases (gas is faster, except for downhill flow)
HL > HL ns
Frictional pressure gradient much higher (due to interfacial shear τi)
Velocity of wave propagation is orders of magnitude slower
Distribution of phases based on prevailing flow pattern (dependent on geometry, in situ rates,
fluid properties)
Concept of superficial phase velocities:
13
and Mixture Velocity, vm = vSL + vSG
Example B1: Multiphase Flow Parameters
Given an average holdup of 0.25, predict all relevant multiphase flow parameters
in a horizontal 3-inch ID flowline operating at a pressure of 147 psia and 100 deg
F producing 1000 BPD at a GOR of 1000 SCF/BBL. Use an average
compressibility factor of 0.9 and assume that none of the gas is in solution.
Area = π D2 / 4 = (3.14) x ( 3/12)2 /4= 0.049 ft2
QL = 1000 BPD x 5.615 (ft3/bbl) / 86400 (sec/day) = 0.065 ft3/sec @ Std conditions
Assuming incompressible liquid, qL= QL = 0.065 ft3/sec
QG = 1000 BPD x 1000 (SCF/bbl) / 86400 (sec/day) = 11.574 ft/sec @ Std conditions
qG = QG x Pstd / (P/z) x (T + 460) / (Tstd+ 460)
= 11.574 x (14.7 / (147/0.9)) x (460+100) / 520 = 1.122 ft3/sec
v SL = qL/ Area = 0.065 / 0.049 = 1.3 ft/sec
v SG = qG / Area = 1.122 / 0.049 = 17.3 ft/sec
HL ns = qL / (qL + qG ) = 0.065 / (0.065 + 1.122) = 0.055
vL = vSL / HL = 1.3 / 0.25 = 5.3 ft/sec
vG = vSG / (1 – HL) = 17.3 / 0.75 = 23 ft/sec
Vertical Flow
Bubble (Bubbly and Dispersed Bubble)
Intermittent (Slug & Churn)
Annular
Inclined Flow
Upward Inclination (see Vertical Flow)
Downward Inclination (see Horizontal Flow)
Flow pattern boundaries may vary significantly with even slight changes in inclination
angle. As such, empirical horizontal and vertical pattern maps are not suitable for
predicting flow patterns in a pipe or wellbore where the inclination deviates by even a few
degrees from vertical/horizontal. Computer-generated mechanistic models that rigorously
account for inclination (e.g. Barnea et al) are more appropriate for such predictions.
15
Horizontal Flow Patterns
Stratified Flow
• at low flow rates the liquid and gas separated due to gravity Mandhane Map
• at low gas velocities the liquid surface is smooth, (stratified (Empirical)
smooth)
• at higher gas velocities, the liquid surface becomes wavy, Dispersed
Flow
Well Flow
Taitel-Dukler-Barnea Model
(Mechanistic)
Vertical Pipe Flow Patterns
Superficial Liquid Velocity (m/s2)
DISPERSED BUBBLE
BARNEA
BUBBLY
TRANSITON
ANNULAR
SLUG OR CHURN
SuperficialLiquid
Superficial Liquid
Gas Velocity
Velocity
Velocity (m/s22)) 2)
(m/s
(m/s
17
Example B2: Predicting Flow Pattern
Procedure:
From inclination angle, determine appropriate prediction map to use
Estimate in situ rates from standard production rates
Compute superficial phase velocities
Predict flow pattern from map
where:
frictional gradient = - f TP ρ TP vTP |vTP| / (2 gc D)
elevation gradient = - ρs g/ gc . Sin φ
kinetic energy gradient = - ρTP v TP . dv TP /dL
19
Recommendations
Multiphase Flow Correlations
(from Chevron Pipeline Design Manual)
Pressure Drop
Near Horizontal General Modeling Guidelines
Low GOR - Beggs & Brill
Gas/Condensate
High Velocity – Eaton-Oliemans Liquid holdup accuracy requires detailed pipeline elevation profile
Low Velocity – None
Near Vertical Flow pattern-dependent mechanistic analysis is required for
Gas/Condensate – Gray, Hagedorn & Brown accurate holdup prediction
Gas/Oil - Hagedorn & Brown
Inclined Up - Beggs & Brill (fair) Pressure profile is dependent on holdup accuracy (elevation
Inclined/Vertical Down – None (Beggs & Brill with caution) gradient)
Flow Patterns
Near Horizontal – Taitel-Dukler (except Dispersed-Bubble
boundary where a fixed VSL = 10 ft/sec is recommended)
Near Vertical – Taitel-Dukler-Barnea
20
Terminology
Symbol Definition
VL , VG Phase velocities (ft/sec)
HL Liquid Holdup
HL ns No slip holdup
Subscript Definition
L, G, O, W Liquid, Gas, Oil, Water
i, w Interface, wall
std Standard conditions (60 °F, 14.7 psia)
TP Two-phase
ns No slip
m mixture
21
C. Multiphase Phenomena in Flow Assurance
Slugging phenomena
22
Modeling Multiphase Flow Behavior
1 2 3 4 5 6 7 8
HL P T FP HL P T FP HL P T FP HL P T FP HL P T FP HL P T FP HL P T FP HL P T FP
Path 1
A
Path 2
B
Common Uncertainties:
Flow pattern boundaries are not fully understood (and “blurry”)
Holdup predictions do not scale up well for large diameter pipes
Pressure drop error could be as high as 20 percent
Errors greater for rough terrain, extreme velocities (high or low)
26
Factors Impacting Corrosion / Erosion
Where
27 ρns = ρL . HL + (1 – HL) ρG
Hydrodynamic Slugging
Hydrodynamic slugs are generated at moderate liquid and gas rates (see flow pattern
map) and are a common occurrence in most multiphase flowlines.
