MEK 4450 – Multiphase pipeline

transport (IFE)
Lecture notes 2013-10-22,
Morten Langsholt

• Multiphase technology – What, why, how

• Pipe flow – single and multiphase flow
• Importance of relevant experimental data
• From lab to field scale
• Multiphase test facilities
• Lab-demo with measurements
MEK 4450 Multiphase Flow - IFE Oct. 22, 2012
 Multiphase pipe flow – a key technology
for oil and gas production

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 What’s multiphase transportation?
• Transport of gas, oil, water, chemicals and
possibly solid particles in the same pipe
• Reduces need for new production platforms
• Gather production from many wells and send
to existing platform or shore
• Subsea separation and pumping/compression
may be required
• More cost efficient
• Often requires chemicals to prevent corrosion
and solids precipitation that can possibly
restrict or stop the flow

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Multiphase transportation challenges

• Capacity problems due to viscous oils, emulsions etc.

• Solids precipitation can restrict or stop the flow
• Liquid accumulation during low flow rates in gas
condensate pipelines
• Large flow transients during production ramp-up
• Slugging and other instabilities can give
problems in the receiving facilities
• Erosion/corrosion

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 Application of multiphase flow models
• Tool for system design
• Piping and equipment dimensioning
• Heating and thermal insulation
• Chemical choice and dosage
• Part of system simulator
• Integrated system design
• Subsea solutions
• Operator training
• Operation support – system overview
• Surveillance: Compute non-monitorable parameters
- Liquid content, leak detection …

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 Pipe Flow –
Some considerations related to single
and multiphase flow

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Calculation of flow in pipes

out

in

• Conservation of • Thermodynamics
• Energy
• Mass
• Momentum
MEK 4450 Multiphase Flow - IFE Oct. 22, 2012
 out
Mass conservation in

• Single-phase : Mass in - mass out = accumulated mass

• Multiphase: Mass transfer comes in addition, e.g. for condensate:

Mass in - mass out + local condensation = accumulated mass

• Steady state single-phase flow:

G = density *pipe area*mean velocity = ρAU=constant along a
pipeline

• Gas: Pressure reduced with 50% implies a doubling of U

• Oil: Small density variations => U constant along pipeline

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Momentum balance – single-phase:
L

θ
PR

PL
Friction

• Pressure gradient large enough for flow: Velocity depends on friction

( PL − PR ) A = m g sin ( θ ) − Friction

• Friction = Friction force per area * wall area

Friction = τ w (U , ...) ∗ π D L
Veggskjærspenning
MEK 4450 Multiphase Flow - IFE Oct. 22, 2012
 Multiphase Pipe Flow Depends on:

Fluid properties Pipe geometry Environment

Density Diameter T, external

Viscosity Wall roughness Insulation
(buried?)
Phase fractions Pipeline profile/ T at inlet
Conductivity topography P at inlet
Heat capacity P at outlet
Surface tension
Etc...
Varies with P and T !
P=pressure, T=temperature

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Oil samples -
large differences in
fluid properties

Crude oils
• Njord
• Visund
• Grane
• Statfjord C
Midgard
Condensates
• Sleipner
• Midgard

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Multiphase flow
Three-phase flow (here):
Simultaneous flow of oil-gas-water in the same pipeline

Flow regimes:
Describes (intuitively) how the phases are
distributed in the pipe cross section and along the pipeline

Superficial velocity:
The velocity a phase will have
if it were the only fluid present

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Flow regimes steeply inclined pipes

Bubbly flow: ”Churn”-flow: Annular flow:

Little gas, large Uoil More gas, large Uoil High Ugas, low Uoil
(All inclinations) (steep inclinations) (wide range of incl.)

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Stratified/wavy- near horizontal pipeline

Stratified flow. Ugas normally >> Uoil

Large waves: More effective liquid transport

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 Hydrodynamic slugging
Taylor-bubble

Liquid slu

• Large waves that eventually block

the pipe cross section  pressure
build up
• Intermittent flow – liquid slugs
divided by gas pockets
• Effective liquid transport
Slug front in three-phase flow
• Void in slug: Volume fraction of
entrained gas bubbles in the slug

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Need for experimental data
• MP-flows are complex due to the simultaneous presence of different
phases and, usually, different compounds in the same stream.
• The combination of empirical observations and numerical modelling
has proved to enhance the understanding of multiphase flow
• Models to represent flows in pipes were traditionally based on
empirical correlations for holdup and pressure gradient. This implied
problems with extrapolation outside the range of the data
• Today, simulators are based on the multi-fluid models, where
averaged and separate continuity and momentum eq. are established
for the individual phases
• For these models, closure relations are required for e.g. interface and
pipe-wall friction, dispersion mechanisms, turbulence, slug
propagation velocities and many more
• These can only be established with access to detailed, multi-D,
data from relevant and well-controlled flows

