Flow Assurance Lecture Notes Oct 24 2017
Flow Assurance Lecture Notes Oct 24 2017
Flow Assurance Lecture Notes Oct 24 2017
Baxter
Flow Assurance
Pressure Drop
Flow Patterns
Slugging
1 INTRODUCTION 3
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2.1 Hold-Up 5
3 FLOW REGIMES 6
5 SLUG FLOW 24
6 PIPELINE TOPOLOGY 30
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1 Introduction
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Flow assurance has become a critical technology area for the oil and gas industry. The
simultaneous flow of gas and liquid through pipes, often referred to as multiphase flow,
occurs in almost every aspect of the oil industry. Multiphase flow is present in well tubing,
gathering system pipelines, and processing equipment. The use of multiphase pipelines has
become increasingly important in recent years due to the development of marginal fields and
deep water prospects. In many cases, the feasibility of a design scenario hinges on cost and
operation of the pipeline and its associated equipment. Confidence in the flow assurance
analysis – pressure loss, heat transfer, fluid chemistry, transient effects – is essential to
developing a safe and operable design.
Multiphase flow in pipes has been studied for more than 50 years, with significant
improvements in the state of the art during the past 15 years. The best available methods can
predict the operation of the pipelines much more accurately than those available only a few
years ago. The designer, however, has to know the key areas requiring analysis and which
methods to use in order to deliver the most accurate results.
dP ∆ (v ) 2
∫ ρ
+ g .∆X +
2
= −W f − W
ρ ⋅ f ⋅ L ⋅ v2
∆Pf =
2⋅ D
For multi-phase flow it is apparent that a single density no longer applies as does a single
velocity. Similarly other necessary properties viscosity, heat capacity etc. Immediately it is
clear multi-phase flow will be much more complex to analyse.
2.1 Hold-Up
Liquid hold-up is the ratio of the volume of liquid in the system to the total volume. It is an
important feature of multi-phase flowlines as it will affect pressure drop, slug generation, rate
of pipeline cooldown and other design and operational features.
If an equal volume rate of gas and liquid are introduced into a horizontal pipeline it might be
expected that the liquid
hold-up i.e. the fraction of
liquid volume to the total
volume, would be 50%.
This is unlikely to be the
case as the gas is much
more mobile than the liquid
and will slip through the pipeline resulting in a higher than 50% liquid hold up.
The level of hold up will also be influenced by the pipeline angle. In upflow the gas will slip
much more readily through the liquid resulting in higher hold-ups. In downfall the liquid will
start to run downwards due to gravity hence the hold up will be smaller.
Furthermore, as the liquid viscosity is significantly greater than the gas velocity, a pressure
force will give a larger gas velocity than liquid velocity. This will cause a slip between the
(average) gas and liquid velocity. This slip (hold-up)is not caused by gravity, and thus is also
present in horizontal pipe sections.
Terminology used in the development of multi-phase flow correlations follows;
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Liquid Holdup Hl
Ratio of the volume of a pipe segment occupied by liquid to the volume of the pipe segment
Hl = volume of liquid in a pipe segment/volume of pipe segment
Value varies from 0 to 1
Gas Holdup or gas void fraction Hg
Hg = 1.0 - Hl
No-Slip Liquid Holdup – λl
Ratio of volume of liquid in a pipe segment divided by volume of pipe segment which would
exist if the gas and liquid travelled at the same velocity (no-slippage)
λl = ql / (ql + qg)
Where ql and qg are liquid and gas volumetric flow rates
No-Slip Gas Holdup – λg
λg = 1.0 - λl = qg / (ql + qg)
Two-Phase Velocity/ Mixture Velocity - vm
The velocities of the gas and liquid in the pipe are prime variables in the prediction of the
behaviour of the multiphase mixture. Most multiphase flow prediction methods use the
superficial gas and liquid velocities as correlating parameters. The superficial velocities are
defined as the in situ volumetric flowrate of that phase divided by the total pipe cross
sectional area. Or, the velocity in the pipe if the gas or liquid were flowing alone.
The following can be readily shown;
vm = vsl + vsg mixture velocity, vm, is the sum of the two superficial velocities
vsl = ql / A – superficial liquid velocity vl = ql / (A.Hl) – actual liquid velocity
vsg = qg / A – superficial gas velocity vg = qg / (A.Hg) – actual gas velocity
λl = ql / (ql + qg), but vsl = ql / A and vsg = qg / A, so
λl = vsl / (vsl + vsg) = vsl / vm
Note, some researchers refer to superficial velocity as j, the volumetric flux.
3 Flow Regimes
In multiphase flow, the gas and liquid within the pipe are distributed in several fundamentally
different flow patterns or flow regimes, depending primarily on the gas and liquid velocities,
physical properties and the angle of inclination. Observers have labelled these flow regimes
with a variety of names. Over 100 different names for the various regimes and sub-regimes
have been used in the literature.