Slug Length Prediction
A. Prudhoe Bay Model (Brill et al)
Mean slug length (ft) is given by:
Liquid Holdup
3) Determine gas and liquid phase velocities from holdup
HLst
4) Determine slug frequency (slug/hr) from:
Liquid Holdup
Lm = exp(- 3.579 + 7.075 (ln(D)) 0.5+ 0.059 ln(Vm) – 0.7712 ln(D)) = 247 ft
HLst
From Hill & Wood (BP) Model:
Slug Factor = (HL - HL,bubble) / (HL,slug - HL,bubble) = (0.5 – 0.2) / (0.83 – 0.2) = 0.47
Mean slug length (for Hill & Wood model) Ls = 0.47 x 9 / (100 / 3600) = 154 ft
Slug Frequency (for Brill et al Prudhoe Bay model) = 3600 * 0.47 * 9 / 247 = 62 slug/hr
29
Terminology
Symbol Definition
30
D. Thermodynamics
31
Single Component (Average) Properties for
Oil, Gas, and Water
To be able to solve the oil or gas problems, pressure-volume-
temperature (PVT) relationships and physical properties of gases, and
liquids are essential.
To get these properties, one can define a multi-component fluid system
compositionally, or just as Liquid, Gas, and Water mixture based on the
overall measurable data.
The Gas Oil Ratio, and Water Cut are easy to measure in the field.
32
Ideal Gas Law
PV=nRT
where
p = absolute pressure, psia
V = volume, ft3
T = absolute temperature, °R
n = number of moles of gas, lb-mole
R = the universal gas constant which, for the above units, has the
value 10.730 psia ft3/lb-mole °R
n = m/ MW
PV = ( m / MW ) R T
where
m = weight of Gas, lb
MW = Molecular Weight of the Gas
ρg = m / V = (P MW) / (R T)
where
ρg = Density of gas, lb/ft3
PV=znRT
34
Black Oil and Empirical Models
Black Oil Model is where the phase behavior of the mixture is based on
experimentally derived prediction methods of gas and liquid phases for
bubble point pressure, solution GOR, FVF, and viscosity.
• The relative gravity of the oil, gas, and water phase are required.
• All three phase gravities has to be known even if they are not expected to be
present in the mixture.
Empirical Models predict the fluid properties that will define the behavior of
the fluid mixture with changes in Pressure and Temperature.
• Gas Compressibility
• Solution Gas Oil Ratio
• Oil, Water Formation Volume Factor
• Gas, Oil densities
• Gas, Oil Viscosities
35
Gas Compressibility
• Standing-Katz
Tpr= T/Tpc where Tpc = Σ (yi*Tci)
Ppr= P/Ppc where Ppc = Σ (yi*Pci)
SGgas=0.687461379
37
Procedure for Predicting Gas Compressibility
Procedure
Calculate the Apparent Molecular Weight of the gas Mg =Σ (yi*Mi) 19.93 lb/lb-mol
Calculate the Specific Gravity of the gas SGg Mg / Mair 0.688
Calculate the Pseudo Critical temperature Tpc = Σ (yi*Tci) 404 °F
Calculate the Pseudo Critical Pressure Ppc = Σ (yi*Pci) 779 psia
Calculate the Pseudo Reduced Temperature Tpr = T/Tpc
1.36 °F
Calculate the Pseudo Reduced Temperature Ppr = P/Ppc 1.54 psia
Read the corresponding Compressibility Factor from
the Standing and Katz Chart z-factor 0.75
A=(yH2S+yco2) 0.187
B
= yH2S 0.17
Calculate the Adjusted Pseudo Critical Temperature T’pc = Tpc- ε 363 °F
Calculate the Adjusted Pseudo Critical Pressure P’pc = (Ppc* T’pc)/(Tpc+B(1-B)*ε 690.6 psia
Recalculate the Pseudo Reduced Temperature and
the Pseudo Reduced Pressure using the adjusted Pseudo Critical T and P
T’pr 1.51 °F
P’pr 1.75 psia
Read the Gas Compressibility Factor from
38 the Standing and Katz chart z-factor 0.82
Solution Gas Oil Ratio
• Solution Gas Oil Ratio (Rs )
The bubble point pressure equation is reversed to solve for the solution gas oil ratio.
When oil is reaches to surface conditions some natural gas to come out of solution due to the P
and T change. The gas/oil ratio (GOR) is defined as the ratio of the volume of gas that comes out of
solution, to the volume of oil at standard conditions.
A point to check is whether the volume of oil is measured before or after the gas comes out of
solution, since the oil volume will shrink when the gas comes out.
In fact gas coming out of solution and oil volume shrinkage will happen at many stages of the flow
while the hydrocarbon stream from reservoir through the wellbore and processing plant to export.
• Lasater
for Rs≤Rp Rs = [ (379.3*35*ϒo,,sc)/Mo]/[ϒg /(1-ϒg ] ( suggested for °API>15
)
• Standing
for P≥1000 Rs = ( ϒg*(P*X)1.20482/ (18)1.20482 ( suggested for °API<15
)
for P<1000 Rs = ϒg*[X(P/13.36)0.93023 ]1.24082
where X = 10(1.0125API-0.00091T)
• Vazquez-Beggs
for API≤30 Rs =SG*(P1.0937)1011.172A
for API>30 Rs =SG*(P1.187 )1010.393A
39
where A= API/(T+460)
Oil and Water Formation Volume Factor
Oil Formation Volume Factor ( Bo)
Standing
for P < Pb Bo = 0.972 + 0.000147 * F1.175 + C
Glaso
Vazquez-Beggs
for P < Pb and API ≤30 Bo = 1+4.67x 10-4* 0.175 D*10-4 -1.8106RsD*10-8
for P > Pb and API >30 Bo = 1+4.67x 10-4* 0.175 D*10-4 -1.8106RsD*10-8
where D=(T-60)API / SG
Determine the liquid phase density for a 3 phase mixture given the
following data.
Assume oil formation volume factor is 1.2 and Rs is 100 scf/stb at insitu
conditions.
SGoil= 0.876
ρLIQ = 48.11lb/cuft
41
Composional PVT Analysis
Not only the properties of oil, gas, and water, but also the phase behavior
changes with the changes in Pressure and Temperature. The phase behavior
will determine the condensation or the evaporation of the phases, hence
determine the vapor-liquid split and the thermodynamic properties of the
phases.
