Multiphase pipe flow a key technology

for oil and gas production

Pipe Flow: Some considerations related to

single and multiphase flow

Calculation of flow in pipes

out
in

Conservation of
Energy
Mass
Momentum

Thermodynamics

Mass conservation
out

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)
= UA = constant along a pipeline

Momentum balance single-phase:

L
PR

PL

Friction

Pressure gradient large enough for flow: Velocity depends on friction

(PL PR) A m g sin ( ) Friction

Friction = Friction force per area * wall area

Friction

w (U , ...) D L
Veggskjrspenning

Multiphase Pipe Flow Depends on:

Fluid properties
Density
Viscosity
Phase fractions
Conductivity
Heat capacity
Surface tension
Etc...

Pipe geometry
Diameter
Wall roughness
Pipeline profile/
topography

Environment
T, external
Insulation
T at inlet
P at inlet
P at outlet

Varies with P and T !

P=pressure, T=temperature

Oil samples large differences in

fluid properties
Crude oils
Njord
Visund
Grane
Statfjord C
Condensates
Sleipner
Midgard

Midgard

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

Flow regimes steeply inclined pipes

Bubbly flow:
Little gas, large Uoil
(All inclinations)

Churn-flow:
More gas, large Uoil
(steep inclinations)

Annular flow:
High Ugas, low Uoil
(wide range of incl.)

Stratified/wavy- near horizontal pipeline

Stratified flow. Ugas normally >> Uoil

Large waves: More effective liquid transport

Hydrodynamic slugging
Taylor-bubble
Liquid slug

Large waves that eventually block

the pipe cross section pressure
build up
Intermittent flow liquid slugs
divided by gas pockets
Effective liquid transport
Void in slug: Volume fraction of
entrained gas bubbles in the slug

Slug front in three-phase flow

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 equations 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,
multidimensional, data from relevant and well-controlled flows

Conclusion: we need models based on physics to

extrapolate beyond lab data

Lab

Field

Dimensionless numbers dynamic similarity

Reynolds number, ratio of the inertial forces to

the viscous forces,
Re=

Laminar vs
turbulent flow

=rvL/m

Froude number, ratio of a body's inertia to

gravitational forces or ratio of a characteristic
velocity to a gravitational wave velocity

Wave
propagation,
outlet effects,
obstructions

Weber number, relative importance of the fluid's

inertia compared to its surface tensions:

Formation of
droplets and
bubbles.

Conditions in pipeline
Hydrodynamic forces proportional to rU2
1 m/s

= 1 kg/m3

P = 100 bar
1 m/s

Corresponds to 10 m/s

Conditions in pipeline
Gas liquid interaction: governed by D*DU2
Wind = 3 m/s
Light breeze

Ug = 3 m/s

P = 100 bar

= 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

Conditions in pipeline Drops and bubbles

Hydrocarbon systems can have very low surface tension, in particular gascondensate systems. Encourages generation of smaller drops and bubbles.
Typical values: Air water: 0.07 N/m vs. Gas condensate: < 0.005 N/m
Inertial
U 2 d
We

Surface tension

60 mm/h

Gravitational
gd 2
Eo

Surface tension

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%)

Test facilities for study of

multiphase flow behaviour

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, 2013

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

Some test facilities in Norway

IFE Well Flow Loop

+ All inclinations
+ Indoor
+ High gas density
+ Transparent pipes
+ Cost effective

SINTEF Large Sc.

+ Large L/D
+ Large diameter
+ High pressure, N2

Statoil - Herya

+ Real oil-gas system

+ Formation water
+ High pressure
+ Long, large L/D

- Short, low L/D

+/- Medium diam.

- Fixed inclination
- Expensive to run
- Outdoor

- Cumbersome to change
inclination
- Small diameter
- Steel pipe
Expensive to run
- Outdoor

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, preseparator
15: Return pipe, gas
16: Return pipe, liquid
17: Test section
18: Winch
MEK 4450 Multiphase Flow - IFE Oct. 22, 2013

Worldwide test loops

Worldwide test loops

Instrumentation

Gamma densitometers
PIV (Particle image velocimetry)
X-Ray tomography
LDA/PDA (Laser Doppler anemometry/Phase Doppler anemometry)
ECT (electrical capacitance tomography)
FBRM (Focused beam reflectance measurement)
PVM (Particle vision and measurement)
Shear stress probes

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

vary widely (1 m 100 m)

Measures wall friction and the

hydrostatic pressure difference
between the taps

dp/dz [Pa/m]= dp/dL, where

dp is the differential pressure
measured with the
transducer and dL is the
distance between the
tappings

Holdup=Cross-sectional liquid fraction (H=1-a)

Gamma densitometer
Attenuation of photon flux due
to absorption and scattering

Single media:

where N is the intensity, m is

the attenuation coefficient
(material property) and x is the
distance travelled in the media

Two-phase gas-liquid

This can be developed to

and explicit equation for the
Holdup