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Chapter 22
Chapter 22
INTRODUCTION
Many oil-producing nations of the world have shifted to deep offshore. Offshore oil
production from deep water has greatly increased since 1995, with an approximate value of
20million barrels of oil equivalent per year from deep waters (Yong and Qiang, 2010). Riser
slugging is a flow regime that occurs in multiphase pipeline-riser systems and is mostly
characterized by severe flow and pressure oscillations. The irregular flow arising from riser
slugging can cause large operational problems for the downstream receiving facilities, which
requires an efficient and effective way to remove or mitigate riser slugging is necessary.
Recently, anti-slug control systems that stabilize the flow in the pipeline at the same
operating conditions that uncontrolled would yield riser slugging has emerged as the
preferred solution to avoid riser slugging. A major flow assurance issue in multiphase flow is
the slugging phenomenon; the formation of slug arises from the flow regimes commonly
found with the liquid and gaseous phases of hydrocarbons when in transit (Al-Kandari,
1999).
Many of the fields are too small to accommodate a standalone offshore processing facility. In
addition, many of the existing fields are in plateau production phase; thus, tying production
pipelines from satellite fields to an existing one becomes very popular to use common
offshore processing facility. The transportation of the produced crude is usually done in
oil and gas pipelines is a cardinal problem for all oil and gas producers. It is characterized by
large pressure and production fluctuations. Multiphase flows have a dominant occurrence in
the majority of upstream oil and gas pipelines. The flow regimes existent in these pipes have
1
different mitigation methods in design and operation to control flow-related issues, such as
corrosion or severe slugging at the slug catcher. The transportation of the produced crude is
carried out usually in multiphase pipelines. In so doing, one of the challenges encountered is
slugging. Slugging in oil and gas pipelines is a cardinal problem for all oil and gas producers.
Characterized mainly by large pressure and production fluctuations. Being able to predict the
due to slugging is by choking. In practice, oil and gas industry have used this method for
many years to eliminate severe slugging by manipulating the valve opening at the exit of the
riser, which unfortunately could negatively affect production (Taitel, 1986; Yocum, 1973).
The use of controller, however, has been reported to be able to help alleviate this problem by
stabilizing the system at larger valve opening (Ogazi, 2011). Significant efforts have been
concentrated on modelling and understanding the slug attenuation mechanism for choking
(Jansen & Shoham, 1994) and active slug control (Storkaas, 2005).
Slug flow is a flow assurance issue that staggers production and, in some cases, ‘kills the
flow’ of the well. Severe slugging, a type of slugging which usually occurs at the base of the
riser column, causes large amplitudes in the fluctuation of pressure within the riser column
and consequently damages equipment placed topside Slugging can be observed within the
vertical or inclined flexible riser and within the horizontal section of the piping lying on the
flowing upwards, does tend to assist the initiation of slug flow (Al Kandari 1999).
The riser is a flow pipeline commonly applied in the oil and gas industry to connect the
horizontal upstream subsea pipes with the topside (downstream) facilities. The function of the
riser is to transportation of produced fluids (water, oil and gas) to the topside facilities for
processing and transportation. The riser height varies between a few hundred metres to more
2
than 2000 metres, depending on the depth of seabed from the topside. In addition, the riser
diameter varies depending on design; however, it is designed into different shapes, like the S-
shaped riser (Ogazi, 2011). Severe slugging phenomenon is a four-stage cyclic flow condition
that occurs in the order as shown in Figure below. One major condition for the occurrence of
severe slugging is the presence of dips and low points in the pipeline. This causes liquid to
accumulate at these dips, due to balance of pressure by opposing gravitational force. The tie-
in lines from the satellite fields are conveying the untreated well stream, consisting of a
mixture of gas, oil, water and in some cases sand, from the wellhead clusters into the
production platforms. The flow assurance challenges associated with the transport of this
mixture over long distances involves handling physical flow-impeding phenomena such as
slug flow and sand transport and physio-chemical flow-impeding phenomena such as
3
1.1 Statement of the Problem
Slug flow may occur on different length and time scales depending on the underlying
principle for the slug flow formation. Riser slugging occurs when liquid blocks the low-point
where a down-sloping pipeline is attached to a riser. The blockage usually initiates the slug,
which then grows upward in the riser and back through the pipeline. This can continue up
until the pressure build-up over the slug is sufficiently high to blow it out of the riser, (Buller
et al., 2002). For more severe cases, the riser slugs can fill up the entire riser and can be
several hundred meters in length. The inlet separator on the receiving facilities is not large
If such a large slug were to arrive at the separator, it would cause overfilling which would trip
the production. Even smaller riser slugs can be problematic, as the uneven feed to the process
will lead to poor separation, varying compressor load and wear and tear on the equipment.