42
Example D3 – Liquid Fraction
Determine the Liquid Fraction of the HC mixture from the given Phase
Diagram at the following conditions:
43
Hydrates
Gas Hydrates are formed by the C1, C2, CO2, H2S at ≈ P>166 psi
High velocity- through chokes, narrowing valves due to Joule Thompson effect
Agitation, i.e. heat exchangers, separators
Nucleation sites are the points where phase change is favored, such as:
Imperfections in the pipeline
A weld spot
Fittings
Scale
Dirt
Sand
Presence of Free Water not necessary but the gas-water interface
creates a nucleation site for hydrate to form
44
Hydrate Prediction
The point at which hydrates form is dependent on the composition of the
gas.
EXAMPLE: For a gas with a specific gravity of 0.7, and a pressure of 1000 psia, the temperature
below which hydrates would be expected to start forming would be 64ºF.
If the pressure is reduced to 200 psia, the temperature below which hydrates would
be expected to start forming reduces to 44ºF
45
Hydrate Formation Prevention
47
Methanol versus Glycol
Methanol Glycol
• Used at any Temperature • Not under 15 oF high viscosity
• Prevents hydrate formation better then • Difficult to separate from liquid HCs
DEG and EG on per lb basis • DEG has higher vaporization when <20 oF
• Injection technique not critical over EG
• Good fraction of Methanol • If not sprayed properly on the wet gas, as
evaporates into gas. fine droplets , then it may not work
• Not as economical • Diluted glycols
• Low recovery cost • Separate
• High vaporization loss • Reconcentrate
• Unless feeds into TEG unit, where • Reuse
easily recovered in the regen • Good for
• Good for • Continuous injection
• Low gas volumes • High gas volumes
• Temporary cases • Not in long lines
• Rarely needed • Do not dissolve hydrates that already
• Long flow lines formed
• Dissolves the hydrates already formed
48
Methanol Injection Problems in Facilities
• If gas feeds into a glycol plant for dehydration after methanol injection:
49
Economics -
Comparison of Hydrate Prevention Methods
Rule of Thumb:
50
Cloud Point and Pour Point Definitions
In the petroleum industry, cloud point refers to the temperature below which wax
in liquid hydrocarbon form a cloudy appearance. The presence of solidified
waxes thickens the oil and clogs.
Pour point of a liquid is the lowest temperature at which it will pour or flow
under prescribed conditions. It is a rough indication of the lowest temperature at
which oil is readily pumpable. In crude oil a high pour point is generally
associated with a high paraffin content.
51
Waxes
Waxes are :
• The organic compounds of the crude
• Insoluble in the crude at the producing conditions
• High molecular weight C18-C60 alkanes
• C18 to C36 (paraffin waxes, macrocystalline waxes)
• C30 to C60 (microcrystalline waxes),
• They are:
• aliphatic hydrocarbons (both straight and branched chain),
• aromatic hydrocarbons,
• naphthenes
• resins and asphaltenes.
• Melting point, Boiling point, and Solubility of the HC mix is profoundly
effected by the presence of alicyclic, aromatic, and condensed rings.
• Deposits as solid when the temperature falls below the cloud point
• The cloud point determines the rheology of waxy crudes
• Above the cloud point, flow is Newtonian
• Below the cloud point flow is non-Newtonian due to wax/solid
precipitation
52
Problems with Waxes
53
Formation of Wax
Wax Formation
Pressure
Wax deposits have potential to Bubble Point
54
Wax Mitigation and Prevention:
Wax Deposition Removal Techniques:
• Mechanical
Pigging - Scraping wax from the pipe wall and mixing it with the crude
in front of the pig
• Thermal
Maintaining or increasing the temperature of the crude above the WAT
can prevent wax from settling on the pipe wall, or help to remove softened
wax.
• Chemical
Chemical Solvents and Dissolvers
• substituted aromatics blended with gas oil.
• Chlorinated solvents – environmental concerns.
Wax Prevention
Wax Inhibitors
• Crystal Modifiers
• Pour Point Depressants
• Dispersants
• Surfactants
55
Wax Deposition Rate Measurements
Static cold finger A cold surface is immersed in a reservoir of oil for set Quick Simple No flow effects.
duration then removed and inspected. The surface can Small volumes of sample. Risk of depletion of wax in small
simple cooled block or finger, cooled tube or Deposit formed. sample volume.
sophisticated probe. Deposit directly inspected.
Accurate control of temperatures.
Useful inhibitor screening tool. Adaptable for live oil.
Dynamic cold finger As above but shear can be applied to flow the oil over As above Risk of depletion of wax in small
the surface. This can be achieved with stirring or Addition of shear sample volume.
immersing the surface in a flowing stream. Accurate control of shear/stress or flow Difficult to simulate pipeflow and
For better control concentric cylinders are used. velocity. turbulence.
Difficult to monitor in-situ deposition
Useful inhibitor screening and deposition until end of test.
characterization tool.
Capillary/tube blocking Warm oil is displaced through a narrow bore tube until Quick Simple No direct measure of deposit.
pressure increase indicated restriction or blockage. Small vols of sample Laminar flow regimes only.
Often used in uncontrolled cooling but better results Qualitative measure of in-situ Uncertain temperature profiles and heat
achievable with set temperature regimes. deposition rates. transfer rates.
Live oils.
Recirculating flowloops Oil is pumped through a section of pipe in which Simulates pipeflow regimes. Complex equipment.
conditions of temperature and flow can be defined. Limited sample volumes No direct measure of deposit at specific
Deposition can be detected by increasing pressure and Control of temperature and flow rate. points.
recovering of deposit. Qualitative measure of in=situ Need to recondition recirculating oil.
Useful qualitative tool for assessing deposition deposition rates/ DP insensitive in Laminar flow.
characteristic. Potential waxing outside deposition
section.
