SPE-192878-MS Maximizing Pipeline Flexibility With Drag Reducing Agents

SPE-192878-MS
Downloaded from http://onepetro.org/SPEADIP/proceedings-pdf/18ADIP/3-18ADIP/D031S076R004/1199882/spe-192878-ms.pdf/1 by MOL Pakistan Oil & Gas Co BV, samana ishaq on 05 April 2021
Maximizing Pipeline Flexibility with Drag Reducing Agents
Ray Johnston and Yung Lee, Liquid Power Specialty Products Inc.
Copyright 2018, Society of Petroleum Engineers
This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 12-15 November 2018.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.
Abstract
Drag reducing agents (DRA) have been applied to pipelines since they were first commercialized by Conoco,
Inc. in 1979, and have proven to be a reliable tool for the pipeline industry. Over the past 40 years, adoption
of DRA has been widespread across the globe, in a broad range of climates and in a variety of hydrocarbon
fluids.
DRA are valuable tools as they can reliably provide flexibility in the operation of a pipeline. Because
DRA can be applied over a range of dosage levels in the pipeline, they offer a range of options in terms
of operating points at higher flow rates or lower pressures. DRA can be used to substantially increase flow
rate in a capacity limited pipeline, or maintain flow rate in a derated line. They can also be used for energy
savings, bypassing pump stations. DRA can bring substantial value to pipeline operations through aversion
of flow loss, and through minimizing capital and energy costs.
The latest generation of DRA have demonstrated very high performance potential in terms of drag
reduction performance and supply logistics. New pipelines are increasingly considering DRA usage and
flexibility during the design stage, which can minimize capital and operating costs.
Introduction
Drag reducing agents (DRA) were first used commercially in crude oil pipelines in 1979 with the temporary
loss of an operating pump station on the TransAlaska Pipeline (Conoco, Inc.'s first commercial gel DRA,
CDR). The use of DRA allowed the full production rate of the Prudhoe field to continue to be transported
to the shipping port at Valdez. Since that time, these additives have undergone several generations of
advancement in performance and handling. Nearly 40 years later the use of DRA spans the globe.
Advancements in handling allow DRA to be used in the extremely cold climates of the Arctic regions to
the searing hot climates of the Arabian desert. DRA use is widespread across varying environments, from
the jungles of South America to distant offshore platforms in the North Sea.
Today, DRA are being injected into more than 100 pipeline systems around the world. Used in the
treatment of more than 30 million barrels of hydrocarbon liquids per day, DRA use includes more than 650
pump station injection sites. The typical injection rate at each site varies between 1 and 100 ppm, with a
variety of dosage factors, including the level of drag reduction desired and the flowing viscosity of the oil.
2 SPE-192878-MS
Levels of drag reduction up to 83% (percent reduction in frictional pressure drop) have been achieved in
long-distance pipelines, resulting in flow rates greater than twice the untreated capacity of the pipeline.
A unique characteristic of DRA is that the technology can be applied to nearly all areas of the oil industry.
DRA can be used to increase the production flow of crude oil to the wellhead, from the wellhead to gathering
sites, and from offshore platforms to shore. DRA has also been used to increase loading rates from land
tankage to offshore tankers. The largest volume use for drag reducers is in treating long-distance land-based
pipelines moving crude oil from production areas to refineries. These pipelines often involve a large number
of pump stations and may span a distance of more than one- thousand miles. With nearly four decades of
demonstrated DRA application to crude oil worldwide and the resultant refining of that oil without incident,
the industry has shown that DRA can be safely applied to crude oil without negative impact to the refinery
process. Ten years ago, a revolutionary new DRA was commercialized to treat the heaviest crude oils,
which was not previously achievable with traditional DRA. Since that time, a portfolio of high-performing
products has been available to cover a broad spectrum of crude oil from 10°API to 60°API gravity.
Drag reducers have also been applied to the products pipeline market since the mid-1980s. The use of
DRA in gasoline and diesel for more than 30 years has demonstrated that application at appropriate levels
can be done without negative effects to the engines in which these fuels will eventually be combusted.
Because of their high-performance capabilities, DRA are often injected into pipelines to allow the bypassing
of an intermediate pump station or to reduce the number of operating pumps at a given station. Use of DRA
in this manner can yield a significant reduction in operating and energy costs.
With a dedicated logistics team and a network of global supply chain partners, DRA can be supplied and
implemented quickly in all regions of the world. Because of the potential value DRA can bring to a pipeline
in terms of flexibility in operation, reduced operating costs, and aversion of lost revenue, many pipeline
operators are gaining familiarity with DRA as a valuable tool available to their system.
How DRA Works