Hence, riser slugging must be avoided in pipeline-riser systems. In the last few years, A
number of different control structures and controller designs are considered for the mitigation
of slug flow but the preferred solution to avoid and reduce the problems associated with riser
slugging has been to design the system such that the slugging potential is minimized or to
change the boundary condition, by reducing the topside choke valve opening to remove the
slug flow from the system None of these solutions are optimal, hence the need to compare
The main aim of this research work is to demonstrate how standard industry tools can be used
to predict and analyse slug formation and further investigate techniques for mitigating and/or
4
1.3 Objectives of the Study
development concepts of handling and mitigating the slug flow issues in a riser.
ii. Simulate field data (measurable parameters) using flow assurance simulator (OLGA
software).
iii. Compare the results of the simulated OLGA results of the different slug flow mitigation
techniques and deduce the optimal technique for the given Western African field.
The most popular slug flow mitigation techniques are not always optimal and it is necessary
to develop an optimal solution for site specific deep offshore production projects. And this is
what this research aims to achieve through simulating different techniques using same field
data to be able to determine the optimal solution for slug flow in West Africa through
comprehensive analysis.
Majority of the techniques for attenuating slug formation in risers are developed from
numerical simulations in simulators such as the Schlumberger OLGA and others and in most
cases have not been deployed in a field situation. As such, selecting a field case study that
allows for trying the various techniques can be an arduous task as some field cases are not
5
Chapter 2
Literature Review
2.0 Overview
Multiphase flow regime is a term popularly used in multiphase flow studies to classify the
different flow patterns, which occur during multiphase flow through pipes (Balino et al.,
2010). instability, which imposes a major challenge to flow assurance in the oil and gas
industry. The oil and gas industry encounters slug flow during their production activities.
Thus, the multiphase slug flow can be classified into three different types, based on the
1. Hydrodynamic slugging
3. Severe slugging
Hydrodynamic slug flow, which occur mainly in horizontal pipes is initiated from stratified
flow due to two broad hydrodynamic mechanisms, namely: the natural growth of
hydrodynamic wave instabilities generated on the gas-liquid interface, and the accumulation
of liquid caused by sudden pressure and gravitational force imbalance, due to undulation in
Operation induced slug, this type of slug is induced due to certain operations performed
depressurisation,
6
Severe Slug, this type of slug flow is caused by the undulations and dips in the pipeline
geometry, topography, and network (Pots et al., 1985). Towards the end of the operational
life of an oil reservoir, the reservoir pressure can become depleted or the Gas-to liquid ratio
(GLR) can become very low. In such conditions, the gravitational pressure dominates the
flow resistance, and liquid accumulates at the pipe dips, thereby blocking the flow channel
The spatial distribution of the phases in multiphase flow is dependent on operating conditions
Such as phase velocities and pipeline angle. The different configurations the flow can arrange
Itself in are called flow regimes or flow patterns (Taitel et al., 1980). The possible flow
Patterns include stratified flow, annular flow, bubbly flow, slug flow and churn flow. Various
Intermediate flow patterns can also be present in pipelines. Slug flow can occur on different
time- and length scales depending on the underlying mechanism for the slug flow formation.