56
Cloud Point Methods
- Recommended Indirect Methods
DSC When wax crystallizes from crude oil, small Small sample size. High cooling rates potential for
quantities of heat are generated(Much like heat Automated. subcooling.
given off when water freezes). The temperature at Quick. Sensitivity: low wax contents difficult.
which this “heat of fusion” first occurs can be Can estimate wax content. Subject to interpretation.
detected by a Differential Scanning Calorimeter,
DSC.
Infrared Detection/ Light Infrared Detection/ Light Scattering Wax crystals Sensitive. Unrepresentative sample size.
Scattering will deflect and scatter light passing through the Small sample size. Subject to interpretation
oil. Infrared can be absorbed by waxes and will Suitable for live fluids. Little published validation.
penetrate black oils. Changes in light reflected or
absorbed as the oil cools will indicate wax
forming.
Thermodynamic Model uses compositional analysis of oil and Predicts cloud point and solid wax Very detailed input data.
prediction published properties of components to predict phase for range of pressures and oil Needs tuning to measured value.
solubility of wax components. compositions.
57
Cloud Point Methods- Not Recommended Methods
Visual and turbidity test The term cloud point is taken from turbidity test Simple. Sensitivity( needs finite amount of
used to determine wax precipitation from fuels. Representative sample size. crystals)
(ASTM D2500) The wax crystals are detected by a change in Adaptable for live fluids. Operator dependent (Visual only)
turbidity as the wax crystallizes. Often this test is Wide range of cooling rates. Other solids may be detected
performed by eye but turbidity meters increase Not suitable for Black Oils.
sensitivity.
Viscosity As solid wax crystallizes it will effect the oils Representative sample size. Sensitivity. May require presence of
rheology causing non-Newtonian behavior. The significant solid wax phase.
Newtonian viscosity / temperature relationship of Underestimating initial crystallization.
the oil is altered as the solid phase increases. May detect other solids formation.
Subject to interpretation.
Pyknometry Crystallization will change the temperature / Representative sample size. May detect other solids formation.
density relationship of the fluid as it cools. Suitable for live fluids. Sensitivity. May require presence of
(New techniques are improving significant solid wax phase.
sensitivity) Underestimating initial crystallization.
Subject to interpretation.
No published validation.
58
Asphaltenes
Asphaltenes
59
59
Treatment and Prevention of Asphaltenes:
60
60
Asphaltenes
61
Asphaltenes Test Methods Summary
62
Scale and Mitigation Strategies:
There are different types of scales.
• Calcium Carbonate
• naturally exists in the resevoir (carbonate reservoirs)
• Scale forms:
• with co-mingling of produced fluids from different producing zones or
reservoirs
• normally with decrease in pressure, carbon dioxide is released, and pH
changes to form scale.
• Mitigation:
• dissolution by acidification or application of calcium carbonate scale
inhibitor.
• Barium Sulphate
• In general barium sulphate scale results from water incompatibility,
• primarily from either seawater injection and / or seawater breakthrough,
• co-mingling with produced water rich in barium.
• highly insoluble and will deposit at temperature drops across the production
processing plant.
• Mitigation strategies::
• removal of sulphate ions from seawater for re-injection,
• application of barium sulphate scale inhibitors
• treatment with dissolvers.
63
Scale and Mitigation Strategies:
• Iron Sulphide
• Iron Sulphide scale is deposited where microbial enhanced corrosion has
become a serious problem.
• The scale is derived from the reaction of iron oxide from corrosion and
hydrogen sulphide,
• a by-product of sulphate reducing bacteria metabolism.
• Treatment for iron sulphide is application of a specialist chelating and
dissolution agent followed by microbial control with biocide application.
• Calcium Sulphate
• Calcium Sulphate scale is relatively soluble and only poses a real problem when
conditions are close to the solubility limit and super-saturation occurs.
• Sodium Chloride
• Sodium Chloride scale is caused by a saturation and evaporation process and is
readily removed by warm water in most cases.
64
E. Transport Properties
Gas viscosity
65
Viscosity Definitions
Oil viscosity μo = F( P,T, SGo,SGg, Rs) usually reported in PVT Analysis. If not
available, then the correlations are used.
Dead Oil Viscosity Viscosity of the oil at atmospheric conditions with
no gas in solution and the system temperature.
66
• Viscosity Prediction Methods
Dead Oil Viscosity Correlations
• Beal
• Beggs-Robinson
• Glaso
• Chew- Connaly
• Beggs-Robinson
μL = 10 X -1
Where
X = 103.0324-0.02023 API / T1.163
67
• Oil-Water Viscosity – Emulsions
Emulsion Viscosity
• Woelflin Correlation
Good Bw< 40%
Bw> 40% too high
μe/μo = 1 +2.5 Cw
Woelflin Viscosity Data
where Cw is the Water Fraction of the Water Phase When Brine in mixture is above 60-70%,
brine becomes the continuous phase.
68
Example E1 –Emulsion Viscosity
relationship: 600.0
500.0
Viscosity, cp
300.0
0.0
50.0 70.0 90.0 110.0
69
Emulsion Mitigation
Causes of emulsions High WATER Content
• That is the way with some wells
• Poor Cementing
• Poor reservoir management
• Poor Operating practices
• Production of excess water
• Excess turbulence in flow created by
• Over pumping
• Poor maintenance of plunger
• Maintenance Valves in rod pumps
• More than needed gas lift gas
• Centrifugal pumps with a downstream throttling valve
Else use:
• Emulsifiers
70
• Other Fluid Properties
Specific Heat Capacity of the fluid - Very important parameter in heat transfer
71
F. Heat Transfer Analysis
72
Heat Transfer Phenomena
T ambient
Buried Pipeline Area of Cross-Section
T inlet T fluid
The rate of heat transfer per unit length (Btu/hr/ft) is given by:
dH/dL = U A (T fluid – T ambient)
where U overall heat transfer coefficient, Btu/hr-ft2-degF
A cross-sectional area of pipe, ft2
T ambient temperature of surrounding, deg F
T fluid average temperature of fluid in pipe, deg F
From basic calorimetric calculations, the change in pipeline fluid temperature due to heat transfer
to the surroundings is given by:
The heat transfer coefficient U is determined by analyzing the combined effect of the
three modes of heat transfer:
Conduction - within a solid or between solid bodies (e.g. pipe wall and soil)
Convection - achieved through the movement of fluid (e.g. submerged pipe)
Radiation - energy emitted as electromagnetic waves from a hot body
Note that radiation heat transfer is generally not significant in flow assurance (with the
exception of steam injection)
73
Example F1 – Pipeline Heat Transfer
T ambient = 40 deg F
Buried Pipeline, U = 1.0 Btu/hr-ft^2-degF, Pipe Length = 10,000 ft Pipe Outer Diameter = 12 inch
T inlet =100 deg F
Q = 5000 BPD Oil Gravity = 0.8, Specific Heat Capacity = 0.5 Btu/lb/degF
Determine the outlet temperature for 12-inch x 10,000 ft buried crude oil (sp gravity =
0.8) pipeline flowing at 5000 BPD, given an overall heat transfer coefficient of 1.0 Btu/hr-
ft2-degF.
