The Norsk Hydro Multi Phase Flow Loop. A High Pressure Flow Loop For Real Three-Phase Hydrocarbon Systems
The Norsk Hydro Multi Phase Flow Loop. A High Pressure Flow Loop For Real Three-Phase Hydrocarbon Systems
www.elsevier.com/locate/flowmeasinst
The Norsk Hydro Multi Phase Flow Loop. A high pressure flow loop for real
three-phase hydrocarbon systems
Berit Robøle a , Harald Knut Kvandal a,∗ , Reidar Barfod Schüller b
a Norsk Hydro Oil and Energy Research Centre, Porsgrunn, Norway
b Norwegian University of Life Sciences, Ås, Norway
Abstract
In order to achieve better understanding and better predictive models for three-phase systems, Norsk Hydro ASA has designed and built a
unique industrial-scale test facility for investigations of such systems.
The test facility includes a 200 m long 3 diameter flow loop where a section can be tilted upwards or downwards. The fluids can be any
combination of real hydrocarbon oil, gas and water (with salts included) as long as the partial pressures of CO2 and H2 S are below 20 bar and
0.05 bar, respectively. The maximum operating temperature and pressure are 140 ◦ C and 110 bar absolute, respectively.
The test facility is designed to implement total control of both flow conditions and system chemistry. This makes it possible to undertake
investigations on the phenomena that occur in multiphase flow. It is optional to add production chemicals to the process fluid.
The test facility is presented in detail with descriptions of the chosen solutions, the instrumentation and the range of possible applications. It
has successfully undertaken tests with a large range of well fluids from the North Sea, and a listing of these tests is included.
c 2006 Published by Elsevier Ltd
Keywords: Test facility; Three phase flow loop; Real hydrocarbon system; Multiphase flow; High pressure
Table 1
Technical specifications of the Multi Phase Flow Loop
Fig. 2. The main part of the Multi Phase Flow Loop, including separator, pumps and heat exchangers. The maximum operating pressure and temperature are
110 bar and 140 ◦ C, respectively.
3.1. Design basis The three-phase separator is the centre of the system. It
acts as a central reservoir of the three phases. In addition, the
The Multi Phase Flow Loop was built to address the water phase and the oil phase can be stored in buffer volumes.
phenomena that occur in multiphase flow in real three-phase The three phases, oil, gas and water, flow from the separator
hydrocarbon/water systems. This brings about a requirement to to individual pumps/circulator, which are fitted with variable
have complete control with both the flowing conditions and the speed controllers, to a mixing point.
chemistry. There are two different mixing points in the MPFL: the
Control with flowing conditions involves: Y-junction and the T-junction. The Y-junction is designed to
• Pressure generate stratified flow, if possible. The water phase is fed
• Temperature horizontally at the bottom, the oil phase horizontally above the
• Flow rates of all the phases water phase, and the gas phase is fed at the top. The other
• Good separation behaviour in separator mixing point is the T-junction, where the oil and water is pre-
• Thermodynamic equilibrium where this is required mixed in a T-junction before the gas is added. This mixing
• No unwanted disturbances to flow such as sudden steps device will favour dispersed flow instead of stratified flow, and
where pipes are connected. tests done in the MPFL have shown differences in pressure
• Control with wax and hydrates drop and flow pattern by alternating between the two mixing
Control with chemistry involves: points. Chemicals can be added to the system, so it is possible
to perform tests with the addition of different types of inhibitors
• Correct composition (corrosion, hydrate, flow improvers, etc.).
• Control with contaminants such as corrosion products and
The main part of the MPFL is shown in Fig. 2. The flow
other surface active chemicals.
from the test section enters the three-phase separator, where the
3.2. Design mixture flow is separated into a gas, an oil and a water phase.
The gas leaves the separator at the top and flows through the
The Multi Phase Flow Loop is a recirculating system that is gas circulator before the temperature is controlled in the gas
able to operate with three phases, oil/water/gas, at pressures of cooler. From the gas cooler, the gas flows optionally to the well
up to 110 bar absolute. The allowable temperature range is from manifold in the Multipurpose Test Area or to the three-phase
−5 to 140 ◦ C. mixing point upstream from the test sections.
