Pipe Flow : Philosophy, sizing, and simulation

Presenter: Rizaldi

Module objectives
By

the end of this module you will:

Have knowledge whats behind the flow Recognize and identify parameter, criteria, and proper equation for pipe sizing Get Brief introduction Hydraulic simulation (pipephase as case study)

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Introduction

Proper design and fully accomplish consideration should be taken in order to optimize performance and avoid undesired event

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Fluid Behaviour
Newtonian

Fluid : viscosity is proportional to relative movement rate/shear stress newtonian Fluid : viscosity is not proportional to relative movement rate

Non

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Reynold Number
At

low flowrate pressure drop is proportional to the flowrate, but as flowrate increase until certain points, the relationship between two become nonlinear

Re Re

= momentum/viscous shear stress = .v2/(.v/D)

Re

= .v.D/

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Reynold Number
Flow

Regime based on Reynold number :

a.

Re < 2000 = Laminer :

fluid elements moved in smooth layers relative to each other with no mixing

b.

Re > 4000 = Turbulence : unstable flow pattern, characterized by high degree of mixing of fluid elements

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Conservation of mass

For

steady state :

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Conservation of momentum

(bernouli eq)

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Conservation of Energy

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Bernouli Equation (derivation form)

for

liquids :

For

gas : modified Bernoulli

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Sizing and Hydraulic Evaluation

What

do we need to know ?

What

are the critical Parameter?

correlation/equation to be used?

Which What

are the outputs?

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What do we need to know?

Phase : Single phase Liquid, Single phase gas, two phase, slurry (not to be discussed). Phase determine the characteristic of fluid and to be consider to derive proper equation

Flowrate : Quantity of the fluid, in volumetric rate or in mass rate.Consider maximum and minimum condition which will happen during operation Process condition : Temperature, Pressure.

Fluid properties : Viscosity, density

System arrangements (elevation, fittings, pipe length)

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What do we need to know (summarize)

Phase

Flowrate
Temperature Fluid Fluid

viscosity density change

Elevation

Fittings
Pipe

length
12

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Critical Parameter
Velocity

(max, min, erosion velocity, sonic velocity, entrainment velocity, noise velocity) drop

Pressure

Select

diameter in which will give satisfied parameter value

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Velocity

Limit between certain values to attain economical and safe operation Erosion velocity : Commonly used as parameter for two phase flow, velocity at which erosion or excessive wear on elbows will start to occur identified by equation : C/(m^0.5) Where C = empirical constant, = 100, if continues solid free = 125, for non-continues solid free service

= 150 200, for continues solid free (employing corrosion resistant alloy)
Where m = density of liquid-gas mixture

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Velocity

Noise velocity :

Velocity at which will cause noise above the noise limit (commonly 85 dB - 90dB). API 14 give identification above 60 ft/s

Sonic velocity :

The maximum velocity that a compressible fluid flowing in a pipe of uniform cross-section can achieve is limited by the maximum velocity of pressure wave travel in the pipe, which equivalent to speed of sound. Noise and vibration increase when sonic velocity approached. Can occur in liquid called chocked flow

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Pressure Drop
Items

of pressure Drop :

a. Line friction loss

b. Fitting loss c. elevation change d.miscelenaous loss : Control valve, heat exchanger, flow element

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Typical velocity and Pressure Drop Limitation (fluor daniel)

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Typical velocity and Pressure Drop Limitation (Chevron manual)

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Typical velocity and Pressure Drop Limitation

Two

phase flow velocity limit:

min : 10 ft/s (API 14 E)

max : erosion velocity

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Pressure Drop Equation

Proper

equation shall be use for spesific case/phase : a. Single phase liquid flow b. Single phase gas flow c. Two phase flow

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A. Single Phase Liquid Flow

Straight

pipe, using Darcy Equation :

Elevation

loss :

Fitting

Loss :

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A. Single Phase Liquid Flow

Fitting

loss can also be obtained using equivalent length method :

Friction

factor ( f ) obatined using moody/darcy friction factor :

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A. Single Phase Liquid Flow

For

liquid with Re > 2000 , using Colebrook Equation:

Where

f = friction factor d = pipe diameter

E = pipe roughness

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A. Single Phase Liquid Flow

Gravity Flow Mechanical Energy Balance : Friction Lost : E = W (V2/2g) (k1 + fL/D + k2)

(V12/2g + H1 + 144 P1/d) W1 (V22/2g + H2 + 144 P2/d) W2 = E

D = (W0.5) (1.78 + fL/D)0.25 / (150.6 d0.5 X0.25)

since;

constant mass flow & no pipe size change,

V = V1 = V2

k1 and k2 are K factors for pipe entrance and exit L is total equivalent pipe length excluding the entrance and exit effect in ft D is pipe diameter in ft d is the liquid density f is Darcy friction factor W equals W1 or W2 A is the pipe cross sectional area in ft2 X is the gravity flow driving force in ft g is gravitational constant, 32.174 ft/sec2

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General Equivalent Length (GPSA)

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B. Single Phase Gas Flow

Two

models :

a. Isothermal
straight pipe loss :

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B. Single Phase Gas Flow

Fitting

loss :

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B. Single Phase Gas Flow

B.

adiabatic flow (use in many simulation software)

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C. Two Phase Flow

Flow

regime :

Horizontal vs Vertical
Horizontal

: Bubble, Plug, Stratified, Wavy, Slug, Annular, Mist/Spray Flow.

Vertical

: Bubble, Slug, churn(froth), annular

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C. Two Phase Flow

Bubble

Flow :

Plug

Flow :

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C. Two Phase Flow

Stratified

Flow

Wavy

Flow

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C. Two Phase Flow

Mist/spray

Flow

Slug

Flow

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C. Two Phase Flow

Pressure

Drop Calculation :

a. Duikler Taitel
b. Beggs and Brill

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C. Two Phase Flow

A.

Dukler Taitel

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C. Two Phase Flow

Dukler

Taitel Maps

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C. Two Phase Flow

Beggs

and Brill

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C. Two Phase Flow

Beggs

and Brill

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C. Two Phase Flow

Beggs

and Brill

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C. Two Phase Flow

Beggs

and Brill Maps

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C. Two Phase Flow

No. 1 2

Other Methods (summary)

Flow Direction Methods Mandhane (Dukler / C&M/ L&M) Eaton-Dukler Flow Map Yes No
1)

Liquid Holdup Yes Yes

Horizontal Yes Yes

Vertical Upw. No No
2) 4)

Downw. No No
2) 4)

Inclined 6 6

3
4a 4b 5 6 7

Dukler-Taitel
Beggs & Brill

Yes
Yes Yes No No
3) 3)

Yes
Yes Yes Yes Yes Yes

Yes
Yes Yes Yes Yes Yes

6
4)

Beggs & Brill / Palmer KSLA - Oliemans Eaton - Oliemans BJA-2

Yes Yes No No

Yes Yes No No

Yes
5)

Yes

6 6

8
9 10 11 12a 12b

Mukherjee / Brill
Orkiszewski Gray Hagedorn-Brown HTFS Homogeneous Flow HTFS with Slip

Yes
Yes No No No No

Yes
Yes Yes No
6)

Yes
No No No Yes Yes

Yes
Yes Yes Yes Yes Yes

Yes
No No No Yes Yes

Yes
No No No Yes Yes

No Yes

13

Duns and Ros

Yes

Yes

No

Yes

No

No

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C. Two Phase Flow

Mandhane

The Mandhane method is a hybrid horizontal flow correlation, which is a combination of other existing correlations. These are selected based on the flow regime predicted by the Mandhane flow map. This method gives better matching results with test data than any of the methods used on its own. Holdup predictions for the Annular, Annular-mist flow regime, however, are not satisfactory by any of the methods. A new correlation has to be developed.For inclined lines (less than 6 degrees upwards or downwards) the pressure drop is calculated as for horizontal lines. The pressure recovery is calculated using the two-phase density.