Drag reducing agents, also known as flow improvers, are ultra-high molecular weight polymers. Because of
their extremely large size on a molecular scale, a single DRA polymer in solution can associate and interact
with thousands of oil molecules. When this interaction occurs near the pipe wall under turbulent flow, the
number of turbulent bursts at the wall are dramatically reduced. This results in a reduction of the intensity
of turbulent eddies which propagate to the pipe center. Likewise, the energy loss to the eddy currents is
reduced, resulting in a more efficient transfer of energy to the longitudinal movement of oil down the pipe.
Physically this shows up as a reduction in the pressure loss (friction factor) that occurs at a given flow rate in
the pipe. The effect can be quite dramatic as local drag reduction levels of 80% or greater can be achieved.
Figure 1 gives an indication of the performance that can be achieved with DRA at various ppm levels of
injection into a pipeline. The drag reduction performance is calculated as the percentage reduction in the
frictional pressure losses that occur in the pipeline at a given flow rate.
SPE-192878-MS 3
Figure 1—Observed Performance of DRA in Crude Oil Pipelines
There are some misconceptions about DRA based upon their historical appearance in concentrated forms.
When supplied as a concentrated solution, the DRA polymers form an elastic gel. However, because they
are added at much lower ppm levels to the pipeline, DRA do not alter the viscosity of the treated pipeline
fluid (they are not viscosity modifiers), and they do not change the density of the fluid. DRA do not coat
pipeline walls; on the contrary, they must be in solution homogeneously to create the full drag reduction
effect. DRA do interact to change or alter the turbulent flow. As such, they require turbulent flow in the
untreated case to be effective.
Because DRA molecules are extremely large and a single polymer molecule can interact with so many
flowing oil molecules, the molecules are susceptible to breaking under the shear forces which can be
imparted by the various oil molecules moving at different velocities. Shear degradation of the molecules
does occur to some extent with the higher shear forces near the pipe wall. This will slightly and gradually
lower the drag reduction effect as the treated fluid moves down the pipeline. However, the ultra-high shear
forces which occur in a mainline pump are enough to fully break down the DRA polymer to a point of "no
drag reduction effect." If drag reduction is needed in a second pipeline segment downstream of a mainline
pump, new DRA must be injected into the downstream segment.
Using DRA
Figure 2 illustrates the effect and utilization of the drag reducer within a pipeline system. In this figure, the
hydraulic system curve for the pipeline fluid (untreated) is shown. This is a single curve with the head or
pressure requirement increasing exponentially with the fluid flow rate. This is the total pressure required to
move the given fluid down the pipeline. For a given pump curve (hydraulic head available from the pump
impeller at a given flow), there is only one operating point where the two curves intersect. This single point
represents the maximum flow rate that would be achievable in that given pipeline system. With variable
pump speeds or throttling, the pipeline can operate only along the single system curve. The pipeline is
limited to that curve.
4 SPE-192878-MS
Figure 2—DRA Utilization within Pipeline System
The system curves for the pipeline fluid with DRA treatment are also shown. Because DRA can be
injected at multiple ppm levels, there are multiple system curves available depending upon the treatment
level. With DRA, there are a multitude of operating points available along the pump curve. Likewise, there
is more than one maximum flow rate that might be achievable in the system. With variable speed pumps
or throttling, there is a field of operating points for the pipeline. Depending upon the situation desired, the
pipeline can be operated at a new operating point which represents almost total flow increase with very
little decrease in pressure. Alternately, the pipeline can be operated at the original flow rate with much less
pressure head requirement.
The availability of DRA to the pipeline industry offers tremendous flexibility in pipeline operating
systems. A pipeline operator can tune the DRA injection level to achieve an operating pressure/flow rate
operating point which fits the current needs. As these needs change, the operator can adjust the DRA
injection levels to optimize his system, and can achieve the desired flow rates with an optimized power or
energy requirement on the system. If an unexpected bottleneck occurs within a pipeline (such as a sudden
derating of the pipe), the pipeline operator can use DRA to continue to operate at the normal flow rate with
a much lower pressure. If production barrels at a field site exceed the pipeline designed capacity to move
those barrels, then DRA can be injected to allow the increased flow rate while still operating under the
other design limits. If the operating costs or issues with an intermediate pump station become too high, then
injection of DRA can be considered to shut down the intermediate pump station and allow it to be bypassed.
DRA also provides for flexibility as it can be implemented within a short period of time. Injection skids
designed for the considered DRA along with a supply of the DRA product can be placed at a site, with very
little capital requirement. Likewise, if the need for DRA goes away, then the injection can be stopped. DRA
offers flexibility in that use can be continuous for system optimization or injection can be strategically used
for "as needed" scenarios.
Example Cases for Application