The process fluid can be any combination of real crude oils The oil flows from the separator to the oil circulation pump.
as long as the partial pressures of CO2 and H2 S are below 20 Downstream from the oil circulation pump, the flow can either
bar and 0.05 bar, respectively. The water may contain salts, thus flow through or bypass the liquid heat exchanger. The oil phase
a representative water phase can be used in the system. is mixed with the water at an optional T-junction or in the three-
166 B. Robøle et al. / Flow Measurement and Instrumentation 17 (2006) 163–170
Fig. 3. The 3 Flow Loop and the Choke Test Section.
phase Y-junction upstream from the test sections. In order to The Flow Loop contains two test areas, as shown in the
direct the oil flow to the well manifold in the Multipurpose Test figure. The first test area is situated just upstream from the
Area, no gas or water passes through the Y-junction, and the oil bend in the inclined test section. The second test area is situated
flow is directed from downstream from the junction to the well upstream from the separator. The test sections are placed such
manifold. that the flow is not effected by anything but the pipe. The first
The water flows from the separator to the water circulation test section is placed more than 880 L/D from the last bend, and
pump. To gain temperature control, the water can optionally the second test section is placed 700 L/D from the bend in the
flow through the liquid heat exchanger. Downstream from the inclined section, and 190 L/D from the inclined section bypass.
liquid heat exchanger, the water can be routed to the well The flow to the Choke Test Section flows from the
manifold in the multipurpose test area, or to the test sections test section to the multiphase pump. Downstream from the
via, optionally, the oil/water T-junction or to the gas/oil/water multiphase pump, the flow can be routed to the Multipurpose
Y-junction. Test Area, or to the Choke Test Section, where different choke
The liquid levels in the separator are of great importance in designs and geometries can be tested.
controlling the gas/oil/water mixture. In order to maintain the Fig. 4 shows the Multipurpose Test Area. The flow from
optimal levels, oil and water can be moved to the oil and water the separator enters the test area in two optional ways, either
buffer tanks. Downstream from the oil and water pumps, a flow through the well manifold system, where gas, oil and water can
be mixed to three different mixtures, which in turn is mixed on
can be directed to the oil and water tank, respectively. In need of
the manifold. The purpose of the well manifold is to simulate
more oil or water in the flow loop, the oil and water is returned
the influence of different well streams and the mixture of these
to the loop upstream from the oil and water pump, respectively.
on downstream processing equipment. The other route from the
Likewise, the liquid in the liquid heat exchanger is alternating,
separator to the test area is via the multiphase pump in the choke
depending on the volumes needed in the flow loop.
test section.
Fig. 3 shows the Flow Loop and the Choke Test Section. The test area is a 50 m × 20 m area situated on the ground,
The gas/oil/water mixture flows from the separator to the 60 m which makes it easy to connect processing equipment. The
long horizontal part of the test section. In the last part of the equipment to be tested can arrive either as complete skids or
horizontal section, the flow can be directed to the Choke Test as processing equipment, which can be connected to exiting
Section. After the 60 m of horizontal piping, the flow can return pipes. From the test area, the mixture flow returns to the MPFL
to the separator, or enter the inclined section. The inclined separator.
section continues straight ahead for 40 m before a U-turn brings
the flow back the 100 m to the separator. The total length of 3.3. Materials
the flow loop, including the inclined section, is 200 m. If the
inclined section is bypassed, the length is 120 m. If needed, the Since H2 S can be present up to 0.05 bar partial pressure, the
flow loop can be bypassed, and the flow returns directly to the test facility is built to comply with standard NACE MR0175–90
separator. for Sulfide Stress Cracking Resistant Metallic Materials for
B. Robøle et al. / Flow Measurement and Instrumentation 17 (2006) 163–170 167
Waterfield Equipment. The test facility is basically built of compression machine. The sealing system is a Crane double
Duplex Steel, W.Nr. 1.4462, X2CrNiMoN 22-5, UNS S31803. mechanical seal, and a small amount of sealing fluid leaks into
All process-wetted parts are Duplex Steel, Incolloy 825, or the process stream.
Hastelloy C-276. Monell K-500 can be used as the material in The sealing fluid is petroleum distillate without any added
glands. Grafitti spiral glands with interior and exterior rings in chemicals. (In fact, it has the diesel fractions of Oseberg crude
Monell K-500 are used to connect process piping. with no added chemicals, especially produced at the refinery for
the MPFL.)