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C. Two Phase Flow

KSLA-Olemans

For the calculation of holdup and pressure losses, however, this method can only be used for horizontal and inclined lines up to 10 degrees, upwards and downwards and for vertical lines, in between 70 90 degrees. For all other inclinations, the results have to be treated with care. The liquid holdups are systematically 13% over-predicted. A test facility was made for an 8 line at 75 bar and the results from the field tests were confirmed by the method. The liquid loadings were increased to give other flow regimes than stratified wavy flow. The pressure drop is calculated using the two-phase density for upward and for downward flow, except for stratified downward flow, where the gas density has been used

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C. Two Phase Flow

BJA-2

This method has been specially developed for large diameter, high-pressure gas / condensate pipelines with low liquid volumes of 1% or less. The pressure-loss

calculation procedure is similar in approach to the Oliemans method, but accounts for the increased interfacial shear resulting from the liquid surface roughness. These correlations appear to give consistently more reliable holdup and pressure drop predictions than the other correlations tested and have been used in the design of several large pipeline and gas gathering systems in the North Sea. Baker Jardine and Associates (BJA) have developed this method from pipeline operating data

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C. Two Phase Flow

MULHERJEE-BRILL

The prediction of flow pattern is based on experimental data on air-kerosene and air-lubricating oil mixtures in a 3.81 cm ID pipe, working at about 8-9 barg. Flow regime maps were drawn for different inclination angles, including horizontal and vertical flow. Different empirical equations for the flow regime transitions are proposed that are functions of inclination angle for both upflow and downflow. In general, the flow regimes and their transition for upflow were similar to those proposed by Duns and Ros for vertical upflow. For downflow, the flow regimes and
transitions conformed more to the Mandhane et. al. type of flow regime map. The stratified flow regime in downflow was bound to be affected appreciable by the angle of inclination. For downhill flows, this method normally overpredicts the pressure drop with 10 40% for 1 to 45 degrees inclined lines. All other pressure drop calculations for other line inclinations are very well matching

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C. Two Phase Flow

ORKISZEWSKI

The Orkiszewski method is a hybrid vertical flow correlation, which is a combination of other existing correlations, with the contribution of one himself. Measurements were done on oil wells with oil-gas and oil-water-gas mixtures in 3 8.75 lines. Do not use this method for lines larger than 10. Instead use a 10 diameter pipe and recalculate the loadings, so that the line velocity stays the same. This will give reasonable results

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C. Two Phase Flow

GRAY

The Gray method has been especially developed for gas condensate wells, and should not be used for horizontal pipes. The recommended ranges for use are:
Angle of inclination 70 degrees Velocity 15 m/s Pipe diameter 3.5 inches Liquid condensate loading 50 bbl / MMSCF (280 m3/106 Nm3)

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C. Two Phase Flow

HAGEDORN-BROWN

This correlation is not flow regime dependent and basically their calculation method is the extended homogeneous case, assumed for the total pressure gradient . Hagedorn and Browns major contribution is their holdup correlation for vertical flow. They did not measure holdup experimentally, rather they measured the pressure gradient and calculated the holdup necessary for the total pressure gradient to give the observed value. They used a very large amount of data, collected for pipe between 1 and 2 diameter

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Hydraulic Simulation (Pipe phase case study)

Modelling

both single phase and two phase flow inside pipeline and piping networks and includes standard industrial compositional and noncompositional PVT predictive methods.

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Hydraulic Simulation (Pipe phase case study)

Calculation

module : Network and Single link

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Hydraulic Simulation (Pipe phase case study)

Input

for thermodynamic calculation : Tabular PVT,Black Oil, Compositional methode PVT : user inputs some properties

Tabular

Compositional

: user inputs fluid composition, while phase and properties generated by built-in thermodynamic function. Oil : at minimum, user input API gravities, gas oil ratio, Gas Heating Value, Pressure and temperature to estimate properties

Black

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Hydraulic Simulation (Pipe phase case study)

Pressure

Drop Correlation method can be

selected
Heat

transfer model can be selected

Using

source and sink method. Data on one of side shall be completed to run the iteration. arrangements can be modeled

Pipe

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Hydraulic Simulation (Pipe phase case study)

Calculation

method

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Hydraulic Simulation (Pipe phase case study)

Pressure

Drop Calculation method

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Other hydraulic simulation used by Tripatra,PT

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