ENGI 8673 Subsea Pipeline

Engineering

Lecture 03: Pipeline Hydraulics

Shawn Kenny, Ph.D., P.Eng.

Assistant Professor
Faculty of Engineering and Applied Science
Memorial University of Newfoundland
spkenny@engr.mun.ca
Lecture 03 Objective
To provide an overview of flow assurance
To provide simple tools for assessing
single phase flow pipeline hydraulics

2 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Overview Flow Assurance
System Deliverability
Line sizing
Production rate
Pressure profile and boosting
Thermal Behaviour
Temperature profile
Passive or active mitigation
Product Chemistry
Waxing, asphaltenes
Hydrates
Scaling, erosion, corrosion
Operability Characteristics
Steady-state, transient
Shut-down, start-up
System Performance
Mechanical integrity
System reliability
Ref: Watson et al. (2003) Ref: McKechnie et al. (2003)

3 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Flow Assurance Hazards
Mechanical
Corrosion
Erosion
Flow
Slugging Ref: Hydro (2005)

Emulsion
Deposition
Scaling
Sand
Wax & asphaltenes
Hydrates Ref: BakerHughes (2005)

4 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Flow Assurance Strategies
Mechanical
Hydraulics
Line sizing
Pumping, compressor
Chillers, heaters
Processing Ref: Hydro (2005)

Dehydration
Chemical removal
Intervention
Inline pigging
Plug removal

Ref: Rosen (2005); Paragon (2005)

5 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Flow Assurance Strategies
Thermal
Burial
Insulation
Heating
Ref: Hydro (2005)

Panarctic Drake F-76 Flowline Bundle

6 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Flow Assurance Strategies
Flow Performance
Drag reduction
Drag reducing
agents (DRA)
Liners
Inhibitors Ref: Hydro (2005)

Methanol
Mono-ethylene
glycol (MEG)

Ref: BakerHughes (2005); Ridao (2004)

7 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Overview Flow Assurance
Lecture Focus
Overview of steady-state, single phase flow
Associated Technical Issues
Multiphase, dense flow
Transient flow

Start-up, shut-down conditions

Risk and mitigation strategies

8 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Key Engineering Factors
Pipeline Hydraulics
Line Sizing
Primary function for product transport
Steady-State Conditions
Operating pressure & temperature profile
Facilities Design
Slug catcher, tank farm

9 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Drivers
Production Rate
Flow rate,
throughput
Velocity, pressure

Operating Cost
D losses &
pressure
Construction Cost
D

10 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Hydraulics Key Input Parameters
Product Characteristics
Phase & composition
Chemical constituents
Pipeline Configuration
Route length
Nominal diameter
Bathymetric & topographic profile
Thermal Profile
Pipeline, soil conductivity
Air, water temperature
Initial Boundary Conditions
Inlet pressure, temperature
Outlet pressure, temperature
Ref: Terra Nova DPA

11 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Fluid Mechanics
Single Phase Flow
Pressure Term

Oil, gas or water Nominal Pipeline Radius

Newtonian fluid
Some heavy oils Velocity
Profile Shear Stress
are non-Newtonian
Constant Flow Rate
Elevation
Pressure Elemental
Length

Gravity

Ref: White (1986)

12 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Single Phase Flow Mechanics
Uniform Velocity
Pressure Term

dZ
r dP + ( 2 r dL ) + g r dL
2
=0 2
Pipeline Radius
dL
dP 2 dZ
= g =0
dL r dL Velocity

Shear Stress
Profile Shear Stress

f u2
=
2 Elevation
f Fanning friction factor Elemental
u mean velocity Length
fluid density

dP f u2 dZ
= g =0 Ref: White (1986)
dL r dL
13 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Integral Formulation
If Constant Over dL
Pressure Term