Temperature at the inlet of the pipeline is 100 deg F and the ambient temperature is 40 deg F.
Assume that the specific heat capacity of the oil is 0.5 Btu/lb/de gF.
Procedure
1. Area of pipe cross-section = 3.14 / 4 * (12/12)2 = 0.785 ft2
2. Mass flow rate = 5000 BPD /24 hr/day * 5.615 ft33/bbl * (0.8 * 62.4) lb/ft3 = 58,396 lb/hr
3. Estimate outlet temperature = 60 deg F
4. Heat transfer gradient, dH/dL = U A (T fluid – T ambient) = 1.0 x 0.785 x (80-40) = 31.4 Btu/hr/ft
5. Change in temperature = dH / Cp / mass flow rate = 31.4 * 10,000 / 0.5 / 58396 = - 10.8 deg F
6. Revised outlet temp (iteration 1) = 100 – 10.8 = 89.2 deg F (error = - 29.2)
7. Repeat Steps 4-6 with new outlet temp
8. Revised outlet temp (iteration 2) = 85.3 deg F (error = 3.9)
9. Repeat iteration steps until convergence
10.Converged outlet temperature (after 4 iterations) = 85.8 deg F (error = 0.1)
74
Overall Heat Transfer Coefficient
Classical Shell Balance
Total Resistance = sum of resistances from convection / Convection due to boundary layer - film
conduction layers
Conduction at inner wall, coating, Insulation
Resistance due to conduction (buried pipe) = diameter * loge((2Z+ (4Z2 – dout2220.5)/dout) / 2ksoil
where Z is the distance from the surface to the centerline of the pipe
Where
Re,surrounding= 1.47 x Reynolds number calculated from pipe outer diameter and surrounding fluid properties
75
Overall Heat Transfer Coefficient, OHTC
76
Subsea Flowline Insulation Methods
• External Coatings
• Flowline Burial
• Pipe-in-Pipe (PIP)
• Electrical Heating
• Hot WaterAnnulus
77
Thermal Conductivities of Soil
Kersten(1949) Κsoil = [ 0.9 log(ω) -0.2]*100.01*ρ
where
Κsoil soil thermal conductivity, [BTU-in/(ft2-hr-°F)]
78
Flowline Burial Depth
Loch (2000)
79
Example F2 – Overall Heat Transfer Coefficient
Calculate the overall heat transfer coefficient for the pipeline in Example F1
given the following data:
pipe diameter (inner) 12 inch
pipe wall thickness 0.25 inch
Determine the relative contribution
insulation 0.5 inch of insulation and burial on the
Burial depth (center line to surface) 24 inch
Pipe Thermal Conductivity 600 Btu/day/ft/F
overall resistance to heat transfer.
Insulation Thermal Conductivity 0.96 Btu/day/ft/F
Soil Thermal Conductivity 24 Btu/day/ft/F Change the heat transfer coefficient
Oil Flow Rate 5000 BPD
Oil Specific Gravity 0.8 water = 1 in Ex F1 to the calculated value and
Oil Specific Heat Capacity 0.5 Btu/lb/degF evaluate the impact.
Oil Thermal Conductivity 1.6 Btu/day/ft/F
Oil Viscosity 3.5 cp
Procedure
1. Area of cross-section = 3.14 / 4 * (12/12)2 = 0.785 ft2
2. Fluid velocity = 5000 BPD x 5.615 ft3/bbl / 86400 sec/day / 0.785 = 0.41 ft/sec
3. Reynolds number = 1488 * 0.41 * (12/12) * (0.8 * 62.4) / 3.5 = 8785
4. Film resistance (convection) = (12/12) / (0.0225 * 1.6 * 87850.8) = 1.944 E-2
5. Pipe wall resistance (conduction) = (12/12) x 1/(2*600) loge (12.5/12) = 3.4 E-5
6. Insulation resistance (conduction) = (12.5/12) x 1/(2*0.96) loge (13.5/12.5) = 4.175 E-2
7. Soil resistance (conduction) = log( (4*242– 13.52)0.5/13.5)/(2 x 24) = 2.877E-2
8. Total resistance = 1.044E-2 + 3.4E-5 + 4.175E-2 + 2.877E-2 = 9.00 E-02
9. Overall heat transfer coefficient U = 1/(9E-2 x 24) = 0.46 Btu/fr/ft2/degF
82
G. Transient Phenomena
83
Common Transient Operations
Transient Condition Operation Impact
Ramp Up / Down Rate change Rate surge
Startup Rate change from zero Pressure surge
Rate surge
Shutdown Compressor / Pump Pressure surge
shutdown
Blowdown Pressure reduction
Terrain Slugging Caused by topography Slug formation, growth and
dissipation
Sphering Periodic operation Rate surge
Pipeline leak / rupture Unplanned Product loss
Environmental damage
Pressure surge
84
Flow Rate Ramp Up
BEFORE AFTER
How Big is the Surge?
