1 - Pipeline Hydraulics-Basics

Pipeline Hydraulics - (single phase)
Session Objectives:
Marine Pipelines - Hydraulics - 1
Pipeline Hydraulics - Basics
Review basics of pipeline hydraulics
Be able to perform single phase flow hydraulics

calculations
Liquid
Gert van Spronsen - Pipelines
Shell Global Solutions International (SGSI) - Rijswijk

Email :
Tel :
& Gas
Awareness of special subject - Heat transfer
Gert.vanSpronsen@shell.com
+31 70 447 3427
2009 Shell Global Solutions International B.V. All rights reserved. Do not distribute without consent of copyright owner
Pipeline Hydraulics - Topics
Types of fluids and their properties
Density, viscosity
Liquid flow
Darcy
Gas flow
AGA
equation, Reynolds number, Friction factor
equation, Compressibility
Special subjects
Heat
Transfer
3
Shell - E&P Pipeline systems
Key Parameters for Pipeline Hydraulics

- Sizing a Pipeline
Flow
Distance
- How much & what to transport
Type of Fluids
Liquids
Fluid quantity (flow rates)

Fluid properties (composition or bulk properties)
- How far & what are the conditions

Distance & elevation
Pipeline conditions (wall roughness, coatings, etc)
Environmental conditions
Crude oil (waxy, heavy)
Condensate
Water
Pressure
- What is the available Pressure drop
Gases
Natural gas (lean, rich)
Two-phase Gas & Liquid
Natural gas & condensate
Crude & associated gas
Available pressure vs. pump/compression power

Pipeline Inlet/Outlet pressures
Liquid Flow
Fluid Density (Definitions)
Density:
[ kg/m3]
Specific Gravity (s.g.)

or relative density rel
Density
Viscosity
Vapour presure
Water content
Nasties CO2, H2S
s = standard condition
(15 C, 1.01325 bar)
Liquid API gravity :
liquid , s
rel =
rel =
water , s
M gas
M air
API =
or
gas ,s
air ,s
141.5
131.5
rel
8
Viscosity Variation with Temperature
Crude Oil Properties

Crude
Country
Ekofisk
Arabian light
Kuwait
Bintulu
Schoonebeek
Langunillas
Boscan
Density
(15 C)
kg/m3
Viscosity
(40 C)
cSt
804
859
870
886
904
967
1,005
2
6
10
6
200
800
20,000
Norway
Saudi Arabia
Kuwait
Sarawak
Netherlands
Venezuela
Venezuela
Ekofisk (14)
Bintulu (8)
visc @40 C =
visc @10 C =
Gamba (16)
visc @40 C =
visc @10 C =
visc @40 C =
visc @10 C =
Langunillas (22)
visc @40 C =
visc @10 C =
2 cSt
4 cSt
6 cSt
15 cSt
45 cSt
100 cSt
800 cSt
10,000 cSt
10
Elevation Pressure Loss
Basic Flow Equations

Po
Pelevation = g h
h
Pi
Friction
Elevation
Acceleration
(=0 if d=constant)
Total
Pfric . = 0.5 v 2
L
f
d
Pelev. = g h
2
o
2
i
Pacc. = 0.5 v v
P = Elevation pressure loss
= Liquid density
kg/m3
= Gravity constant
m/s2
= Pipeline elevation
Ptotal = Pfric . + Pelev. + Pacc.

11
Pa
12
Frictional Pressure Loss - Liquid Flow
Frictional Pressure Loss - Liquid Flow
Darcys equation
Darcys equation
P =
v2
L
f
d
P = Frictional pressure loss
P =
v2
L
8
L
f = 2 Q2 5 f
d
Pa
P = Frictional pressure loss
= Liquid density
kg/m3
= Velocity
v = Velocity
Q = Volume flow
m/s
m3/s
L
d
= Pipeline length
= Pipe internal diameter
m
m
= Friction factor (Moody) (Fanning ff = 4x Moody ff)
Q = Volume flow
m/s
m3/s
L
d
= Pipeline length
= Pipe internal diameter
m
m
= Friction factor (Moody) (Fanning ff = 4x Moody ff)
= Liquid density
Pa
kg/m3
13
14
Pipeline design basic rules:
Friction Factor - Liquid Pipelines
P " Const " Q 2
L
d5
Re =
Pressure drop proportional to Length