Diameter Pipeline Radius

Velocity

Friction (viscosity) Velocity

Profile Shear Stress

Density (gas flow)

f u2
Elevation
dP dZ
= g =0 Elemental
dL r dL Length

f u2
P2 P1 = ( L2 L1 ) g ( Z 2 Z1 ) = 0
r
Ref: White (1986)

14 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Integral Form Not Practical
Variation in Properties
Velocity, density, friction coefficient
Oil and Gas Flow
Heat loss
f Re (T)
Gas Flow
Density
P Q & z
Constant mass flow rate
U
Compressibility
Joule-Thompson (T P)

15 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Frictional Losses
Assumptions
Smooth, uniform internal diameter
Incompressible fluid

Function of Reynolds number

viscosity (Pa s)
U D
Re =

16 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Frictional Losses (cont.)
Friction Coefficient
Fanning [f]
Hydraulic
1
f
( )
= 4 log10 Re f 0.4
radius
Loss D
Manning [m] f = 40.0014 + 0.125 Re0.32
Diameter
m = 4f
Parameters
Reynolds
number, Re Loss U
Surface Re
roughness, k f =
k 0.05mm 16
Corrosion,
erosion,
wax, etc.

17 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Analysis of Turbulent Flow
Theoretical Treatment
Empirical coefficients
Sensitive to surface roughness

0.241L 0.75 0.25 Q1.75

P =
D 4.75

Ref: White (1986)

18 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Pipeline Hydraulics Calculations
Energy Balance per Unit Length
m mass flow rate (kg/s)
h change in enthalpy (J/kg)
EPE change in potential energy (J/kg)
EKE change in kinetic energy (J/kg)
QT heat loss (W)
W external mechanical work (W)
m (h + EPE + EKE ) + QT + W = 0

19 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Line Sizing Gas Flow
Panhandle A Formula
Empirical
Large diameter pipelines

Relatively low pressure (7MPa)

1.07881 0.5394
3 To p1 p2
Q = 438 10 E G 0.4606 D 2.6182
po LT
Q Flow rate (m3/day) L Pipeline length (km)
E efficiency factor (typically 0.92) T mean temperature (K)
po Reference pressure (MPa) G gas gravity (air = 1)
To Reference temperature (K) D pipeline diameter (mm)
p1 Upstream pressure (MPa)
p2 Upstream pressure (MPa)

20 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Line Sizing Oil Flow
Rule of Thumb
Trade-off CAPEX OPEX
D in; Q BBL/day
1 BBL = 42 US gal = 35 Imp gal
1 BBL = 158.97 L

Q
D=
500

D mm; Q m3/s
D = 840 Q

21 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-01
Calculate the line size (nominal diameter)
for a horizontal, single phase oil pipeline
Flow rate, Q = 0.342 m3/s
Fluid density, = 950 kg/m3

Viscosity, = 2 10-5 m2/s = 20 centistokes

Surface roughness, k = 0.006mm

Pipeline segment length, L = 100m

Head loss, hf = 8m

22 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-01 (cont.)
Modified
Moody
Chart

Ref: White (1986)

23 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-01 (cont.)
Using Modified Moody Chart
k 128ghQ 3
= 3.51 109 = = 2.012 10 11
Q 3 L 5

Corresponds to smooth wall

Re = 1.43 0.416 = 72,100

Line size
UD 4Q
Re = = D = 0.302m
D

24 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02
Consider the following pipeline system
transporting 100kBBL/day single phase oil
Oil density, = 850 kg/m3
Viscosity, = 0.01 Pas = 10 centipoise

Inlet pressure 5MPa

Arrival pressure 1MPa

Calculate the line size for a 25km pipeline

25 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Line Sizing Rule of Thumb
Q 100000
D= = = 14.1" 358mm
500 500

Using API 5L (2007)

Select D = 12 (12.75) = 323.9mm
Guess WT = 12.7mm
Q 0.184 m 3 / s
U= = = 2.63 m / s
A 0.3239 - 2 0.0127 2 m 2
( )
4