3.4. The separator
3.5.2. The oil pump
The separator is provided with a splash plate on the inlet The oil pump is of the type Borneman twin-screw pump,
to reduce the incoming momentum. The liquid flows through a Type W6.5ZX1-30/324008. This is a low shear pump that
pal packed plate, before the gas, oil and water mixture flows avoids the production of small droplets. The generation of small
through a perforated plate. Downstream from the perforated
droplets in a recirculating system may cause the formation of
plate, there is a Vessel Internal Electrostatic Coalescer (VIEC)
stable emulsions and must be avoided. The pump is fitted with
element in order to improve the separation. A weir plate
a Burgman seal. A small amount of fluid leaks out through the
separates the oil from the water, both leaving the separator in
seal and is collected in a dedicated pressurised container.
the bottom. The gas exits the separator through a pipe in the
top. The volume of the separator is 2.2 m3 .
The operational conditions of the separator are determined 3.5.3. The water pump
by controlling the liquid levels. The MPFL is equipped with The water pump is an APV canned glandless leakage proof
buffer tanks to maintain the desired water and oil levels in the centrifugal pump of type HMD Type HP 2E SM RES-125 fitted
separator. By shifting volumes to and from the buffer tanks, the with a magnetic drive coupling.
phases leaving the separator can be kept as pure as possible.
There is normally only a few parts per million of oil in the 3.5.4. The twin-screw multiphase booster pump
water phase and less than 0.5% water in the oil phase, except The multiphase booster pump is of the type Borneman twin-
for poorly separating fluid systems. screw pump, Type MPC208X1-57, similar to the oil pump but
much larger. The pump is fitted with a Burgman seal. A small
3.5. Rotating machinery amount of fluid leaks out through the seal and is collected in a
dedicated pressurised container. The pump is able to raise the
One problem that had to be overcome in relation to rotating pressure of the multiphase stream by approximately 40 bars.
machinery in the test facility was the potential contamination
by surface-active agents of the process fluid within the rig. Such 3.6. Heat exchangers
pollutants could, for example, be lubrication oil from bearings
and seals of the rotating machinery.
All the process piping and the process units of the MPFL
3.5.1. The gas circulator are insulated and equipped with temperature-controlled heat
tracing.
The gas in the MPFL is circulated by means of a Bertin
peripheral compressor, Type CP 310.1.008. This is a low
peripheral speed machine that is stable at all operating speeds. 3.6.1. Gas cooler
The gas flows through the vanes several times from inlet to A shell and tube gas cooler is located just downstream from
outlet, hence the machine can be considered to be a multistage the Bertin gas circulator.
168 B. Robøle et al. / Flow Measurement and Instrumentation 17 (2006) 163–170
Table 2
Main control instrumentation of the MPFL
Instrument Model Range Description
Oil flow meter Rheonik Micro Motion 2–700 kg/min Coreolis mass flow meter
Water flow meter Rheonik Micro Motion 2–700 kg/min Coreolis mass flow meter
Liquid flow rate Endress–Hauser 0.1–1 kg/min Coreolis mass flow meter
Gas flow rate Instromet SM-RI 13–250 m3 /h Turbine gas flow meter
Gas flow rate Fisher Rosemount 0.3–2.9 m3 /h V-cone, differential pressure flow meter
Pressure transmitter Rosemount 2088G4A2 0.5–125 bar
Temperature transmitter Pt-100, INOR TRA R6X −10–150 ◦ C
Separator level indicator Sentech Profile Gauge – 40 capacitance probes
of scientific instruments are installed in the test sections. Some the rig. These test probes can include corrosion probes, erosion
of these are off-the-shelf instruments, while others are custom- probes, or simply water wetting probes.
made prototypes. Some have permanent locations, while others Fluid sampling can be performed at several locations;
offer the ability to be used at different locations. from the streams exiting the separator (gas/oil/water) and
from the traversable sampling probe connected to the test
• Five differential pressure transmitters
section area. Samples are taken into pressurised cylinders and
These are open system where the pressure tappings are
no depressurisation takes place before it is required for the
top mounted and gas filled. These offer fast response to
appropriate analysis.
the fluctuations in the test pipe, but suffer from liquid
penetration when the pipe is liquid filled. These are all
5. Published studies from the MPFL
installed with different measuring lengths, which enable us
to monitor any developing flow in the section. Since the MPFL was installed, a number of publications
• Three differential pressure transmitters have been written to present the experimental results. However,
A closed system with membranes and silicon-oil filled these publications are limited compared to the amount of
level tubes. Also installed for different measuring lengths. experiments conducted in the facility. The main reason for
• Four narrow-beam gamma densitometers this is that the unique nature of this facility has given Norsk
Each instrument has a one Ci Cs137 -source facilitating Hydro, as an oil company, a technical edge with respect to the
a 0.016 s sampling rate (62.5 Hz). These are clamp-on understanding of multiphase flow, and thereby a competitive
devices and can therefore be relocated for different tests. The advantage compared with others. Similar arguments apply for
instruments are used for two-phase hold-up measurements the experimental campaigns conducted for process equipment
and flow pattern analysis as well as slug properties (two vendors, where they have ownership of results from the
nearby instruments facilitate cross correlation). experiments.