Following are a few example cases to illustrate these opportunities in more detail.
Example 1. Multi-station Pipeline De-rated in Middle Segment.
Consider a long-distance pipeline with four operating pump stations moving crude oil from production
sites to a refinery. During normal operation, the pipeline moves about 100,000 barrels per day (bpd) of
crude oil and operates at a pump station discharge pressure near the maximum allowable operating pressure
(MAOP) rating of the pipeline. An inspection of the line reveals that the second segment of the pipeline must
SPE-192878-MS 5
be de-rated due to some local corrosion issues. The deration is to 60% of original MAOP. With the deration,
the second segment becomes the pipeline bottleneck. The pipeline can now only move about 75,000 bpd
while operating at the reduced MAOP. All four segments are forced to operate at the lower rate of the second
segment. However, DRA can be implemented at the second pump station. With an injection of a few ppm
of DRA, the pipeline can increase its flow rate back to the original 100,000 bpd rate and still operate at the
reduced MAOP in the second segment. Injection can continue until the pipeline can replace the affected pipe.
The hydraulic profile for this application is shown in Figure 3. Pump Stations A, C, and D continue to
operate normally with a discharge pressure near the original MAOP, and the normal pressure gradients at
the high flow rate. Pump Station B has a discharge pressure at 60% of MAOP and the pressure gradient
for the second segment is less steep with the effect of DRA. All segments continue to move crude oil at
the 100,000 bpd rate.
Figure 3—Hydraulic Profile for Derated Middle Segment
Example 2. Production Rate Exceeds Design Capacity