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A number of workers have generated flow regime maps which can be used to determine
which flow regimes are likely to occur within a particular pipeline (or parts of the pipeline)
under various operating conditions. It is important to know which flow regime since the
regime will determine the pressure drop along the pipe, the liquid hold-up within it and the
nature of the fluid mixture which will have to be treated on arrival. Research on two phase
flow regimes goes back many decades (Baker 1954). Papers by Mandhane et al (1974), Taitel
and Dukler (1976) are often quoted.
With the exception of Taitel and Dukler, these researchers have used an empirical approach to
interpreting experimental results. Taitel and Dukler produced a more theoretical or
mechanistic approach and they compared this successfully with published results. This was a
landmark advance for the science.
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For vertical flow similar regimes are defined. However, as can be seen stratified flow does not
exist.
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Experimental studies of flow regime transitions have shown that each of the flow regime
boundaries reacts differently to changes in the system variables. The following table shows
the sensitivity of the transitions to changes in the major system variables:
Many researchers have attempted to develop simple flow regime maps, usually using
dimensionless parameters on each axis (e.g. Baker, Beggs & Brill). These methods can be
inaccurate since no single parameter can model the sensitivity effects indicated above.
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the dispersed flow regime even though Mandhane would have predicted superficial liquid
velocities too low to cause dispersed flow.
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These two methods can indicate completely differing flow regimes. The engineer now has to
make a decision on which method he/she considers more accurate. The simplistic single
variable axis with Mandhane would be a concern suggesting Baker to be more realistic.
Most early researchers studied multi-phase flow in either horizontal or vertical with low
pressure air, water and steam systems. The inherent concern was what effect will different
properties have on the flow maps. Some of the effects are illustrated in the following figures.
As can be seen, and probably as expected, the effects can be very significant.
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Such significant effects raised concerns that flow regime models were likely to be flawed if
scaled to high pressure oilfield conditions.
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used as slender horizontal separators. The pipe is generally inclined from one to ten degrees
and banks
of these slightly inclined pipes are frequently manifolded together. The are often described as
finger type slug catchers.
The following figure shows the variation in predicted liquid hold-up for a large wet gas
transmission line. As can be seen the correlation predictions can differ by an order of
magnitude. Once gain the engineer is concerned about method accuracy and flow assurance.
Use of an inappropriate correlation could result in a significant under or over prediction of
slugcatcher size.
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A worked example is provided at the end of the lecture notes. Note units of d are mm.
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are compared with flowing wellhead pressures established from well lift curves to ensure
there is adequate wellhead pressure to deliver the production fluids.
There are three categories of flow correlations
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μn = μl. λl + μg. λg
Similarly a no slip two-phase density is utilised.
ρ n = ρ l. λl + ρ g. λg
Recall λl and λg are the no slip liquid and gas hold up.
The two-phase Reynold’s number becomes;
Ren= ρn.vm.d/μn
Where vm is the no slip mixture velocity.
The two – phase friction factor can be determined using the Blasius expression;
ftp = 0.079. Ren-0.25
Two-frictional pressure drop becomes;
ΔPf = 2. ftp. ρn.vm2 /d
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The two-phase pressure drop may be then be estimated from either of the single-phase
pressure drops, using;
where YL and YG are read from the accompanying figure as functions of X. The curve labels
refer to the flow regime (laminar or turbulent) found for each of the phases flowing alone. The
common turbulent-turbulent case is approximated well by;
Lockhart and Martinelli correlated pressure drop data from pipes 25 mm (1 in) in diameter or
less within about 650 percent. In general, the predictions are high for stratified, wavy, and
slug flows and low for annular flow. The correlation can be applied to pipe diameters up to
about 0.1 m (4 in) with about the same accuracy.
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range of viscosities and surface tensions. Nitrogen was used as the gas.
− Pipeline inclination angles between 1° were studied in addition to flow up or down a
hill section ahead of a 50m high vertical riser.
− Over 10,000 experiments were run on this test loop during an eight year period
running in both steady state and transient modes.
− OLGAS considers four flow regimes and uses a unique minimum slip criteria to
predict flow regime transitions.
OLGAS has become an industry accepted tool for the analysis of steady state multi-phase
systems. Also offered by the same group is OLGA – a state of the art transient mutli-phase
simulator. OLGA and OLGAS also have OVIP (OLGA® Verification an Improvement
Project) . This is a multi-client joint industry research and development program for
validation and improvement of OLGA®. The OVIP program is supported by BP, Chevron,
ENI, ExxonMobil, Petrobras, Statoil, Total and Shell. OVIP embodies by far the largest
multiphase flow data collection ever assembled. Containing both experimental and field data,
including gas/condensate pipelines, lower GOR pipelines, well, and transient data. Transient
modelling is a critical aspect of flow assurance and requires highly sophisticated simulators
for accurate analysis.
5 Slug Flow
Slug flow is particularly troublesome flow regime. It presents a difficult pattern for process
control systems.