Pressure drop proportional to Flow Squared
Pressure drop inverse proportional to Diameter to 5th power
Flow capacity proportional to Diameter to 2.5th power
One additional Pump station

B. 10% more flow
C. Decrease from 12 to 10 inch
A.
F (Re, e /d) via Moody diagram
= Liquid density

- capacity 40% up
- pressure drop 20% up
- pressure drop up 2.4 times
Re
v
d
v

=
=
=
=
vd
e =
e /d
Reynolds number
Velocity
Pipe internal diameter
Kinematic viscosity
Dynamic viscosity
Wall roughness
= Relative wall roughness
15
vd
m/s
m
m2/s (106 cSt)
kg/m3
Pa.s (103 cP)
m
16
0.1
Turbulent zone
0.09
Pipeline Wall Roughness
0.08
Critical
zone
Laminar
zone
Transition
zone
Complete turbulence, rough pipes

.05
0.07
Friction Factor
- Moody Diagram
0.06
0.05
Roughness is either absolute () or relative ( /d)
.04
.03
.02
.015
0.04
.008
Roughness is not a physical measurement
Friction factor f
Significant effected by corrosion, erosion or wax

deposits
.006
0.03
.004
0.025
.002
0.02
Relative roughness _
d
.01
.001
.0008
.0006
Smooth pipes
f = 0.019
.0004
Typical values:
0.015
.0002
Standard carbon steel

Heavily corroded steel
Internally coated pipe
Flexible pipe with inner carcass
0.03
1.0
0.01
250/d
mm
mm
mm
mm
.0001
.00005
0.01
Rel.R = 0.00005
0.009
0.008
RE = 8. 10^4
.00001
103
5 6
8 104
5 6
8 105
17
Pumping Power
Gas Flow
Ppower =
Q P
Ppower = Power requirement
kW
= Throughput
m3/s
= Differential pressure
kPa (over the pump)
= Pump efficiency
5 6
8 106
vd vd
=
5 6
8 107
_ = .000 001
d
3 4 5 6
_ = .000 005
d
8 108
18
Compressibility - Gas Density - function of Pressure
Reynolds number =
PM
=
z RT
= Density
kg/m3
P = Pressure
Pa
M = Molecular Weight
kg/kmole
z = Compressibility (correction) Factor
R = Gas Constant
J/kmole.K
= 8314
T = Temperature
K
Z - Compressibility (correction) Factor for Non-Ideal Gases

19
20
Z - factor - Charts (1)
50C
25C
0.80
10C
0C
-10C
0.70
-25C
0.60
0.50
Molar mass = 16.04 kg/kmol

pc = 4640 kPa (abs)
Tc = 191 K
-50C
75C
50C
0.80
25C
10C
0.70
0C
-2 0
0.60
0.90
100C

pc = 4653 kPa (abs)
Tc = 200 K
0.50
150C
75C
0.80
50C
25C
0.70
10 C
0 C
C
0.60
350C 300C
250C
200C
1.00
150C
125C
100C
0.90
1.00
350 C
250 C
200C
Compressibility factor, z
0.90
Temp, C
Temp, C
250 C
200 C
150 C
1.00
1.10
1.10
Temp, C
300C
1.00
1.10
Temp, C
500 C
300 C
200 C
150C
125 C
100C
75C
1.10
-1 0

pc = 4628 kPa (abs)
Tc = 210 K
0.50
0.90
100C
75C
0.80
50C
0.70
25 C
1 0 C
0C
0.60
-2
0.50

pc = 4630 kPa (abs)
Tc = 220 K
-70C
0.40
0.40
0
5000
10000
15000
20000
25000
30000
35000
0.40
5000
Pressure, kPa (abs)
10000
15000
20000
25000
30000
35000
0.40
0
5000
10000
Pressure, kPa (abs)
M = 16.04 kg/kmol
M = 17.40 kg/kmol
15000
20000
25000
30000
35000
5000
10000
15000
M = 18.85 kg/kmol
M = 20.30 kg/kmol
200C
175C
150C
125C
100C
0.80
75C
0.70
50 C
C
25
C
10
0.60
0.50
0C
-1
0.90
150C
0.80
125C
100C
0.70
75C
0.60
50 C

