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Pipe Flow : Philosophy, sizing, and
simulation
Presenter: Rizaldi
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 1
Module objectives
By the end of this module you will: Have knowledge whats behind the flow
Recognize and identify parameter, criteria, and properequation for pipe sizing
Get Brief introduction Hydraulic simulation (pipephaseas case study)
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 2
Introduction
Proper design and fullyaccomplish consideration
should be taken in order tooptimize performance andavoid undesired event
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 3
Fluid Behaviour
Newtonian Fluid : viscosity is proportional torelative movement rate/shear stress
Non newtonian Fluid : viscosity is not proportionalto relative movement rate
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 4
Reynold Number
At low flowrate pressure drop is proportional tothe flowrate, but as flowrate increase until certainpoints, the relationship between two become non-linear
Re = momentum/viscous shear stress
Re = .v2/(.v/D)
Re = .v.D/
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 5
Reynold Number
Flow Regime based on Reynold number :
a. Re < 2000 = Laminer :
fluid elements moved in smooth layers
relative to each other with no mixingb. Re > 4000 = Turbulence :
unstable flow pattern, characterized by highdegree of mixing of fluid elements
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 6
Conservation of mass
For steady state :
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 7
Conservation of momentum
(bernouli eq)
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 8
Conservation of Energy
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 9
Bernouli Equation (derivation form)
for liquids :
For gas : modified Bernoulli
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 10
Sizing and Hydraulic Evaluation
What do we need to know ?What are the critical Parameter?
Which correlation/equation to be used?
What are the outputs?
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 11
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 beconsider to derive proper equation
Flowrate : Quantity of the fluid, in volumetric rate or inmass rate.Consider maximum and minimum conditionwhich will happen during operation
Process condition : Temperature, Pressure.
Fluid properties : Viscosity, density System arrangements (elevation, fittings, pipe length)
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 12
What do we need to know (summarize)
PhaseFlowrate
Temperature
Fluid viscosity
Fluid density
Elevation change
Fittings
Pipe length
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 13
Critical Parameter
Velocity (max, min, erosion velocity, sonicvelocity, entrainment velocity, noise velocity)
Pressure drop
Select diameter in which will give satisfiedparameter value
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 14
Velocity
Limit between certain values to attain economical and safeoperation
Erosion velocity :
Commonly used as parameter for two phase flow, velocity atwhich 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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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 15
Velocity
Noise velocity :Velocity at which will cause noise above the noise limit(commonly 85 dB - 90dB). API 14 give identification above60 ft/s
Sonic velocity :
The maximum velocity that a compressible fluid flowing ina pipe of uniform cross-section can achieve is limited bythe maximum velocity of pressure wave travel in the pipe,which equivalent to speed of sound. Noise and vibrationincrease when sonic velocity approached. Can occur in
liquid called chocked flow
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 17
Typical velocity and Pressure DropLimitation (fluor daniel)
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 19
Typical velocity and Pressure DropLimitation
Two phase flow velocity limit:min : 10 ft/s (API 14 E)
max : erosion velocity
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 20
Pressure Drop Equation
Proper equation shall be use for spesificcase/phase :
a. Single phase liquid flow
b. Single phase gas flowc. Two phase flow
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 21
A. Single Phase Liquid Flow
Straight pipe, using Darcy Equation :
Elevation loss :
Fitting Loss :
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 22
A. Single Phase Liquid Flow
Fitting loss can also be obtained using equivalentlength method :
Friction factor ( f) obatined using moody/darcyfriction factor :
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 23
A. Single Phase Liquid Flow
For liquid with Re > 2000 , using ColebrookEquation:
Where f = friction factor
d = pipe diameter
E = pipe roughness
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 24
A. Single Phase Liquid Flow
Gravity Flow
Mechanical Energy Balance :
(V12/2g+ H1 + 144 P1/d) W1 (V22/2g+ H2 + 144 P2/d) W2 = E
Friction Lost : E = W (V2/2g) (k1 + fL/D+ k2)
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
Dis pipe diameter in ft
dis the liquid density
fis Darcy friction factor WequalsW1 or W2
A is the pipe cross sectional area in ft2
Xis the gravity flow driving force in ft
gis gravitational constant, 32.174 ft/sec2
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 25
General Equivalent Length (GPSA)
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B. Single Phase Gas Flow
Two models :a. Isothermal
straight pipe loss :
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 27
B. Single Phase Gas Flow
Fitting loss :
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 28
B. Single Phase Gas Flow
B. adiabatic flow (use in many simulationsoftware)
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 29
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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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 30
C. Two Phase Flow
Bubble Flow :
Plug Flow :
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C. Two Phase Flow
Stratified Flow
Wavy Flow
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 32