• Traversable two-energy gamma densitometer The vast majority of results that have been published have
This instrument has a 30 mCi Ba source with beam dealt with multiphase pipe flow and multiphase flow through
collimation of 5 × 10 mm. It can be traversed both in chokes. Some of them will be briefly mentioned here:
linear and angular directions and is mounted on a reinforced
carbon fibre pipe that offers the ability to be relocated to any • Utvik et al. [2]
position in the flow loop. By using two energies, three-phase This was an experimental study with the objective of
hold up calculations are facilitated, as well as flow pattern comparing the results from a recombined hydrocarbon fluid
analysis. The instrument also has the potential to produce system and a model oil/inert gas system in a three-phase
two-dimensional (2D) tomographic images of the pipe cross pipe flow. They concluded that the there were significant
section [7]. differences due to the fluid systems, both with respect to flow
• CCD near-infrared (NIR) camera pattern and pressure drop.
This instrument facilitates visual access to the flow, even • Valle and Utvik 1997 [10]
The objective of this publication was the comparison
with recombined crude oil systems, as it utilizes the crude
oil transparency to NIR light [8,9]. It can be mounted on between experimental oil/water data from the MPFL and
model predictions. They concluded that the available
a traversable unit for examining different parts of the pipe
multiphase models could not represent the experimental
cross section.
data from the facility, and related that to the specific fluid
• Traversable conductivity probe
properties of a recombined hydrocarbon system.
The probe measures the electrical conductivity of the
• Utvik et al. 1998, [11]
fluid at the probe tip and is mounted in a traversable unit. It
A similar publication to Valle and Utvik 1998, but here
gives an on/off signal for the difference between water and
presented for three-phase gas/oil/water flow.
oil, hence giving the position of the oil/water interface in
• Kvandal et al. 1998 [12]
stratified flow.
In this publication, field data was compared to
• Traversable capacitance probe
experimental data from the test facility (using fluids from the
The probe measures the dielectric permittivity of the fluid
same field) and the model comparison. They concluded that
at the probe tip and is mounted on a traversable unit [6]. The
the specific observations made in the test facility represented
electrodes are similar to the level probes in the separator.
the observations from the field data.
A system making it possible to insert and retract traversing • Schulkes et al. 1999 [13]
probes is implemented in the design of the test section. This publication presented an experimental study on
This system has most frequently been used with a traversing high-temperature, high-pressure multiphase flow with radial
conductivity probe. Sampling from the process stream at inflow of gas. Their main conclusion was that the main
different locations can also be accomplished by this system. source of pressure loss with radial inflow was due to
Any type of measurement system can be used with the system. frictional effects.
It only needs to be designed to fit the dimensions of the system. • Valle 2000 [14]
The test section is fitted with four flush mounted test probes In his PhD thesis, Valle presented several experimental
that can be inserted and removed with full system pressure in campaigns conducted using different crude oils. He analysed
170 B. Robøle et al. / Flow Measurement and Instrumentation 17 (2006) 163–170
the findings and found a large degree of consistency for [5] Schüller RB, Halleraker M, Engebretsen B. Advanced profile gauge
different oils. for multiphase systems. In: 1st world congress on industrial process
• Solbakken and Schuller 2001 [15] tomography. 1999. p. 126–32.
[6] Schüller RB, Solbakken T, Engebretsen B, Halleraker M. Water
A study on a gas/condensate/water system showed that
concentration and interface positions by single electrode capacitance
the relative pressure drop for three-phase gas/condensate/ probes (SeCaPTM ), In: 2nd world congress on industrial process
water systems showed lower values than for pure tomography. 2001. p. 644–51.
gas/condensate systems. [7] Frøystein T, Kvandal H, Aakre H. Dual energy gamma tomography
• Elseth et al. 2003 [16] system for high pressure multiphase flow. Flow Measurement and
Another study on gas/condensate/water with the objective Instrumentation 2005;16(2–3):289–93.
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