pc = 4588 kPa (abs)
Tc = 239 K
0.50
C
25
C
10 C
0

pc = 4564 kPa (abs)
Tc = 258 K
0.40
0.40
0
5000
10000
15000
22
2
Pin2 Pout
Q2
= C f z Tabs st 5
L
d
Temp, C
450 C
400 C
350 C
300C
250C
225C
200C
175C
1.00
1.10
500 C
350 C
250C
0.90
20000
25000
Pressure, kPa (abs)
30000
35000
5000
10000
15000
20000
25000
30000
35000
Pressure, kPa (abs)
M = 23.20 kg/kmol
M = 26.10 kg/kmol
Pin
Pout
L
C
f
z
Tabs
st
Q
d
=
=
=
=
=
=
=
=
=
=
Inlet pressure
MPa
Outlet pressure
MPa
Pipe length
m
Constant = 5.7 x 10-10
MPa/K
Friction factor (Moody) (Fanning ff = 4x Moody ff)
Additional Gas compressibility factor
Temperature
K
Gas density at standard conditions
kg/ m3
Flow at standard conditions
m3/s
m
23
35000
Gas Flow Pressure Loss - AGA Equation
Temp, C
1.00
30000

1.10
25000
Pressure, kPa (abs)
21
20000
Pressure, kPa (abs)
24
Gas Flow Pressure Loss - AGA Equation
Friction Factor - Gas Pipelines
2
2
Q
2
Pin = L C f z Tabs st 5 + Pout
d
Pin
Pout
L
C
f
z
Tabs
st
Q
d
=
=
=
=
=
=
=
=
=
=
F (Re, e/d) via Moody diagram
v d ac
Re = ac
Inlet pressure
MPa
Outlet pressure
MPa
Pipe length
m
Constant = 5.7 x 10-10
MPa/K
Friction factor (Moody) (Fanning ff = 4x Moody ff)
Additional Gas compressibility factor
Temperature
K
Gas density at standard conditions
kg/ m3
Flow at standard conditions
m3/s
m

vac = Average velocity (actual conditions)

d = Pipe internal diameter
ac = Gas density (actual conditions)
M = Gas molecular weight
P
= Pressure
z
= Additional Compressibility factor
R
= Gas constant (8314)
T
= Temperature
= Dynamic gas viscosity
MP
zRT
m/s
m
kg/m3
kg/kmole
Pa
J/kmole.K
K
Pa.s
25
26
0.1
Turbulent zone
0.09
0.08
Critical
zone
Laminar
zone
Transition
zone
Complete turbulence, rough pipes

.05
Friction Factor
- Moody Diagram
0.07
0.06
0.05
.04
.03
.02
.015
0.04
Friction factor f
.008
.006
0.03
.004
0.025
.002
0.02
Relative roughness _
d
.01
Hydraulics General
.001
.0008
.0006
Smooth pipes
.0004
0.015
.0002
f = 0.011
.0001
.00005
0.01
Rel.R = 0.00005
0.009
0.008
RE = 8. 10^6
.00001
103
5 6
8 104
5 6
8 105
Reynolds number =
5 6
8 106
vd vd
=
5 6
8 107
_ = .000 001
d
3 4 5 6
_ = .000 005
d
8 108
27
28
Fittings Resistance Coefficient - K

Fitting resistance:
L
Equivalent length as a function

of pipe diameter and fitting type
L
26d
Leq
==26
D
LeqD = =5050d
90o Elbow
45o Elbow
Leq = K d
Liquid & Gas Flow Summary
Valves:
L
20
LDeq == 20
L
60
LDeq == 60
Tee Flow Through
Gate valve, K = 10
Check valve, K = 50 - 150
Tee Flow Through Branch
29
30
Characteristics of Liquid Flow
Characteristics of Gas Flow