15000 600
10000 400
bbl
5000 200
0 0
0.0 100.0 200.0 300.0 0 10 20 30 40 50
The discharge rate is generally controlled through an orifice (or valve) to ensure that
these operational issued are addressed.
W = Cd K A P (MW / zT)0.5
87
Example G2 - Pipeline Blowdown
Determine the pressure profile for the blowdown of a 5 mile x 6 inch (ID) gas pipeline
operating at 800 psi when the gas (gravity=0.8) is released through a 3-inch orifice (Cd
= 1.0). Average compressibility is 0.9, k = 1.4, and assume that the pipeline
temperature does not change from its initial value of 39 deg F.
Procedure
1. From geometry, orifice area = 3.14/4 * (3/12)2 = 0.049 ft2
2. Pipeline volume = 3.14/4 * (6/12)2 * (5 x 5280) = 5181 ft3
3. Gas Molecular Weight = 28.97 x 0.8 = 23.18
4. Initial density of gas = 800 * 23.18 / (0.9 * 10.73 * (460+39) = 3.85 lb/ft 3
5. Initial mass of fluid (gas) in pipeline = 3.85 * 5181 = 19934 lb
6. Initial rate of gas flowing through the orifice = 1 x 1.4 x 0.049 x 800 * (23.18/0.9/(460+39)) 0.5 = 12.48 lb/sec
7. Starting from time =0, calculate the following at 100 second intervals
1. Mass rate of gas through the orifice (from the orifice equation)
2. Remaining mass of gas in the pipeline (previous mass – mass rate * time increment)
3. Gas density = remaining mass / pipeline volume
4. Average pipeline pressure = density * z * 10.73 * (460+39) / 23.18
5. Determine the gas discharge rate at standard conditions from the mass rate
6. Plot the pressure and gas flow rate profiles as a function of time
200 5.00
0 0.00
0 1000 2000 3000 4000 0 1000 2000 3000 4000
88
Pipeline Cooldown
When pipeline is shut-in, the fluid temperature drops over an extended
period of time until ambient conditions are achieved. A significant
parameter for cooldown analysis is the “no-touch” period which is the time
available before the pipeline must be started up again.
For a pipeline transporting waxy crude, the no-touch period is the time
before pour point (plus safety margin) is reached
89
Example G3 - Pipeline Cooldown
Given a 10,000 ft x 12 inch subsea pipe with a heat transfer coefficient of 1
Btu/hr/ft2/F and an average fluid temperature of 100 deg F, estimate the no-touch time
when the surrounding temperature is 40 deg F.
Crude oil characteristics: specific gravity = 0.8, heat capacity = 0.5 Btu/lb/F, pour point = 50 deg F
Solution:
From the Lumped Capacitance Cooldown Model, the temperature
T is given by : 120.0
80.0
where Ti is the inside fluid Temperature
Fluid Temp, F
T(t) is the inside fluid Temperature at time t 60.0
To is the ambient temperature
t = period after shut-in 40.0
C = U * Area of Contact / (mass of fluid * specific heat capacity)
20.0
Procedure:
0.0
Fluid mass = 3.14/4 * (12/12) 2 * 10,000 * (62.4 * 0.8) = 391,872 lb 0.00 10.00 20.00 30.00
For a range of time periods (e.g. 0-24 hrs in 1 hr increment) calculate and plot T(t)
From the plot (see right), no-touch time = 11 hr (actual time will be lower)
90
H. Integrated Flow Assurance
Deepwater/subsea systems
91
Fluid Flow, Heat Transfer & Thermodynamics
Hydrate Management
Thermodynamics establishes hydrate limits
Temperature and pressure determine hydrate performance
Heat transfer controls temperature profile
Fluid Flow influences Heat Transfer Fluid Flow Analysis
Predicts Flow & Pressure Behavior
Thermodynamic Analysis
Predicts Fluid PVT Properties Flow Assurance
Integrated Analysis
of Flow Behavior,
Pressure and
Temperature Production Performance
Performance, and Flow rates establish production
Fluid Properties performance
Heavy Oil Transport Pressure determines flow rates
Heat Transfer determines temperature profile PVT properties impact pressure and
Temperature controls viscosity behavior temperature profile
Fluid viscosity establishes fluid flow Temperature and pressure influence
Fluid Flow influences Heat Transfer PVT properties
16000
14000 Wax
Fewer wells, minimal intervention
Premium on reliability 12000
Reservoir
10000
Pressure
Hydrate
Commingling of Limited monitoring of 8000
incompatible fluids wells, pipeline & riser
6000 Asphaltene
4000
Bubble Point
2000 Facilities
High back-pressure Deeper, colder
Need for boosting plugging & deposition 0
0 50 100 150 200 250
Temperature
Flow assurance in deepwater is about designing and operating systems that handle
the many unique challenges of subsea production while mitigating unnecessary risk to
ensure the continuous flow of oil and gas from capital-intensive projects
93
Example H1 – Heavy Oil Throughput Capacity
T ambient = 40 deg F
Buried Pipeline, U = 1.0 Btu/hr-ft^2-degF, Pipe Length = 20 miles Pipe Outer Diameter = 12 inch
T inlet =100 deg F
Q = 5000 BPD Oil Gravity = 0.8, Specific Heat Capacity = 0.5 Btu/lb/degF
Determine the throughput (BPD capacity) for a 12-inch x 20 mile heavy oil pipeline with
an inlet conditions of 250 psi and 100 deg F. The minimum outlet pressure is 100 psi.
The viscosity of the crude is characterized as a function of temperature (deg F) by the
following exponential fit of lab data:
viscosity, cp = 500 x exp (-0.035 (temp in deg F – 50))
Solution Procedure
1.Set the initial estimate of the throughput to be 30,000 - 50,000 BPD
2. Use the iterative procedure described in Example F1 (Pipeline Heat Transfer) for calculation of outlet
temperature for the given inlet temperature of 100 deg F. With a reasonable outlet temperature estimate,
the solution should converge in 4 iterations (or less).