C. Two Phase Flow
Mist/spray Flow
Slug Flow
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 33
C. Two Phase Flow
Pressure Drop Calculation :a. Duikler Taitel
b. Beggs and Brill
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 34
C. Two Phase Flow
A. Dukler Taitel
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 35
C. Two Phase Flow
Dukler Taitel Maps
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 36
C. Two Phase Flow
Beggs and Brill
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 37
C. Two Phase Flow
Beggs and Brill
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 38
C. Two Phase Flow
Beggs and Brill
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 39
C. Two Phase Flow
Beggs and Brill Maps
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 40
C. Two Phase Flow
Other Methods (summary)No. Methods FlowMap LiquidHoldup
Flow DirectionHorizontal Vertical Inclined
Upw. Downw.1 Mandhane (Dukler / C&M/ L&M) Yes Yes Yes No No 62 Eaton-Dukler No Yes Yes No No 63 Dukler-Taitel 1) Yes Yes Yes 2) 2) 64a Beggs & Brill Yes 3) Yes Yes 4) 4) 4)4b Beggs & Brill / Palmer Yes 3) Yes Yes Yes Yes Yes5 KSLA - Oliemans Yes Yes Yes Yes Yes 5)6 Eaton - Oliemans No Yes Yes No No 67 BJA-2 No Yes Yes No No 68 Mukherjee / Brill Yes Yes Yes Yes Yes Yes9 Orkiszewski Yes Yes No Yes No No10 Gray No Yes No Yes No No11 Hagedorn-Brown No No 6) No Yes No No12a HTFS Homogeneous Flow No No Yes Yes Yes Yes12b HTFS with Slip No Yes Yes Yes Yes Yes13 Duns and Ros Yes Yes No Yes No No
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 41
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 theMandhane 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 satisfactoryby any of the methods. A new correlation has to be developed.For inclined lines (less than 6degrees upwards or downwards) the pressure drop is calculated as for horizontal lines. Thepressure recovery is calculated using the two-phase density.
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 42
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 withcare. The liquid holdups are systematically 13% over-predicted. A test facility was made foran 8 line at 75 bar and the results from the field tests were confirmed by the method. Theliquid loadings were increased to give other flow regimes than stratified wavy flow. Thepressure 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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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 43
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-losscalculation procedure is similar in approach to the Oliemans method, butaccounts for the increased interfacial shear resulting from the liquid surfaceroughness. These correlations appear to give consistently more reliable holdupand pressure drop predictions than the other correlations tested and have been
used in the design of several large pipeline and gas gathering systems in theNorth Sea. Baker Jardine and Associates (BJA) have developed this method
from pipeline operating data
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 44
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. Flowregime maps were drawn for different inclination angles, including horizontal andvertical flow. Different empirical equations for the flow regime transitions areproposed that are functions of inclination angle for both upflow and downflow. Ingeneral, the flow regimes and their transition for upflow were similar to thoseproposed by Duns and Ros for vertical upflow. For downflow, the flow regimes andtransitions conformed more to the Mandhane et. al. type of flow regime map. The stratifiedflow regime in downflow was bound to be affected appreciable by the angle of inclination. Fordownhill flows, this method normally overpredicts the pressure drop with 10 40% for1 to45 degrees inclined lines. All other pressure drop calculations for other line inclinations are
very well matching
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 45
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 oilwells with oil-gas and oil-water-gas mixtures in 3 8.75 lines. Do not use this method forlines larger than 10. Instead use a 10 diameter pipe and recalculate the loadings, so thatthe line velocity stays the same. This will give reasonable results
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 46
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)
h l
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 47
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 andBrowns major contribution is their holdup correlation for vertical flow. They did not measureholdup experimentally, rather they measured the pressure gradient and calculated the holdupnecessary for the total pressure gradient to give the observed value. They used a very largeamount of data, collected for pipe between 1 and 2 diameter
d li Si l i ( i h d )
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 48
Hydraulic Simulation (Pipe phase case study)
Modelling both single phase and two phase flowinside pipeline and piping networks and includesstandard industrial compositional and non-compositional PVT predictive methods.
H d li Si l i (Pi h d )
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 49
Hydraulic Simulation (Pipe phase case study)
Calculation module : Network and Single link
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H d li Si l ti (Pi h t d )
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 51
Hydraulic Simulation (Pipe phase case study)
Pressure Drop Correlation method can beselected
Heat transfer model can be selected
Using source and sink method. Data on one ofside shall be completed to run the iteration.
Pipe arrangements can be modeled
H d li Si l ti (Pi h t d )
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 52
Hydraulic Simulation (Pipe phase case study)
Calculation method
H d li Si l ti (Pi h t d )
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PT. TRIPATRAENGINEERS AND CONSTRUCTORS 53
Hydraulic Simulation (Pipe phase case study)
Pressure Drop Calculation method
Other hydraulic simulation used by
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PT TRIPATRA
y yTripatra,PT