In addition, according to the definitions in Buller et al. (2002) slug flow in pipeline-riser
• Hydrodynamic slugging develops in horizontal parts of the pipeline when liquid waves
grow on the gas-liquid interface and eventually close the cross-section, thus forming liquid
slugs.
• Riser slugging occurs when liquid blocks the low-point where a down-sloping pipeline
attached to a riser. The blockage initiates the slug, which thereafter grows upward in the riser
and back through the pipeline. This continues until the pressure build-up over the slug is
sufficiently high to blow it out of the riser, whereupon the entire cycle is repeated.
• Terrain slugging involves slug development where pipelines traverse rough seafloor terrain.
The slug picks up liquid accumulated in inclined sections and may become very extensive.
• Transient slugging is caused by increased liquid flow rates at pipeline exit to processing
facilities in response to changes in operating conditions Of these four, riser slugging, possibly
7
combined with or initiated by terrain slugging, is the most serious for oil/water-dominated
systems.
For the most serious cases, the riser slugs can fill up the entire riser and be several hundred
meters long. The inlet separator on the receiving facilities is not large enough to receive these
slugs. If such a large slug were to arrive into the separator, it would cause overfilling which
would trip the production. Even smaller riser slugs can be problematic, as the uneven feed to
the process will lead to poor separation, varying compressor load and wear and tear on the
Control systems that are designed to avoid riser slugging in pipeline-riser systems are often
called slug controllers. This term is misleading, as it suggests that the riser slugs still exist in
the pipeline, and that the control system is only trying to limit or suppress them. The real role
of these control systems are to completely remove the riser slugs by stabilizing a desired, but
unstable, flow regime that exists at the same boundary conditions as riser slugging. An anti-
slug controller is a controller that stabilizes a desired, non-oscillatory flow regime that exists
at the same boundary conditions as riser slugging and thereby avoids the formation of riser
8
Flow assurance is the process of ensuring the successful and economical flow of hydrocarbon
stream transport from the reservoir to the point of sale (Irmann-Jacobsen, 2013). In recent
years, flow assurance has been the most critical task in deep-water energy production due to
long distances, high pressures and low temperatures (Tarek Ahmed, 2007; Johal, 2012) that
cause financial losses based on production interruption and damage in pipeline or surface
facilities due to solid deposits. Flow assurance is applied to the petroleum flow path during
troubleshooting operation problems, increased recovery in late life, etc. (Tarek Ahmed, 2007)
The major flow assurance issues that needs consideration the most for the production of
multiphase flow through pipelines and risers in offshore or onshore oil and gas field
erosion and emulsions. Slugging is the main issue in this research, so therefore will be
2.1.1 Hydrates
9
Hydrates are crystalline materials similar to ice in structure and form; at high-pressure and
isobutene and inorganic molecules such as CO₂ and H₂S) meet with water, crystalline
The most effective solutions to resolve this issue involve the use of the chemical inhibitors
electrical heating, or the cold flow method (Johal, 2012), as shown in figure below.
(Courtesy: Irmann-Jacobsen)
2.1.2 Slugging
Slug flow is one of the flow patterns occurring in multiphase pipelines. It is characterised by
a series of liquid plugs (slugs) separated by relatively large gas pockets. Slugging in
production pipelines and risers has been a major operational issue due to the creation of
10
Slugging is considered an undesirable type of flow in oil-and-gas pipelines due to causing
challenges in managing the fluid flow. Slugs can create pressure transients and fluctuations,
lead to flooding at the receiving end of the pipeline, and increase deposits and corrosion.