3. Compute the velocity from the estimated flow rate.
4. Compute the viscosity at the average fluid temperature (mean of fixed and calculated outlet temp)
5. Update Reynolds number with the new velocity and viscosity
6. Update friction factor using the laminar flow equation (validate that Reynolds number is within range)
7. Calculate the frictional pressure gradient from the friction factor
8. Compute the outlet pressure for the estimated flow rate.
9. Update the estimated flow rate and repeat Steps 2-8 until the outlet pressure is approx 100 psi. This is the
calculated throughput for the pipeline.
•Reservoir performance
– how it impacts production
96
• Economics of Flow Assurance
97
• Economics of Flow Assurance
Some of the key components of Cap Ex and Op Costs that need to be
included in any economic analysis for evaluating flow assurance alternatives:
• Capital Expenditure
• Drilling and completion of wells
• Pipelines and gathering system installation
• Installation of prime movers (compressors / pumps / multiphase pumps)
• Facilities (platform, slug catcher, separator, heaters, recovery and reinjection,
other topsides)
• Artificial lift installations including related facilities such as compression, power
lines etc.
• Operating Costs
• Facilities maintenance
• Inhibitors/chemicals for hydrates (methanol/glycol), wax, asphaltenes, corrosion,
surfactants, etc.
• Power costs for compressors, pumps, heaters, topsides, etc.
• Personnel (platform, onshore, central support)
• QHSE
98
• Reservoir performance–how it impacts
production
Reservoir Decline
Reservoir Pressure (current) = Reservoir Pressure (previous) * Decline Rate * Cum Production
Note: for gas fields p/z is sometimes used instead of pressure (p) in the above equation
Maximum Drawdown
Drawdown is generally limited to avoid problems such as sand production
Pressure (Psi)
• A well with high water rate will be usually put on
an artificial lift from the beginning.
• Available technologies add energy to the system
to lift the fluids to the surface. There are times an
oil well may need:
• ESP • Hydraulic Pumps
• Gas Lift • PCP
• Rod Pump • Plungers
100
• Integrated Asset Modeling, IAM –
Reservoir, Production, Process Plant, Economics
IAM help to determine :
• impacts of new drilling
• best locations to set compression
• to influence the order and location of the new drilling
• evaluating the impact of third party activity
• investigating gathering system improvement opportunities
• for tubing sizes and evaluation of options versus performance
• identifying wellwork candidates and other production enhancement
opportunities
and to analyze:
• upsets and production losses
• requests from Infill Team on lateral capacity
• uplift for future
• pressure changes for future pipeline projects,
• pressure changes for future compressor projects
• for debottlenecking
In summary, the reservoir decline, added wellhead compressor, the new wells
feeding into the same line, the increased compressor suction pressures, and
the availability of processing facilities, along with the economics can be
coordinated to give the optimized production scenerios.
101
Flow Assurance Monitoring & Control
Subsea monitoring
FPSO
& control data
manifold
ESP flowline
measurements
DTS
102
IAM Visualization
Near Real-Time Field Data and Model Results Monitoring
Business value of these new operating tools achieved
through improved operations efficiency, integrity
management, and organizational performance, by
integrating activities around reservoir, wells,
pipelines, facilities, and commercial decision-making
103 103
Map-based Visualization
104
104
IAM Online Model Calculations
• Mixture Velocity
• Liquid Hold-up
Qomax
The following equation can be used when Pwf < PB < PR
Qo = PI (PR - PB) + 0.5 PI / PB(PB 2 – Pwf2)
Oil Production Rate
106
Example I1 - Oil Well IPR
From a well test, the bottom-hole pressure was measured as 1234 psi at a rate of 2345
bpd. The static pressure in the reservoir after the well was shut-in for 48 hours was
measured as 3636 psi. Lab tests show that the bubble point pressure at the reservoir
temperature of 200 deg F was 2222 psi. Determine the productivity index and
absolute open flow potential and use these values to plot the IPR curve for the well.
Pressure (psi)
= 2792 bpd 2500
2000
Calculate Qo for a range of Pwf using the equation: 1500
1000
Qo = PI (PR - PB) + 0.5 PI / PB(PB2- Pwf2)
500
0
Where: PR = 3636 psi 0.0 1000.0 2000.0 3000.0
PB = 2222 psi Rate (bpd)
PI = 1,07 bpd/psi
107
Example I2 - Integrated Production System
An integrated gas production system extends from the reservoir through the wellbore,
pipeline and compressor flowing into the separation facilities. Estimate the delivery
capacity to a downstream trunk line operating at a fixed pressure of 1000 psia. The
following data applies:
Reservoir
Pressure = 5000 psia, Temperature = 200 deg F, Gravity = 0.75
Deliverability: Cp = 7.8E-6, n = 0.9
Well
Depth = 10,000 ft, Diameter = 4 inch
Average friction factor = 0.015, Average Z = 0.8
Surface Pipeline
Length = 20 miles, Diameter = 6 inch
Surface Temperature = 80 deg F
Average friction factor = 0.01, Average Z = 0.9
Procedure
109
Terminology
Symbol Definition
Pwf Flowing bottom hole pressure (psi)
PI Productivity Index (bpd/psi)
PR Reservoir pressure (psi)
Qo,max Absolute open flow (bpd)
Cp Gas deliverability constant
N Gas deliverability exponent
PB Bubble point pressure (psi)
110
Unit Conversions
112
Workshop J1- Conceptual Design Problem
Platform
After five years, a satellite field is being brought on-stream at the subsea
manifold with a contractual rate of 20 MMscfd. What is the impact on existing
production and how much additional compression is needed to produce both
fields?
