Pipe Flow : Philosophy, sizing, and

simulation

Presenter: Rizaldi
 Module objectives

 By the end of this module you will:

– Have knowledge what’s 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
 Non newtonian Fluid : viscosity is not proportional
to relative movement rate

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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 non-
linear

 Re = momentum/viscous shear stress

 Re = ρ.v2/(µ.v/D)
 Re = ρ.v.D/µ

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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?
 Which correlation/equation to be used?
 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 viscosity
 Fluid density
 Elevation change
 Fittings
 Pipe length

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 Critical Parameter

 Velocity (max, min, erosion velocity, sonic

velocity, entrainment velocity, noise velocity)
 Pressure drop

 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/(ρm^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 ρm = 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 :
(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
 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

 Other Methods (summary)

Flow Direction
No. Methods Flow Map Liquid Holdup Vertical
Horizontal Inclined
Upw. Downw.
1 Mandhane (Dukler / C&M/ L&M) Yes Yes Yes No No ± 6°
2 Eaton-Dukler No Yes Yes No No ± 6°
3 Dukler-Taitel 1) Yes Yes Yes 2) 2)
± 6°
4a Beggs & Brill Yes 3) Yes Yes 4) 4) 4)

4b Beggs & Brill / Palmer Yes 3) Yes Yes Yes Yes Yes
5 KSLA - Oliemans Yes Yes Yes Yes Yes 5)

6 Eaton - Oliemans No Yes Yes No No ± 6°

7 BJA-2 No Yes Yes No No ± 6°
8 Mukherjee / Brill Yes Yes Yes Yes Yes Yes
9 Orkiszewski Yes Yes No Yes No No
10 Gray No Yes No Yes No No
11 Hagedorn-Brown No No 6)
No Yes No No
12a HTFS Homogeneous Flow No No Yes Yes Yes Yes
12b HTFS with Slip No Yes Yes Yes Yes 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
Brown’s 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 non-
compositional 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
 Tabular PVT : user inputs some properties
 Compositional : user inputs fluid composition,
while phase and properties generated by built-in
thermodynamic function.
 Black Oil : at minimum, user input API gravities,
gas oil ratio, Gas Heating Value, Pressure and
temperature to estimate properties

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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.
 Pipe arrangements can be modeled

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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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