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Up-scaling from lab to field

• 13 parameters determine holdup(s) and

pressure drop in three phase pipe flow
• To develop the closure relations, we need data
• To
13
cover9 the parameter space we need, say,
5 ~ 10 data points for 5 point resolution in each
parameter
• We have ~ 200 field data points at present

• It is clearly impossible to cover the parameter space

of three phase pipe flow with data

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

Conclusion: we need models based on physics to
extrapolate beyond lab data

Lab Field

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 Dimensionless numbers – dynamic similarity

• Reynolds number, ratio of the inertial forces to Laminar vs

the viscous forces, turbulent flow
Re= =ρvL/µ

• Froude number, ratio of a body's inertia to Wave

gravitational forces or ratio of a characteristic propagation,
velocity to a gravitational wave velocity outlet effects,
obstructions

Formation of
• Weber number, relative importance of the fluid's droplets and
inertia compared to its surface tensions: bubbles.

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Conditions in pipeline
Hydrodynamic forces proportional to rU2

1 m/s ρ = 1 kg/m3

P = 100 bar
1 m/s

Corresponds to 10 m/s
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 Conditions in pipeline
Gas – liquid interaction: governed by Dρ*DU2
Wind = 3 m/s
Light breeze

Ug = 3 m/s P = 100 bar

ρ = 600 kg/s

Corresponds to more than 30 m/s, i.e. Full Storm

Typical gas-condensate pipe: Gas velocity of 6 – 7 m/s,
corresponding to twice Hurricane force winds

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Conditions in pipeline – Drops and bubbles
Hydrocarbon systems can have very low surface tension, in particular gas-
condensate systems. Encourages generation of smaller drops and bubbles.
Typical values: Air – water: 0.07 N/m vs. Gas – condensate: < 0.005 N/m

Inertial ρU 2 d
We = =
Surface tension σ
60 mm/h
Gravitational gρd 2
Eo = =
Surface tension σ
3 – 6 m/s Drop/bubble sizes
Capillary waves

P = 100 bar 90 000 mm/h

measured in lab
3 – 6 m/s

Liquid layer can be significantly aerated (40% - 70%)

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Test facilities for study of
multiphase flow behaviour

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Open and closed loops
Open loops with air as the gas
phase – atmospheric pressure
• Simple to build, relatively low cost
• Few safety barriers
• Liquid phase e.g. water, vegetable oil
• Common at Universities

Closed, pressurised flow loops

• More complex design, higher costs
• More realistic gas-liquid density ratio
• Crude oils possible (unstable, EX)
• Safety barriers against pressure burst
and explosion

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Design considerations
Main goal for a test loop:
• Establish well controlled and relevant multiphase flows
Common requirements:
• Length/diameter ratio , L>300 D – flow develops along the pipe
• Large diameter – diameter scaling difficult
• Easily changeable pipe inclination
• High gas density to give relevant gas-liquid density ratio
• Large span in flow rates
Cost-benefit:
• Pressure vs gas density; pressure drives costs
• Flow velocities vs pipe diameter; Flow rates drives costs – pumps and
separator
• High L/D and pipe inclination drives cost of building
MEK 4450 Multiphase Flow - IFE Oct. 22, 2012
 Some test facilities in Norway
• IFE Well Flow Loop
• + All inclinations • - Short, low L/D
• + Indoor • +/- Medium diam.
• + High gas density
• + Transparent pipes
• + Cost effective

• SINTEF – Large Sc.

• - Fixed inclination
• + Long L/D
• - Expensive to run
• + Large diameter
• - Outdoor
• + High pressure, N2

• Statoil - Herøya • - Cumbersome to change

• + Real oil-gas system inclination
• + Formation water • - Small diameter
• + High pressure • - Steel pipe
• + Long, high L/D • – Expensive to run
• - Outdoor

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 The Well Flow Loop – Principal Layout
Component list:
1: Oil-water separator
2: Gas-liquid separator
3: Gas compressor
4: Water pump
5: Oil pump
6: Heat exchanger, gas
7: Heat exchanger, water
8: Heat exchanger, oil
9: Main el. board
10: Flow rate meter, gas
11. Flow rate meter, water
12: Flow rate meter, oil
13: Inlet mixing section
14: Slug catcher, pre-
separator
15: Return pipe, gas
16: Return pipe, liquid
17: Test section
18: Winch

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Worldwide test loops

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Worldwide test loops

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Instrumentation
(to be covered next week)