113
Workshop J1 - Engineering Design Concepts
Basic Engineering Concepts Applied:
Reservoir Reservoir Decline
Gas deliverability equation (see Reservoir Pressure (current)
Reservoir Deliverability) = Reservoir Pressure (previous) * Decline Rate * Cumulative
Reservoir decline Production
Drawdown limit Note: for gas fields p/z is sometimes used instead of pressure
Wellbore (p) in the above equation
Pressure gradient (see Momentum Maximum Drawdown
Balance) Drawdown is generally limited to avoid problems such as sand
Heat transfer (see Heat Transfer) production
Manifold
Bottom Hole Pressure > Reservoir Pressure – Max Drawdown Limit
Fluid mixing – temperature
Fluid Mixing at Junction (Subsea Manifold)
Subsea Pipeline
Pressure gradient Mixture Temperature (downstream)
Heat transfer = (Stream1 Temp*Stream1 Rate + Stream2 Temp*Stream 2 Rate)
/ (Stream 1 Rate + stream 2 Rate)
Hydrate prediction temperature
Note: for multiple streams, the downstream temp is the mass-
Riser weighted temperature of all incoming streams
Pressure gradient Simplified Hydrate Prediction
Heat transfer The following empirical model (Hammerschmidt) is used:
Platform Hydrate formation temp (deg F) =8.9 x psia0.85
Compression Compressor Power
HP = 550 * Mass Rate (lb/s) * Head (ft) / Efficiency / g
Head = n / (n – 1) * Pinlet * (Ratio ((n-1)/n) – 1))
114
Workshop J1- Summary of Operating Constraints
Reservoir NA NA NA
Solution cannot violate any of the above constraints for the projected 10-year operating scenario
115
Workshop J1- (Excel File)
Spread Sheet 1 of the Excel file Workshop J1 defines the full problem to be
solved:
Lines 5-10 summarizes the results for a simulation scenario in terms of the
pressure & temp at the key points along the system.
The bright yellow fields in Column D represent the variable to be changed (well
rate, satellite rate, cumulative production, compressor stages).
DO NOT CHANGE ANY OTHER FIELDS
116
Solution to Workshop J1- (Excel File)
Spread Sheet 2 of the Excel file Workshop J1 is the worksheet used to determine the
cumulative production volume from the production profile.
1. In Spreadsheet 1, set satellite production = 0; number of compressor stages = 3 to start the analysis
2. For year 1, set cumulative production = 0 (new field) and adjust Well Production (range: 25-35 MMscfd) until none of the
constraints are violated. Enter this value in Sheet 2 for year 1 and determine the cumulative volume produced by the well
at the end of the year.
3. Enter the cumulative volume in Sheet 1 and repeat Step 2 for Year 2
4. Repeat Steps 2-3 for the first five years.
5. At Year 6, set satellite production = 20 MMscfD and determine the flow rate at which the minimum delivery pressure is
achieved.
6. Note that the hydrate temperature limit is violated because of the cooler satellite production stream. Add another stage of
compression (stages = 4) so that production from the Well increases and the pipeline temperature no longer falls below the
hydrate limit.
7. Repeat Steps 2-3 for the remaining years in the scenario
8. Note that the pipeline temperature falls as well production drops dues to reservoir decline. If temperature drops below the
hydrate limit, add more compression in Year 6 and repeat the steps through the end.
9. The plot on the right shows the predicted production profile for the ten year scenario.
Well Production Profile
35
Well Production, MMscfd
30
25
20
15
10
5
0
0 5 10 15
117 Years of Production
Workshop J2
-Pipeline Operations Problem
88.8 km x16 inch branch line flowing from mainline to refinery (10 ¾ inch pipe for final 8 km)
Inlet Pump Station SP1 – 3x500 kW (1 spare), Intermediate Pump Station SP2 – 2x500kW
units (1 spare).
Pipeline Profile Distance Elevation OD 1500
Elevation, m
KM m inch 1000
Inlet Pump Station (SP1) 0 416 16
Intermediate Pump Station (SP2) 44.6 740 16 500
Highest Point 69.4 1263 16
16/10 Switch 80.8 1100 10.75 0
Refinery 88.8 431 10.75 0 20 40 60 80 100
Current Operations: Pipeline pressure profile (bar) from SCADA at 650 m3/hr:
Crude oil gravity = 0.83 avg. viscosity = 3 SP1 Outlet SP2 Inlet SP2 Outlet High Point Refinery
cSt
Operational service = 170day/yr 74.3 27.3 53 2.2 39.7
Average sand = 390 ppm
How much can pipeline throughput be increased without significant capital
investment (through a combination of existing pump capacity utilization and DRA
injection)? Assume DRA performance is for medium crude per chart on right.
118
Solution to Workshop J2 - (Excel File)
Spread Sheet 1 (Baseline) is the worksheet used to determine the baseline pipeline
operation from current operations data (SCADA pressure profile).
• Key Assumptions:
• Line fill compaction = 1.5% (change in volume at in situ pressure and
temperature)
• Wall thickness = 0.375 inch for 16 inch pipe, 0.365 for 10 inch pipe (Schedule 40)
• Adjust pipe roughness and pump efficiency until predicted profile matches SCADA
• Use adjusted values and calculated pipeline inlet pressure for all subsequent
analysis
• Key Constraints:
• Pressure at Highest Point > 0 bar (else slack line conditions)
• Pipeline velocity < erosional limit (const in API RP14E = 135 for solid (sand)<1
lb/bbl)
Spread Sheet 3 (Costing): is the worksheet used to estimate the DRA and power
costs for the various scenarios.
119
Workshop J2 - Results Summary
The table above summarizes the results for the pipeline throughput analysis.
Flow Rate PS1 PS2 Drag Reduction Injection Rate Injection Injection DRA Cost Add. Power Cost Total
m3/hr units units US gal/day SP1 SP2 euro/day euro/day euro/day
650 2 1 0% 0 No No 0 0 0
Key Observations:
1) Pipeline is operating close to capacity under current conditions (spare pumps not
used, no DRA injection)
2) Throughput cannot be increased beyond 1000 m3/hr without additional capex (new
pump units, pipeline resizing, or looping)
3) Erosional velocity in the 10-inch line will not be a factor if sand is controlled
4) Pump operation (spare) is a more cost effective option than DRA injection
120
References:
121
Contact Information
Nihal.G.Quadir@EICEinternational.com
Kunal.DuttaRoy@EICEinternational.com
122