Gases generally have lower densities than liquids. Therefore, gases have lower heat
capacities, and can cool faster. Under the condition of high gas content, hydrates can form
more easily with the decrease of gas temperature. Increasing the intermittent velocity of the
liquid can also cause corrosion (Bratland, 2010). However, it is important to accurately model
slugging to estimate the frequency and amplitude and determine if the severity of slugging
flow line followed by a vertical riser at low gas flow rates. In this phenomenon, the liquid
accumulations in the riser and curvature section of the flow line blocking the passage of gas
in the lowest point of the system. As a result, the gas front penetrates the liquid blockage
intermittently, causing extremely large slug, severe fluctuations, and flooding of downstream
11
Figure 2.3: Slug formation in the riser of the hydrocarbon pipeline
2.1.3 Naphthenates
Over the past two decades, many operators have faced the complex deposition problem of
naphthenate along with other higher organic and inorganic scale. Such deposits can hinder oil
production in two possible ways, formation of hard and sticky deposit, and creation of sludgy
foam contributing to forming tough emulsion. Naphthenates can cause serious oilfield issues,
such as the potential shutdown of the offshore facilities due to naphthenate deposits, or the
formation of tough micro-emulsion contribute to a decline in oil quality and production rate
(Mohamed et al, 2016). Naphthenates formed from the salts of naphthenic acids when they
12
naphthenate is composed of a heavy mixture of organic acids such as cycloalkyl carboxylic
acids, see figure below (Johal, 2012). The formation of naphthenate salts is an emerging
problem and occurs in the production of crudes with significant amount of naphthenic acids
and produced water with significant amounts of alkali or alkali earth metals (Junior et al.,
2013).
In general, all kinds of naphthenates can cause production losses in oil fields. Naphthenates
can also have a major effect on separation efficiency of the host processing facilities,
especially calcium and sodium types, which the in general, all kinds of naphthenates can
cause production losses in oil fields. Naphthenates can also have a major effect on separation
efficiency of the host processing facilities, especially calcium and sodium types, which the
most are commonly found naphthenates in oil fields (Johal, 2012; Junior et al., 2013). Most
are commonly found naphthenates in oil fields (Johal, 2012; Junior et al., 2013).
2.1.4 Asphaltenes
13
Asphaltenes are polar compounds that when present in the heaviest fractions of the crude oil
and are defined by their solubility characteristics. Precipitated if diluted by normal alkane,
such as n-heptane, and soluble in aromatic solvents such as toluene. During production,
asphaltenes can precipitate because of a large change in pressure, temperature and fluid
Various problems result due to asphalting precipitation, including a decline in the production
rate and other operational problems, such as higher viscosity and water-oil emulsion, etc. In
the industry, there is a consensus that the prevention principle is the best way to solve the
2.1.5 Scales
14
Scales can develop in the transportation system because of water forming deposits, as a
crystalline growth of insoluble salt or oxides held within the water component. Scale
compounds will precipitate out of water when their individual solubility in water can be
exceeded because of incompatibility, and this will reduce the transport capacity of flowlines
and potentially cause plugging, the formation of scale deposits depends on temperature, the
concentration of scale forming species, pH, water quality and hydrodynamic conditions.
Scale inhibition mechanism can be based on the prevention of nucleation and salt crystal
There are different types of scale inhibitors for preventing different kinds of inorganic salt
nucleation and salt crystal growth in the solution (Abdel-Aal et al., 2015; Azizollah et al.,
2017).
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2.1.6 Corrosion
Pipeline corrosion is one of the main causes of subsea pipeline failure. It is necessary to
monitor and analyse pipeline condition likely failure. Subsea pipeline corrosion weakens the
resistance of pipelines to internal and external forces, which is the leading factor that causes
the integrity loss of the pipelines (Yongsheng et al., 2017). When carbon steel pipes are used
in transporting oil and multiphase flow containing a fraction of water, there is usually a high
risk of corrosion. The decision to use carbon steel is usually economic in order to minimise
capital expenditure – and its use usually requires the implementation of a full internal
corrosion management strategy to control corrosion levels throughout the system life.