An offshore field produces about 350,000 bpd of crude oil. An offshore gathering platform and pipeline
system is designed to move the produced oil to shore tankage. The subsea pipeline has an MAOP which
allows for the current production flow while running with a discharge pressure at the MAOP. A new
production zone is implemented which increases the field production capability to 450,000 bpd. The
offshore pipeline is still limited to moving 350,000 bpd with no feasible capital option for increasing the
throughput. The extra 100,000 bpd of oil cannot be produced without increasing the existing MAOP of the
pipe by nearly a 1.6x factor or by supplying some alternate means to ship the oil to shore.
If DRA injection is implemented onto the platform, however, the extra oil can be moved down the
pipeline. Treating the crude oil with a few ppm of DRA can substantially lower the system pressure curve for
the pipeline. The treated system can easily pump the 450,000 bpd rate down the pipeline with the platform
discharge pressure staying below the MAOP. The hydraulic profile for this application is shown in Figure
4. The pressure gradient with DRA at 450,000 is nearly the same as that without DRA at the lower rate
of 350,000.
6 SPE-192878-MS
Figure 4—Hydraulic Profile for Production Rate Exceeding Design Capacity
If the field production capability were to increase even further, even this extra flow could be handled by
injecting at a higher ppm level of DRA. In fact, a flow rate more than double the original maximum could
likely be achieved with DRA, as long as the current MAOP of the pipeline could be achieved (or close to
it) with the existing pumping system.
A real-world application exists today in the Middle East, which represents a combination of the
previous examples. A 24″ diameter pipeline transports a mixed crude oil (70 centistokes, 26°API) at warm
temperatures over a distance of 167 miles. The mixed crude is pumped from a single station to a refinery. The
crude oil available for transport began to exceed the approximate 135,000 bpd base capacity of the pipeline.
The operator wished to increase movement to nearly 200,000 bpd. Simultaneously, the pipeline system was
de-rated to a lower MAOP which reduced its capacity to approximately 100,000 bpd. The operator tested
and implemented DRA. During testing, flow rates of 204,000 bpd were achieved with a DRA injection
level of 81 ppm. The drag reduction level achieved during this testing was 71% drag reduction. With DRA
injection, a flow rate more than double the derated capacity can be achieved in this pipeline.
Example 3. Pump Station Bypass
An existing cross-country pipeline moves refined products (gasoline and diesel) to a market terminal.
The pipeline currently consists of four operating pump stations equally spaced along its 400-mile course.
Pumping energy costs and the operating costs of the pump stations continues to increase substantially. The
pipeline operator decides to lower operating costs by injecting DRA and effectively bypassing half of its
pump stations. DRA injection systems are placed at the first and third pump stations. The flow through
the second and fourth pump stations are placed in bypass mode and its pumps are shut down. By injecting
approximately 10 ppm of DRA at the first and third pump stations, the operator is able to maintain the
normal flow rate of the pipeline. As a result, related pumping energy costs are cut in half. Additionally,
the other operating costs at the two idled pump stations are reduced. If the operator maintains injection of
DRA monthly, the energy demand charges for the bypassed stations can also be dramatically reduced or
eliminated.
The hydraulic profile for this application is shown in Figure 5. The pressure gradient for the treated
product flow is more than 50% less than that for the untreated case. This allows the gradient to cover the
equivalent of two pipeline segments and eliminates the need for the intermediate pumps.
SPE-192878-MS 7
Figure 5—Hydraulic Profile for Pump Station Bypass
Example 4. New Pipeline Design