• Gamma densitometers
• PIV
• X-Ray tomography
• LDA/PDA
• ECT

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 Pressure gradients
• Differential pressure transducers;
many measurement principles,
accuracy, response times etc.
• Connected to an upstream and
downstream pressure tap (small holes
in the wall)
• The connecting pipe is called impulse
pipe.
• Pressure tap can be top/bottom/side
mounted
• Distance between pressure taps can • dp/dz [Pa/m]= dp/dL, where
vary widely (1 m – 100 m) dp is the differential pressure
• Measures wall friction and the measured with the
hydrostatic pressure difference transducer and dL is the
between the taps distance between the
tappings

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Holdup=Cross-sectional liquid fraction (H=1-α)
• Gamma densitometer
• Attenuation of photon flux due
to absorption and scattering

• Single media:

where N is the intensity, µ is

the attenuation coefficient
(material property) and x is the
distance travelled in the media
• This can be developed to
• Two-phase gas-liquid and explicit equation for the
Holdup

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Lab demo and practical work

• Where is what and why – get to know the loop

• The control and data acquisition system
• Demonstration
• Exercise for next week

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Tentative lab-demo - Flow regimes
• Downwards -1o, Usl=0.30 m/s, Usg=1 m/s  Strat. w/smooth interface
• Horizontal, Uso=0.30 m/s, Usg=1.5 m/s  Strat. w/large waves
• Horizontal, Uso=0.30 m/s, Usg=3 m/s  Strat w/ripple waves
• Horizontal, Uso=0.30 m/s, Usg=4-8 m/s  Trans. From strat.  annul.
• Upward 1o, Uso=0.40 m/s, Usg=0.3 m/s  Elongated bubbles
• Upward 4o, Uso=0.12 m/s, Usg=0.9 m/s  Slug flow
• Upward 4o, Uso=0.12 m/s, Usg=3 m/s  Large waves/short slug
• Upward 4o, Uso=0.12 m/s, Usg=5 m/s  Strat. w/drops and void in liq.
• Horizontal, Uso=Usw=0.1 m/s, Usg=1 m/s  Stratified gas-oil-wat.
• Horizontal, Uso=Usw=0.1 m/s, Usg=3 m/s  Strat. mix o/w-gas

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Lab data
T e s t c o nd itio ns F luid p ro p e rtie s
Pressure 4 bara Density Dyn. vis Kin.vis
Pipe dia. 0.099 [m] [kg/m3] [Pa s] [m2/s]
Pipe area 0.0077 [m2] Oil 815 0.002 2.44E-06
Pipe rough 0.00025 [-] Gas 24 0.000015 3.01E-07

Exp no Incl. Usgas Usoil dp/dz Holdup Flow regim

# θ [m/s] [m/s] [Pa/m] [-]

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Stratified flow model in spreadsheet (Excel)
T e s t c o nd itio ns Fluid p ro p e rtie s Ge o me try R e s ults
Pressure 4 bara Density Dyn. vis Kin.vis Pipedia 0.099 m
Pipe incl. 4 [Deg.] [kg/m3] [kg/s m] [m2/s] PipeArea 0.00770 m Holdup 0.2 [-]
Sup. Gas vel. 3.5 [m/s] Oil 815 0.002 2.45E-06 Rel. Pipe rough 0.00020202 - dp/dz 230.7 [Pa/m]
Sup. Liq. Vel. 0.3 [m/s] Gas 23 0.000015 6.52E-07 Abs. Pipe rough 0.00002 m Tuning 1
β δl/π -(ρ l-ρ g )gsin(θ) −τwl Sl/A l τwg Sg /A g τi Si /A g *β F(β) [Si ρ g Ug 2 /ρ l gA g ]0.5 [Si ρ l Ul 2 /ρ l gA l ]0.5 τwg τwl τi Al Ag
Holdup WetAng,dl Gravity WallSh,liq WallSh,g Int.Shear Grav.dom. Fr,gas Fr,liq Area,L Area,G
3 3 3 3 2 2
0 [-] [N/m ] [N/m ] [N/m ] [N/m ] [-] [-] [m ] [m ]

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012

 Exercise for next week

1. Open the Excel-file and get familiar with how to use it

2. Use data from the lab test and ‘plug’ the data into the model. Compare
the predicted holdup and pressure drop values with the measured data
for the different test conditions. Discuss the results.
3. For pipe inclination 3 deg. and Usl=0.5 m/s, calculate and plot the
pressure drop as a function of the gas velocity. Explain the results.
4. Describe what occurs for pipe inclination 4 deg, Usl=0.001 m/s and
Usg= 3.5 m/s.

MEK 4450 Multiphase Flow - IFE Oct. 22, 2012