Various mechanisms have been postulated for the corrosion process; all of these involve the
formation of a carbonic acid ion or bicarbonate when CO2 is dissolved in water. This process
can lead to corrosion, of the material at a rate that is greater than that from general acid
corrosion with the same pH value. The mechanism of corrosion is dependent on the quantity
of the CO2 dissolved in the water phase, and predictions of corrosion levels are currently
based on the knowledge of CO2 partial pressure and the use of correlations such as De Waard
16
2.1.7 Emulsions
With a combination of low ambient sea temperature and high fluid viscosity due to inversion
water cut conditions, tight emulsions can occur between the water and oil phases. This can impair
the separation efficiency at the processing facility, and thus cause a loss in the production of the
asset. In system shutdown conditions, the rheology of the fluids may change from Newtonian to
non-Newtonian, exhibiting characteristics of high yield stress during low shear rate production
start-up operations. In these conditions there may be a need to inject de-emulsifiers into the
subsea facilities and also to ensure that sufficient pressure is available to re-start the system
Inappropriate handling and management of the petroleum emulsions can cause serious
detrimental effects on public health and environment due to its high toxicity and high production
quantity worldwide; naphthenic acids and heavy metals are the major toxic components in the
petroleum emulsions, which are highly lethal for microorganisms, aquatic algae and aquatic
Wax deposition refers to the formation of a layer of separate solid phase and the eventual
growth of this layer on a surface in contact with the crude oil. Wax deposits can be formed
from an already precipitated solid phase (wax) through mechanisms of shear dispersion,
gravity settling and Brownian motion, or from dissolved wax molecules through a molecular
Wax deposition in the pipe can only occur when the inner pipe wall temperature is below the
wax appearance temperature, also referred to as the cloud point temperature. The precipitated
wax molecules near the pipe wall start to form an incipient gel at the cold surface. The
incipient gel formed at the pipe wall is a 3-D network structure of wax crystals and contains a
17
The incipient gel grows as time progresses and there are radial thermal and mass transfer
gradients as a result of heat loss to the surrounding area, as shown in figure 10 (Lee, 2008).
One of the important issues is that the wax deposit is not solid wax, but a gel that consists of
solid wax crystals and trapped liquid. The deposit is also known to harden with time in a
process termed aging (Venkatesan and Creek, 2007; Tordal, 2006). The precipitation of wax
components out of the oil is responsible for changes in the waxy crude oil properties,
including the gelation of oil and an increase in viscosity (Zhu et al., 2008). Wax contains a
high molecular weight n-Paraffin and consists of long chain alkanes with 20 to 50 carbon
atoms (Time, 2011). Wax can precipitate as a solid phase when the crude oil temperature
drops below the wax appearance temperature (WAT): the temperature at which the first wax
crystals start to form in the crude oil in a cooling process (Dantas Neto et al., 2009).
18
(Courtesy: Lee, 2008; Al-Yaari, 2011)
Multiphase flow modeling or thermo-hydraulic analysis is one of the two pillars of Flow
(gas, liquids, solids) in a pipe is called a flow pattern or flow regime. In the 1950s flow
patterns (Baker, 1954) were observed and used for pressure and flow calculations in
multiphase pipes as summarized in references (Brennen, 2005 and Brown, 1980). Different
flow patterns are observed from experimental tests and field/plant multiphase pipes. Use of
regimes improved the prediction accuracy, but inconsistencies of calculated pressures existed
near the transition boundary due to the use of different sets of correlations in different flow
regimesMultiphase flows have a dominant occurrence in the majority of upstream oil and gas
pipelines. The flowregimes existent in these pipes have different mitigation methods in
design and operation to control flow-related issues, such as corrosion or severe slugging at
the slug catcher. Being able to predict the regimes usingmeasurable variables enables the
industry and academia developed many correlations based on experimental data andfield
data.
19
Figure 2.8: Flow regime types for multiphase flow in horizontal pipes
(Courtesy: Bratland)
Dimensionless analysis was used to expand the aplications range. The transport properties of
the multiphase fluids are calculated from Black Oil models. Beggs and Brill (Beggs, 1973)
correlations are one of the widely used multiphase system calculations. During any decision
In steady-state single-phase flow in a pipe, the classification of the flow is whether the flow is
laminaror turbulent. Laminar flow is when the particles in the flow move axially in one
direction.