Gas
Liquid can be considered incompressible
No change in density
No change in velocity
Linear pressure drop
Independent of pressure level
Oil
Length
P = f ( , + Q,d,L )
= f ( pressure, temperature )
= f ( pressure, temperature )
Gas is compressible
Density changes with pressure
Velocity changes with density
Non-linear pressure drop
Pressure drop depends on pressure level
Length
Length
Gas
V =
Q
A
Length
31
Pressure
Velocity
P = f ( , + Q,d,L )
= f ( temperature )
= f ( temperature )
Velocity
Pressure
Oil
32
Summary Single Phase Hydraulics
Pressure Drop calculation
Darcys equation for liquid
AGA equation for gas
Heat Transfer
Pipe wall roughness
Roughness / Smoothness significant for gas
Smoothness less significant for liquid
33
34
Key Parameters for Pipeline Heat Transfer
Pipeline Heat Transfer Schematic
Pipeline surrounding
Pipeline coating(s), buried - y/n, water/air
Ambient temperature
Soil
Heat loss
Flow
Q
Pipeline dimensions
Ta
Diameter, Length
Inlet
Flowrate, Specific heat
Non-flowing conditions
Pipeline cooling under flowing conditions
Heat capacity of pipeline fluid

Heat capacity of pipe & coating materials
Pipeline fluid looses heat to surrounding

Function of: heat transfer, heatflow & pipe dimensions
35
T = To
Flowing conditions
Pipeline
36
Pipe Heat Transfer Coefficient
Overall Heat Transfer Coefficient
Pipe and Coatings:

1
Utotal
Dr
D1 K1
D2
D3
D4
K2
Dr
Ln (Di+1/Di)
TOTAL:
2 Ki
Where:

D = Reference diameter
r

Ki = Thermal conductivity of coating

U = Heat transfer coefficient

Bd
H = Burial depth to centre of pipe

Di = Diameter of coating i
K3
1
Utotal
=U
internal
+ U1 +U 1
pipe
environment
Q
Temperature
(m)
Product
w
(
mK )
( mwK )
Pipe Environment
TProd
(m)
(m)
TAmb
Distance
37
38
Soil Heat Transfer Coefficient
Soil Conductivity - Effect of Moisture

K soil
U soil =
Bd
Ksoil
0.5 D i Ln
Di D
o
H=
Not to be used if
Bd < Do
Usoil
Ksoil
Bd
D
i
o
1 + 1 H2
H
0.5 D 0
Bd
= Soil heat transfer coefficient

= Soil thermal conductivity
= Burial Depth (centre pipe)
= Diameter
J/m2.s.C
J/m.s.C
m
m
= internal
= outside
39
40
Pipeline Cooling at non-flowing conditions
Pipeline Temperature Profile Calculation

at flowing conditions
x
T Ta
T = x
=e y
Ti Ta
x - at distance - x
i - inlet
a - ambient
y=
Q Cp
dr U
Cp
dr
U
t
T Ta
T = t
=e
Ti Ta
= Flowrate
= Fluid density
= Specific heat capacity*
= Reference diameter
= Overall heat transfer coeff.
Where :
T* = Dimensionless temperature
T = Temperature
m3/s
kg/m3
J/kg.C
m
J/m2.s.C
t - at time - t
i - inlet
a - ambient
d r Cp
U
* Correct for more layers
Cp
dr
U
= Flowrate
= Fluid density
= Specific heat capacity*
= Reference diameter
= Overall heat transfer coeff.
m3/s
kg/m3
J/kg.C
m
J/m2.s.C
* Correct for more layers
= Characteristic time for heat loss

i.e. time over which temperature is reduced by 63 %
y = Characteristic heat transfer length

i.e. length over which temperature is reduced by 63 %
41
42
Example Temperature profiles
Example Pipeline Cover - Effect of Dumping

Temperature
Temperature
C
s
Where :
T* = Dimensionless temperature
T = Temperature
4.000 m
(REF)
0.5 m
(min)
Gas
Oil
pipeline
Oil
Rock Cover
Sand Cover
Joule Thomson
Low OHCT/High C
Cooling
0.3 m
(min)
Ambient
High OHCT/Low C
Ambient
(REF)
SAND
Density = 1.6 T/m3

D100 = 3.0 mm
D50 = 1.0 mm
D1
= 0.25 mm
Length
Gas
- Joule Thomson effect
2.000 m
ROCK
Density = 1.7 T/m3

