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Pipeline Drag Reducers

Marawan, H.
E.G.P.C.
Abstract
Pipeline drag reducers have proven to be an extremely powerful tool in fluid
transportation. High molecular weight polymers are used to reduce the frictiona]
pressure loss ratio in crude oil pipelines, refined fuel and aqueous pipelines.
Chemical structure of the main used pipeline drag reducers is one of the
following polymers and copolymers classified according to the type of fluid to ; low
density polyethylene, copolymer of 1-hexane cross linked with divinyl benzene,
polyacrylamides, polyalkylene oxide polymers and their copolymers, fluorocarbons,
polyalkylmethacrylates and terpo'ymer of styrene, alky] acrylate and acrylic acid .
Drag reduction is the increase in pump ability of a fluid caused by the addition
of small amounts of an additive to the fluid. The effectiveness of a drag reducer is
normally expressed in terms of percent drag reduction.
Frictional pressure loss in a pipeline system is a waste of energy and it costly .
The drag reducing additive minimizes the flow turbulence, increases throughput and
reduces the energy costs. The Flow can be increased by more than 80 % with existing
assets.
The effectiveness of the injected drag reducer in Mostorod to Tanta crude oil
pipeline achieved 35.4 % drag reduction and 23.2 % flow increase of the actual
performance The experimental application of DRA on Arab Petroleum Pipeline
Company (Summed) achieved a flow increase ranging from 9-32 % .

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Introduction:
Oil transportation companies are experiencing a need

to increase their

efficiencies and transport capabilities The frictional Pressure drops or drags ,


responsible for energy losses and limiting the throughput of oil pipelines , can be
significantly reduced by injecting long chain polymers (flow improvers ) .
Pipeline flow improvers, or drag reducing agents, have been utilized in the
Petroleum industry for more than 35 years . The first application of drag reducers in
the petroleum industry was to reduce the down-hole pressure loss during pumping of
fluids down hole to fracture-tight formations. One of the first large-scale pipeline
applications was to increase the throughput of crude oil on the Trans-Alaskan
Pipeline in 1979. Because of the reduction of the apparent viscosity, drag reducers are
useful in saving energy required for pumping.
By reducing the frictional pressure loss, drag reducing agents (DRA) can
increase throughput by more than 90% of the pipeline's mechanical capacity .

Drag Reducers are used in pipeline systems for :


1. Throughput improvement
2. Power optimization
3. By - passing intermediate pump stations
4. Batch management
5. scheduled maintenance
6. shortening barge download time
7. Peak shaving
8. Operating pressure reduction

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Drag Reducers Mechanism:


Drag reduction, as defined by Savins " , is the increase in pump ability of a
fluid caused by

the addition of small amounts of an additive to the fluid . The

effectiveness of a drag reducer is normally expressed in terms of percent drag


reduction . At a given flow rate, percent drag reduction is defined as :

o/oDR

A Po - A Pp

Equation 1

]00

APp
APo is the base frictional pressure drop of the untreated fluid.
Pp is the frictional pressure drop of the fluid containing reducing polymer .

Percent drag reduction is a measure of drag reducing additive performance, but


it does not reflect the primary' end use of drag reducers . Normally, the reduced
frictional pressure drop is used to increase flow rate without exceeding the safe
pressure limits within the pipeline system . The relationship between percent drag
reduction and percent flow increase can be estimated using the following equation 3:
0.556
% Flow increase =

(
)
L 100-%D.R J

]\ * 100
J

Equation 2

Where % D.R. is the percent drag reduction as defined in Equation 1 . Equation 2


assumes that frictional pressure drop is proportional to flow rate raised to the 1.8
power, for both treated and untreated fluids, and that the discharge pressure is
constant for both the baseline and increased flow rates .
Drag reduction occurs by the interactions between elastic macromolecules and
turbulent flow niacrostructures

. In turbulent pipe flow, the region near the wall,

comprising a viscous sub layer and a buffer layer, plays a major role in drag
reduction
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December 2004

The most serious problem in the effectiveness of drag reducers is the chain
degradation of polymers by shear strains in turbulent flow. Ultra high molecular
weight polymers are more susceptible to shear-induced degradation \ and polymers
with linear chain-structure are more vulnerable than branched polymers 6'

and

natural gums of semi-rigid structure . The mechanism of shear degiadation is


assumed to be associated with chain elongation .The chain degradation is often
observed when the shear rate is increased to a critical point, after which drag
reduction sharply decreases .