When liquid and gas are flowing together in a pipeline, the liquid can form slugs that are
divided by gas pockets. The formation of liquid slugs can be caused by a variety of
mechanisms:
1. Hydrodynamic effects (surface waves)
2. Terrain effects (dip in pipe layout)
3. Pigging
4. Startup and blow-down
5. Flow rate or pressure changes
Hydrodynamic slugs, in horizontal and near horizontal pipes, are formed by waves growing
on the liquid surface for a height sufficient to completely fill the pipe. In vertical pipes the
hydrodynamic slugs are associated with Taylor bubbles. The hydrodynamic slugging is
difficult to prevent since it occurs over a wide range of flow conditions. The repeating
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impacts of hydrodynamic slugging can cause fatigue. It is therefore important to predict the
slug volume, velocity, and frequency of such slugs.
Furthermore, several hydrodynamic slugs can gather together due to terrain effects, creating
larger slugs – slug growth.
A particular form of terrain slugging is created where a pipeline slopes downwards and joins a
vertical pipeline (riser). In this flow phenomena liquid stalls in the riser, fills the riser and is
blown out when the accompanying gas bubble has sufficient pressure to overcome the
imposed hydrostatic head. The transient surges of liquid and gas associated with severe slugs
can cause major problems for topside equipment – typically separators and compressors.
Understanding and controlling the phenomena is essential for safe operation and to prevent
shutdowns and associated lost production.
Other types of slugging are initiated by pipeline operations. Pigging of a pipeline causes most
of the liquid inventory to be pushed from the line as a liquid slug ahead of the pig. Shut down
of a line will drain the liquid that is left in the line down to the low points. During restart the
accumulated liquid can exit the pipeline as a slug. Also, increasing or decreasing the flow rate
of either gas or liquid leads to a change in liquid holdup. This can come out in the form of a
slug, depending on the rate of change of flow rate.
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Slugs then grow as they pick up liquid in low spots or join with an adjacent slug.
The empirical Scott, Shoham and Brill correlation takes account of slug growth and can be
used as a first approximation.
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For a terrain slug to be initiated a number of criteria need to be satisfied that are somewhat
similar to those for severe slugging. For example, the flow in the upstream section needs to be
stratified, whereas the flow in the downstream section needs to unstable. Although often not
very accurate, several correlations exist in the literature to predict the length and frequency of
hydrodynamic slugging. To predict the effect of topological variations on the downstream
development of these slugs a transient simulation can be made with a dynamic tool utilising a
slugtracking option (such as available in OLGA). This option includes a model to insert slugs
in dips, based on the local criteria. Thereafter the slug front and tail is tracked when the slug
travels through the pipeline. The slug can grow or shrink, can split up in two slugs, or can
merge with other slugs. Results obtained with slug tracking should be interpreted with care.
This is not exact science, and there is room for improvement (both with respect to the
numerical and physical modelling). Experience shows that size and frequency of the slugs that
appear at the outlet with the slug tracking simulation are often dependent on user-defined
parameters for slug initiation. Terrain slug can growth is very much dependent on the
topography and flow regimes encountered during the slug propagation along the pipeline.
Severe slugging is an extreme case of terrain induced slugging. The cycle of slugging is
described.
Pipeline of downward gradient meets riser base.
1. Liquid blocks the base of the riser.
2. Riser fills with liquid if accompanying gas bubble has insufficient pressure to overcome
liquid head. Riser continues to fill.
3. Once riser is full the backpressure stabilises however the accompanying gas bubble
pressure continues to rise
4 Once the gas bubble pressure is greater than the riser back pressure the riser starts to unpack.
5. Slowly at first then accelerating as the head in the riser reduces. The accompanying gas
pocket then discharges into the separator.
Severe slugging produces gas and liquid flow and pressure transients which are very difficult
to manage.
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3. The flow line is operated either in the stratified or annular flow pattern but not in
slug flow.
The criteria for severe slugging are summarized in the flow pattern map for the pipeline
upstream of the riser base, as depicted in the following. Severe slugging will typically occur at
turndown production, and/or at late field life when the riser is in the hydrodynamic slugging
regime and the gas production is low.
When severe slugging occurs, more energy is consumed due to the regularly varying gas and
liquid velocities in the line. Extra static head loss occurs when the riser is fully filled with
liquid.
The possibility of severe slugging can be determined using the following procedure;
1. Assume all the liquid in the system acts to fill the riser – calculate (dp/dt) riser. Calculate
rate at which riser fills in m/s and convert to a pressure rise.
2. Calculate the no slip hold up and, assume no slip exists in the downward sloping portion
of the flowline.
3. Calculate the gas volume in the downward sloping line assuming no slip.
4. Calculate the gas volume flow at average pipe line conditions .
5. Calculate (dp/dt) flowline the ideal gas law – rate of pressure rise will be linear with volume
flow into gas volume in the sloping line section.
6. Evaluate (dp/dt) flowline / (dp/dt)riser – less than one severe slugging possible.
7. Calculate superficial velocities and check for stratified flow or annular flow.
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6 Pipeline Topology
Note that Pipeline topography can have a large influence on slugging characteristics and also
on pressure loss. Accurate seabed bathymetry is very important for multi-phase analysis.
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Key Learnings
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