D100 = 75 mm
D50 = 50 mm
D1 = 8 mm
D15
< 0.3
D50
Length
43
44
Fluid Temperature & Pipeline Surrounding
Typical Thermal Conductivity & OHTC (Overall Heat Transfer Coefficient)
Crude Arrival Temperature

at Platform Riser
Coating
W/m,C
Pipe, Coating and burial
25
2050 m Cover
from Wellhead
20
Total Cover
7300 m
3600 m Cover
from Platform
15
Projected
Increased
750 m Cover
from Wellhead
10
Carbon steel
Stainless steel
43.0
21.0
36, 3 concrete
36, 3 con, buried
Bitumen
Coal tar enamel
Polyethylene
FBE
Polyurethane foam
Syntactic foam
0.7
0.7
0.4
0.2
0.2
0.03
24, 2 concrete
24, 2 concr, buried
23
2.5
16, FBE
16, FBE, Buried
16, Syntactic foam
16, Pipe in pipe
160
3.5
5
1
Concrete
Sand - wet
Sand - dry
Clay
12, FBE
12, FBE, Buried
12, Syntactic foam
12, pipe in pipe
160
4
5
1
Instrumentation
Malfunction
5
0
10
15
20
25
Dumping Operations-Days
Sand Dumping
Commenced
Sand Dumping
Completed
OHTC
W/m2,C
16
2
1.0 - 1.5
0.8 - 2.4
0.4 - 1.0
0.3 - 1.2
45
46
Pipeline Hydraulics Exercise Oil Pipeline Sizing
Oil Production
150,000 bbl/day
16 pipeline from Platform to onshore tank farm
Is the pipeline large enough?
Water depth at platform 167 m, deck 20 above sea level

Onshore tank farm on a 30 m hill, tank 15 high
Crude oil density
Crude viscosity
Ambient temperature
Pipeline Internal diameter
Pipe wall roughness
Pipeline design pressure
42
0.01
5
395
0.03
149
API
Pa.s
o
C
mm
mm
bara
Shell Global Solutions is a network of independent technology companies in the Shell Group. In this presentation the expression 'Shell' or 'Shell Global Solutions' is
sometimes used for convenience where reference is made to these companies in general, or where no useful purpose is served by identifying a particular company.
47
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1 - Pipeline Hydraulics-Basics

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1 - Pipeline Hydraulics-Basics

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Pipeline Hydraulics - (single phase)

Marine Pipelines - Hydraulics - 1

Pipeline Hydraulics - Basics

Review basics of pipeline hydraulics

Be able to perform single phase flow hydraulics

Gert van Spronsen - Pipelines

Shell Global Solutions International (SGSI) - Rijswijk

Awareness of special subject - Heat transfer

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Topics

Types of fluids and their properties

equation, Reynolds number, Friction factor

Pipeline Hydraulics - Basics

Shell - E&P Pipeline systems

Key Parameters for Pipeline Hydraulics

- How much & what to transport

Fluid quantity (flow rates)

- How far & what are the conditions

Crude oil (waxy, heavy)

- What is the available Pressure drop

Two-phase Gas & Liquid

Natural gas & condensate

Crude & associated gas

Available pressure vs. pump/compression power

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Fluid Density (Definitions)

Specific Gravity (s.g.)

Liquid API gravity :

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Viscosity Variation with Temperature

Crude Oil Properties

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Elevation Pressure Loss

Basic Flow Equations

P = Elevation pressure loss

Ptotal = Pfric . + Pelev. + Pacc.

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Frictional Pressure Loss - Liquid Flow

Frictional Pressure Loss - Liquid Flow

P = Frictional pressure loss

P = Frictional pressure loss

= Friction factor (Moody) (Fanning ff = 4x Moody ff)

= Friction factor (Moody) (Fanning ff = 4x Moody ff)

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Pipeline design basic rules:

Friction Factor - Liquid Pipelines

P " Const " Q 2

Pressure drop proportional to Length

One additional Pump station

F (Re, e /d) via Moody diagram

Pipeline Hydraulics - Basics

Pipeline Hydraulics - Basics

Pipeline Wall Roughness

Complete turbulence, rough pipes

Roughness is either absolute () or relative ( /d)

Roughness is not a physical measurement

Significant effected by corrosion, erosion or wax

Standard carbon steel

Pipeline Hydraulics - Basics