Table (1) : Types of Drag Reducers Agents

Cheniicate'

<

' "-

; - <

Description - , , - , -i'/-'

Linear low density polyethylene

a-Olefins up to 10 mole %
a-olefins are 1-hexene, 1-octene, 1-

Copolymer of linear a -olefin with


crosslinkers 10

decene,and 1-dodecene
Cross linkers are divinylbenzene or
organosiloxanes with pendent vinyl
groups

Polyacrylamides , polyalkylene oxide Water


polymers and their copolymers
Fluorocarbons

l4

soluble

drag

reducer

for

emulsions
For asphaltenic crudes oils
Esters with C-10 to C-18 and ionic

Polyalkylmethacrylates15"19

monomers reduces friction in flow of


hydrocarbons by a factor of 5 at
concentrations of 25 ppm

Terpolymer of styrene, alkyl acrylaie Styrene includes also t-butyl styrene


and (acrylic acid or methacrylic acid)

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(drag reducer for hydrocarbon fluids)

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December 2004

CH2= C H - C

X
N

C H

CH

t O

CH3
o
_.. I
_'/

~C
\ ) _

CH2-Cc

OH

H
Acryl amide

Acrylic acid

CH = CH2

Methacrylic acid

CH=CH 2

fOJ

^rH/v/-^CH3

CH =CH 2
Styrene

1-Hexene

p-Divinylbenzcne

Fig. (1): Monomers for Copolymers of Acrylamide and Acrylic Acid and Styrenics .

Linear low density polyethylene is a copolymer of ethylene and olefins. It


is obtained by co polymerization utilizing Ziegler-Natta catalysts. Concentrates may
be prepared by precipitating the polymer from a kerosene solution with isopropanol21
The resulting slurry concentrate dissolves rapidly in hydrocarbon streams
Effect of Flow Improver Additives on Paraffin Deposition
In waxy cnide's , the wax has a tendency to become deposited during storage of
the crude oil in the tanks and also while flowing through pipelines . The deposition
in the pipeline severely affects the pipeline throughput. The deposits have to be
periodically removed from the storage tanks and the pipelines by pigging
operations.

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Experimental Application of Drag Reducer on


Petroleum Pipeline Company (PPO Oil Pipeline Networks
Two main pipelines were selected to conduct Drag Reduction Trials :
The first is the Crude Oil line from Mostorod to Tanta
The second is the Fuel Oil line between Mostorod and Suez .
Three different commercial chemicals, A,B and C and a Pump skid were used in the
trial.
Test I : Crude Oil - Pipeline Test.
DRA (A) & (C) injected in the Mostorod to Tanta Line .
Test 2 : Fuel Oil - Pipeline Test.
DRA (A) &(B) injected in the Mostorod to Suez Line .
Crude Line Test :
The purpose of this test was to demonstrate the use of DRA in reducing the
frictional pressure loss on a pipeline system . In order to check the effectiveness of
the injected Drag Reducer, it is first necessary to determine the baseline conditions ,
the pressure and flow rates experienced on the line when no DRA is injected . It is
also necessary to have a complete line filled with the crude oil and to collect data for
at least a couple of hours to reflect normal static conditions . On obtaining steadily
consistent data, the DRA is injected . Pressure and Flow Rates data are monitored
during line fill and comparisons are made between line fill conditions with and
without DRA .

Baseline Data Collection :


Normal operating conditions, during the pumping of Crude Oil in the Mostorod
to Tanta Pipeline, were monitored for two days . Discharge Pressure and Flow Rates,
at Mostorod and arrival pressure at Tanta, were logged . After analysis and discussion
the baseline flow rate was determine to be 328 m3/hr . This was achieved with a
pressure difference of 45 kg/cm2 between Mostorod and Tanta .
^626}
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DRA (A) Injection :


Injection of DRA (A) was started at 12:00 AM on the First day at a
predetermined rate until line fill was completed . Line fill is considered to be the
moment at which the treated Crude Oil has displaced all the untreated Crude Oil from
the pipeline sections . With baseline data collection, pressure and flow rates are
monitored every hour until line fill is completed and the data has stabilized .
DRA (C) Injection :
Injection of DRA (C) was started 12:00 PM on the second da\ and data
collection are monitored in the same manner as in the previous test .
Crude Oil Line Test Schedule
Mostorod To Tanta
Date
1st day
2nd day
2nd day
2nd day
2nd day
2nd day

Time
10:00 PM
12:00 AM
07:00 PM
11:00 PM
12:00 PM
10:00 PM

Event
Start of Crude Oil at Mostorod .
Start DRA (A) injection at Mostorod .
Line Fill to Tanta - DRA (A) .
Trial DRA (A) Complete .
Start DRA (C) injection at Mostorod .
Trial DRA (C) complete .

Mostorod to Tanta Test Results


Within a few hour of injecting DRA (A) the flow rate was increasing steadily . The
enclosed graph of flow rate against time shows that such increase continued during
line fill, then leveled off producing a steady state condition representing a 23.2 %
flow increase . reference to the enclosed data table and graphs . Drag reduction of
35.4 % was achieved at a dosage of 115 ppm, with approximately 11.5 US gallon? of
DRA (A) per hour . The DRA (C), although producing a flow increase, did not
match the DRA (A) performance .
DRA (A)
Drag Reduction : 35.4 % .
Flow Increase : 23.2 % .