Turbulent flowis when the particles in the flow move axially and radially, and interact with
one another. If the flow isturbulent, the pipe wall properties, or friction factor, becomes
important. The higher the friction factor, themore turbulent the flow becomes. What dictates
the flow type is the balance between inertial forces andviscous forces, which can be estimated
by Reynold’s number.
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2.2.1 Flow Patterns
Single-phase flow is divided into laminar and turbulent flow regimes depending on their
Reynolds numbers. In multiphase flow the discrimination becomes more complex. Gas and
liquid distribution may vary when flowing in a long pipe, resulting in different flow regimes
(Time, 2009). A brief description of the flow regimes or patterns that may occur in vertical or
horizontal flow will be given in this section. In general, one may discriminate between five
flow regimes for vertical upward multiphase flow: bubble flow, slug flow, churn flow,
annular, and mist flow. The flow regimes change in this order by increasing the gas rate for a
given liquid rate (Zavareh, Hill, & Podio, 1988). The most important flow patterns for
multiphase flow in wells are slug and churn flow patterns. They are often referred to as
In bubble flow, the liquid is the continuous phase and the free-gas phase is presented as small
bubbles. The gas-bubbles are randomly distributed in the liquid flow, and the diameter may
vary. Due to different sizes of the gas bubbles, they travel with different velocities. The liquid
phase however moves with a more uniform velocity. The gas phase, except for its density,
Slug flow is characterized by alternating slugs of liquid with large bubbles of gas. Large gas-
bubbles are made as the smaller gas-bubbles coalesce when gas velocity increases. The larger
bubbles are called Taylor bubbles. Smaller bubbles of gas are contained in the liquid slugs.
The liquid is still the continuous phase, because of a liquid film covering the Taylor bubbles
(Orkiszewski, 1967).
21
As the gas velocity is increased further, the large gas-bubbles become unstable and may
collapse. When this happens, churn flow occur. Churn flow is a highly turbulent and chaotic
regime. Neither gas nor liquid phase appears to be continuous. Oscillatory, up and down
motion of liquid, is characteristic for churn flow (Zavareh, Hill, & Podio, 1988).
In annular flow, gas is the continuous phase. Gas flows with a high rate in the centre of the
pipe. The liquid is found as a liquid film coating the pipe wall and as entrained droplets in the
gas phase. The gas-phase becomes the controlling phase (Orkiszewski, 1967).
The gas phase is continuous, and the bulk of the liquid is entrained as droplets in the gas
phase. Determination of flow regime will be important for parameters such as holdup and
thereby pressure-drop predictions. Results of studies on flow regimes are often displayed in
the form of a flow regime map (Brennen, 2005). Flow maps are generated to relate flow
patterns to flow rates and fluid properties. Boundaries in a flow regime map represent where
a regime becomes unstable. The growth of the instability will lead to a transition to another
regime. These transitions can be rather unpredictable because they may depend on otherwise
minor features of the flow, as the wall roughness or entrance conditions. Hence, the flow-
pattern boundaries are not distinctive lines, but more poorly defined transition zones. Many
different flow regime maps have been published, based on different correlations for flow-
regime prediction.
In the early days, before the oil and gas industry began exploring offshore, reservoir fluids
were relatively "clean" with comparatively low pressures and temperatures. Pipeline
hydraulic calculations and mechanical designs were simple. As the industry progressed,
22
moving into deeper water, reservoirs and reservoir fluids became more complicated.
Pressures and temperatures were higher as the producing formations were being drilled
deeper. The large majority of fields were onshore, but occasionally, a field would extend into
a lake or ocean.
Drilling would continue offshore made from wooden trestles or artificial islands. Some
notable examples were the Canadian side of Lake Erie, Santa Barbara, California, and St.
Mary's Lake in Ohio. Caddo Lake, between Texas and Louisiana, was drilled after some oil
field hands in a boat crossing the lake noticed gas bubbles rising to the lake's surface. They
proceeded to ignite these bubbles all the way to shore and convinced their company to drill.