26 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Reynolds Number
U D ( 850 kg m ) ( 2.63 m s )( 0.3239m 2 0.0127m )
3

Re = = = 6.67 10 4
0.01Pa s

Fanning Friction Factor

Assume k = 0.001
f = 0.0059

27 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Check Erosion Velocity
Reduces wall thickness
Generates noise

Empirical expression

122 122 m
Umax = = = 4.2
kg s
850
m3

m m
U = 2.63 < Umax = 4.2 ok
s s

28 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Pressure Drop
dP f u2 dZ
= g =0
dL r dL

Friction loss only

P =
f U L
2
=
( )
0.0059 850 kg m 3 ( 2.63 m s ) ( 25000m )
2

= 5.81MPa
r 0.14925m

Allowed P = 5MPa 1MPa = 4MPa

Reselect D

29 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Using API 5L (2007)
Select D = 14 = 355.6mm
Assume WT = 12.7mm
2
Q m 0.2985m m
U = = 2.63 = 2.15
A s 0.3302m s

U D ( 850 kg m ) ( 2.15 m s )( 0.3302m )

3

Re = = = 6.03 10 4
0.01Pa s

P =
f U L2
=
( )
0.006 850 kg m 3 ( 2.15 m s ) ( 25000m )
2

= 3.57MPa
r 0.1651m
Acceptable P

30 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Example 3-02 (cont.)
Field Life Scenario
Reduced production rate
10 years
20kBBL/day
Produced water
CO2, H2S
Q m 20kBBL day m
U= = 2.15 = 0.43
A s 100kBBL day s
Potential
Water drop out
Extensive corrosion at clock position 6 and low spots

31 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Multiple Phase Flow
Phase
Gas
Liquid (oil, water)
Solid (sand)
Flow Regime
Multiple modes
Irregular flow
Vibration
Ref: Hydro (2005)
Emulsion
Oil and water mixture
Viscosity P
Slugging
Hydrodynamic,
elevation induced
Process upset, shut down
Surge
Volumetric, mass flow rates

32 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
Reading List
1. Cochran,S. (2003). Recommended Practice for Hydrate Control
and Remediation. World Oil, September, pp.56-65.
[2003_Cochran_RP_Hydrate_Control_Remediation.pdf]

2. McKechnie, J.G.and Hayes, D.T. (2003). Pipeline Insulation

Performance for Long Distance Subsea Tie-Backs. 14p.
[2003_McKechnie_Insulation_Performance_Long_Distance_Tie_
Backs.pdf]

3. Wasden, F.K. (2003). Flow Assurance in Deepwater

Flowlines/Pipelines. Deepwater Technology, October, pp.35-38.
[2003_Wasden_FA_Deepwater_Flowlines.pdf]

4. Watson, M., Pickering, P. and Hawkes, N. (2003). The Flow

Assurance Dilemma: Risk versus Cost? E&P, May, 4p.
[2003_Watson_Flow_Assurance.pdf]

33 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03
References
API 5L (2007). Specification for Line Pipe, Forty-fourth Edition. 44th
Edition.
BakerHughes (2005). http://www.bakerhughes.com/bakerpetrolite
Hydro (2005). http://www.hydro.com/ormenlange/en
Paragon (2005). http://www.paraengr.com
Rosen (2005). http://www.roseninspection.net
Ridao, M.A. (2004). Optimal use of DRA in oil pipelines. IEEE
International Conference on Systems, Man and Cybernetics,
pp.6256-6261.
Watson, M., Pickering, P. and Hawkes, N. (2003). The Flow
Assurance Dilemma: Risk versus Cost? E&P, May, 4p.
White, F.M. (1986). Fluid Mechanics. 2nd Edition, McGraw-Hill, ISBN
0-07-069673-X, 732p.

34 2008 S. Kenny, Ph.D., P.Eng. ENGI 8673 Subsea Pipeline Engineering Lecture 03