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December 2004

iMostorod Tanla Crude Line

Mostorod to Tanla Crude Line


DBA (A)

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Fuel Oil - Pipeline Test


Data was collected and logged in the same manner as for the Crude Oil
Pipeline test above . Additional information such as pressure and temperature at the
heater station was also logged .
DRA (B1 Injection :
Injection of DRA (B) was started on the 1st day and similar to the Crude Oil
test, flow increase could be seen after only a few hours , with the injection rate at 150
ppm flow rate continued to increase before leveling off at 290 m3/hr . This represents
a 13.7 % flow increase over the 255 m3/hr baseline flow rate.
DRA (A) Injection :
Injection of DRA (A) was started 3rd day . Once again the injection rate was set at 150
ppm . It can be seen from the enclosed graph of Drag Reduction against time . The
effect of the DRA (A) was to reduce the Drag Reduction and hence reduce the Flowrate . Since the trend was obvious, there was no point in wait for a complete line fill
and the test was terminated at 19:00 hours .
Fuel Oil Line Test Schedule
Mostorod To Suez

Time

Event

l day

09:00 PM

Begin Baseline Data Collection .

Tday

01:00 PM

Start DRA (B) injection at Mostorod .

3 rd day

02:00 PM

Line Fill to Suez - DRA (B) .

3 rd day

07:00 PM Trial DRA (B)Complete .

Date
sl

day

08:00 PM

Start DRA (A) injection at Mostorod .

4 day

07:00 PM

Trial DRA (A) complete

J
lh

/629 s )
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December 2004

Mostorod To Suez Test Results


Significant benefits could be seen in a very short time after injecting the

DRA (B).

The enclosed graph shows a Drag Reduction of 19.5 % at Line Fill, resulting in a
flow rate increase of 13.7 % . It was equally obvious that the DRA (A) did not
perform as well in the Fuel Oil as it did in the Crude Oil .

DRA (B)
Drag Reduction : 19.5 % .
Flow Increase : 13.7 % .

BPP DRA(A) Trial Mostorod to suez


too

DRA(B)
300

DRA(A)
90

l\
/l_A/\/\
%

280
\y

c
c
e

V /

BO

as 250

CL
Q

tf ~ \

70

if

Average Flow Rale

-I 60

-3- Norm DP

220

203 I

U - U X L U X l I ; 11 I I M I I I I i IJU ; H I I i i ljLUOJJlJ.UJ^IJ^JJ-U-U-U.LUj.LUJJ_LI.J-U-U-i.U_lJ.^.iJ
'.3:00

19:00 01:00 07:00

13:00 19:00 01:00 07:00

13.00 13.00 01:00 07:0-0

13:00 19:00

Time

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December 2004

i
I jg

DRA (B) Trial Mostorod - Suez


30
DRA(B)

-e- DR
%Flo

DJR\

.10 i i

i i i i i i i i i i 11 i i i i i i i i i i i

13:00

19:00

01:00

07:00

13:00

inc

(A)

i i i i i i i i i i i i i 11 1 1 . i i i i 1 1 1 1 i i i i

19:00
Time

01:00

07:00

13:00

19:00

Petroleum Pipeline Company


DRA Trials

- , 7 - ' Pipe line

->. Mostorod jSuez

Mostorod - Tanta

Fluid Treated

Fuel Oil

Crude Oil

Baseline Flow Rate

255

328

Achieved Flow Rate

290

404

Flow Rate Increase, %

13.7%

23.2 %

Drag Reduction, %

19.5

35.4

DRA Dosage, ppm

150

115

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December 2004

Conclusions and Recommendations


All the tests gave positive results . In both pipelines a significant and
demonstrable flow increase resulted during a short period of time after DRA was
injected . It was not necessary to wait until a line fill before improvements were
clearly shown . The DRA could therefore be used simply to speed up the transfer of
oils from one location to the other or, equally important, it could be used to maintain
flow rates at a lower pressure difference . This is of particular significance if there are
Main Oil Line pump failures or if part of the pipeline has to be pressure down rated
for any reason . Significant energy savings can also be made by the use of the DRA .
The speed of Pumps can be reduced to bring down operating costs .
Experimental Application of DRA on Arab Petroleum
Pipeline Co. (Summed)
Pipeline Data :
* Length : 370 km
* Diameter : 42 " .
Crude Types :
* Arabian Light (AI) .
* Arabian Medium (AM).
* Arabian Heavy (AH).
* Iranian Light (II) .
* Iranian Heavy (IH).

Application Result:
DRA Concentration (PPM)
Flow Increase (%)

AM
23

IL

9-11

17

23

AH
28

19-21

34

53

66

53

34

28-32

47

92

118

95

47

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IH

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17

References
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December 2004

15 Hameed, M. S.; Taha, E. U Al-Jarrah, M. M. F.: "Observations on the Effect


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EP 256979 (1988)

17 Ritter, W.; Pietsch, O.; Zoellner, W.; Herold, C. P.; Von, Tapavicza, S.: "Use
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