In 1810, Humphrey Davy identified gas hydrates in laboratory experiments. Hydrates became
pipeline problems in field gathering lines installed in the early 1900s. At that time, they were
not considered a significant problem because there was little or no market for natural gas. In
The maximum water content in sales gas was not specified since it was unnecessary. In 1927
paraffin were identified as a nuisance to the upstream oil industry due to their precipitation
and accumulation on the wall of the well tubing string, and on the sand face to plug the pores,
which resulted in congealing of oil in the transportation lines and on tank bottoms (Reistle,
1927). The 1970s and 1980s saw a major increase in empirical correlation development
through experimental data methods based on Friction Factor simplifying the application of
the Moody diagram (Churchill 1973, 1977). Taitel (1976) started the trend of mechanistic
modelling of multiphase flow. Others tinkered with the formulation of the equation with the
multiphase flow (MPF) software began in earnest along dual paths—the Petroleum path and
the Nuclear Power path. Computer hardware became physically smaller, faster, and less
23
some being programmable with Basic Code. Geophysical modelling improved with three-
dimensional models.
In the 1990s, −2000s this period saw continual improvement in the science of flow
assurance. Computers were more powerful and faster, engineers developed a better
understanding of what was important in design and, later, to track during operations
personal efficiency and the efficiencies of their software and computers Flow Assurance
and transportation activities (Buller et al., 2002). Pipeline insulation is required to keep the
production fluids warm to manage the solids. The types of insulation are summarized as
follows:
An insulation material should have low thermal conductivity in the production environment,
should below cost and be easily applied on flow lines. Various foams and composite
The properties necessary for an insulation material are thermal conductivity, density,
permeability, strength, flexibility and long-term stability. Aging, pressure and temperature
have significant effects on the thermal performance of an insulated flowline (Wang, et al.,
2000). Flow modelling includes single phase flow, multiphase flow (2, 3 and 4 phases); heat
and mass transfer at interfaces; flow system dynamic behaviours; operation scenarios, upset
24
scenarios; fluid-structure interaction (internal); and sometimes Computational Fluid
• Two phase flow – oil/gas, oil/water; gas/water. The analyses and simulation
technologies are well developed and mature. Commercially available software (such
• Three phase flow – oil/gas/water; liquid/gas/solid (sand, other particles). The analysis
Anti-Agglomerate (AA) low dosage hydrate inhibitor is applied). The analytical and
Fluid and flow simulation combined can provide solid deposition rates and locations. Fluid
and flow modelling are critical to Flow Assurance Engineering and influence every phase of
the project.
25
Figure 2.9: Flow Bundles
The Present Flow Assurance became a mature engineering discipline for engineering and
operation support with recognized simulation tools, knowledgeable teams of operators and
contractors, laboratories and manufacturers. Few new concepts have been initiated since 2013
due to the drop in oil prices. The focus has moved to lowering development costs by reducing
conservatism in Flow Assurance Engineering design and operations support. Flow Assurance
evolved from using qualitative guidelines in facilities design to using quantitative methods. A
decision concept that was risk-based for flow assurance have been proposed (Morgan, 2015;
26
One of the ways of eliminating fluctuation because of slugging is by choking. In practice, oil
and gas industry have used this method for many years to eliminate severe slugging by
manipulating the valve opening at the exit of the riser, which unfortunately could negatively
affect production (Taitel 1986). Controller has been used, and it has been reported to be able
to help remove this problem by stabilizing the system at larger valve opening (Ogazi 2011).