As indicated earlier, nearly 40 years of DRA injection in pipelines and the advancements that have
occurred in product form and performance have proven its reliability to the industry. Today, injection
systems can be installed that continuously inject with virtually no downtime and product supply can be
maintained with certainty. With this high reliability, the designers of new pipeline systems can consider the
use of DRA into their design, as DRA offers design flexibility. If the anticipated flow capacity or need for
the new pipeline is not certain; if the need is defined as a range of flow rates with levels of uncertainty, then
the pipeline can be designed to meet a lower flow rate. This can be done with the knowledge that DRA may
be used to obtain a higher flow rate than the design capacity if the need arises.
Likewise, because the use of DRA at various injection levels gives the pipeline an unlimited array of
operating points for a given system, the designer of a new pipeline has much more flexibility in choosing
pipeline parameters such as pipe diameter, wall thickness, and segment length in design options. Once a
base design is established to meet the design basis, the designer may then choose designs with less capital
investment and plan for DRA injection to allow the base design flow rates to still be met. The designer may
opt for a thinner pipe wall which has a lower MAOP and lower pipe cost. The designer may opt for a smaller
pipe diameter, which would yield a slightly higher MAOP and lower pipe cost. However, the overall capacity
without DRA would be substantially lowered due to the higher pressure gradient. The pipeline designer
may also consider designing for longer station-to-station segments, resulting in fewer total operating pump
stations. This could yield much lower capital costs for the pump stations and yield long term lower operating
costs. The use of DRA would allow for the much lower pressure gradient needed in this design.
Table 1 lists more specific parameters around pipeline design considerations as discussed in the previous
paragraph. These values are approximate and are shown as an illustration of the options which DRA use
allows in the design. The design calculations are based upon ANSI/ASME Standard B31.4 Code. The basis
for this example is a 500-mile cross-country pipeline moving a 5 centistoke, 35°API crude oil. Laying of 24-
inch standard wall pipe (seamless, Grade B pipe) with the calculated MAOP would allow for a maximum
flow rate of 250,000 bpd with 5 operating pump stations (100-mile segments). A design considering a thinner
wall (0.312-inch wall thickness) would suggest less pipe in the ground, but have a design MAOP which is
slightly lower. The lower MAOP would mean that the untreated capacity of the pipeline would be less at
229,000 bpd. However, DRA injection of less than 2 ppm at each pump station would allow the capacity to
reach the original 250,000 bpd. A similar design could consider an even thinner pipe wall (0.281-inch wall
thickness), and would yield an untreated capacity of 217,000 bpd. In this case, DRA injection of about 3
ppm at each pump station would allow the capacity to be back to the original level.
8 SPE-192878-MS
Table 1—Example Pipeline Design Options with DRA
Designs considering lower pipe diameter would also allow for smaller pipe expense. These designs would
have slightly higher MAOP, but much less untreated capacity due to the higher pressure gradient. Placing a
22-inch diameter pipeline into the ground would lower the untreated capacity to about 207,000 bpd. Injecting
approximately 4 ppm at each pump station would allow capacity to return to the original level. Placing an
even smaller 20-inch diameter pipe into the ground would cause a lower untreated capacity of 167,000 bpd.
This smaller pipe would require an injection level of about 10 ppm DRA at each pump station to attain the
original capacity of 250,000 bpd.
Lastly, a design that considers less pump stations and longer segment lengths between stations is shown
in the table. Three pump stations, instead of five, would mean substantially less capital costs for the
construction of stations, and likely substantially less operating costs during the life of the pipeline. The
capacity of the pipeline with the longer segments between stations would only be 189,000 bpd for the
untreated crude oil. However, with injection of DRA at the three planned stations at a level between 7 and
8 ppm, the capacity of the pipeline would be 250,000 bpd.
Conclusion
In summary, the use of DRA adds tremendous flexibility to the operating options for existing pipelines and
to the design considerations for future pipelines. This flexibility also brings along substantial value. This
value can come from increased revenues with higher flow capacities and from substantially reduced power
consumption and operating costs. Lastly, this value can come from the averted need for substantial capital
investment, either in an operational event that reduces capacity or in the design for a new pipeline.
Disclaimer
The data presented is based on test results and experiences that LiquidPower Specialty Products Inc. (LSPI)
believes are reliable and is supplied for informational purposes only. LSPI disclaims any liability, damage
or injury that results from the use of the data and nothing contained herein shall constitute a guarantee,
warranty or representation (including freedom from patent liability) by LSPI with respect to the data, the
products described or their use for any specific purpose, even if that purpose is known to LSPI.
SPE-192878-MS 9
References
1. Burger, E.D., Munk, W.R., and Wahl, H.A. 1980. Flow Increase in the Trans Alaska Pipeline
Using a Polymeric Drag Reducing Additive. Paper SPE 9419 presented at the SPE Annual Fall
Technical Conference and Exhibition, Dallas, September 21-24.
2. Beaty, W.R., Johnston, R.L., Kramer, R.L., Warnock, L.G., and Wheeler, G.R., 1984. Drag
Reducers Increase Flow in Offshore Pipelines Without Additional Expansion. Oil & Gas Journal,
August 13, pp. 71–74.
3. Carradine, W.R., Hanna, G.J., Pace, G.F., and Grabois, R.N., 1983. High-Performance Flow
Improver for Products Lines. Oil & Gas Journal, August 8, pp. 92–98.
4. Schoneberger, R.J., Erickson, K.S., Curry, J.M., 1992. Drag Reducer Helps Boost Crude Thruput
During Hydrotest. Pipe Line Industry, June.
5. Dreher, W.R., Johnston, R.L., and Smith, K.W., 2006. Field Use Supports Move to Suspension-
based DRA. Oil & Gas Journal, Vol 104.39, pp. 55–60.
6. Johnston, R., Pierce, J., and Lauzon, P., 2008. Heavy Crude Oil Production Increase Through the
Use of a Novel Flow Improver Product. A Case Study. Presented at the 2008 World Heavy Oil
Congress, Edmonton, Alberta, Canada, March 10-12.

SPE-192878-MS Maximizing Pipeline Flexibility With Drag Reducing Agents

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SPE-192878-MS Maximizing Pipeline Flexibility With Drag Reducing Agents

Uploaded by

Copyright:

Available Formats

SPE-192878-MS

Copyright 2018, Society of Petroleum Engineers

How DRA Works

Example Cases for Application

Figure 3—Hydraulic Profile for Derated Middle Segment

Example 2. Production Rate Exceeds Design Capacity

Example 4. New Pipeline Design

Table 1—Example Pipeline Design Options with DRA

You might also like