Significant efforts have been concentrated on modelling and understanding the slug
attenuation mechanism for choking (Jansen & Shoham 1994) Up until the last few years, the
preferred solution to avoid or reduce the problems associated with riser slugging has been to
design the system such that the slugging potential is minimized or to change the boundary
condition (that is, reducing the topside choke valve opening) to remove the slug flow from
None of these solutions is optimal. Design changes often involve installation of expensive
equipment such as slug catchers and reducing the topside choke valve opening introduces
extra Pressure drop that will limit production when the reservoir pressure goes down as the
feedback control to avoid riser slugging. The key concept in that paper was to avoid riser
slugging by automatically adjusting the topside choke valve position based on an algorithm
with a pressure measurement upstream of the riser and a flow measurement in the riser as
inputs. Hedne and Linga (1990) used a more conventional PI controller based on an upstream
pressure measurement to avoid riser slugging. Both these papers are based on experimental
work in medium scale flow loops and show the potential for using control solutions to avoid
riser slugging in pipeline-risers systems. The benefits of using a control solution are that no
expensive equipment is needed and that no significant pressure drop is added to the system.
However, the work of Schmidt et al. (1979), Hedne, and Linga (1990) did not result in any
27
In the last ten years or so, there has been a renewed interest in control-based solutions to
avoid riser slugging. Courbot (1996) presents a control system to prevent riser slugging
implemented on the Dunbar pipeline. The approach in this paper was to implement a control
system that uses the topside choke valve to keep the pressure at the riser base at or above the
peak pressure in a the riser slug cycle, thus preventing liquid accumulation in the bottom of
the riser. This approach effectively removed riser slugging in the system, but it did so by
automating the old choking strategy rather than affecting the stability of the flow regimes in
the pipeline. This means that an extra pressure drop was introduced in the system due to the
high set point for the pressure controller. Henriot et al. (1999) presents a simulation study for
the same pipeline as Courbot (1996), where the set point for the riser base pressure is set
considerably lower. In this work, the controller is probably stabilizing an unstable operating
point rather than just keeping the process away from the riser-slugging region, although this
Self-lift approach in severe slug mitigation, the self-lift approach was invented and developed
as a method to eliminate severe slug in multiphase flow subsea lines (Barbuto, 1995).
Barbuto (1995) described this novel approach as the use of an auxiliary line that connects the
downwards inclined flowline with the main riser. A schematic detailing the configurations of
the connection points is below, with Point A – the connection point between the auxiliary line
and the vertical line (main riser); Point B – the connection point between the production line
and the auxiliary line; and Point C – the connection point between the production line and the
vertical line. This design mitigates severe slug by conveying the gas of the multiphase flow
from point B to point A; this is possible due to the differences in pressure at point B and A.
(Barbuto, 1995). The gas bubbles conveyed into the vertical line help break up the liquid
slugs (Ogazi, 2011). Moreover, the quantities of gas contained in oilfields were either greater
28
or lesser compared to the oil (Shotbolt, 1986). That meant that although the gas cap of a
reservoir was not noticeable, the oil still contained a considerable amount of dissolved gas.
Tengesdal (2002) used this novel approach to model the mitigation of severe slug at the riser
base. The approach was not considered to need any additional gas injection from the platform
and was therefore termed ‘self-gas lifting’ (Tengesdal, 2002). This approach appeared to be
quite beneficial as any extra-cost needed to compress external gas for mitigation of severe
slugs, to transport the gas, and to store it on platforms topside, could all be reduced or
completely waived. The following conclusions were deducted from the research that: The
approach caused a reduction of hydrostatic head within the riser and of the pressure in the
production line. From experimental observations, it is ideal to have the injection point at the
same level or slightly higher than the take-off point for optimum performance. From the
experiments, it was observed that a small choking was needed to stabilize the flow when the
29
injection point is at a higher level than the take-off point. This approach to mitigating severe
slug was not sensitive to changes with liquid and gas flowrates.
Skofteland and Godhavn (2003) made use of the conventional PID controllers to stabilize the
flow in pipeline-riser systems and reports both field experience from the Heidrun field and
Hollenberg et al., (1995) presented an approach that was different for removing severe
slugging from a pipeline-riser system. By introducing a small separator on top of the riser, the
gas and liquid flow can be controlled separately above a certain frequency. This structure,
called the S3 R Slug Suppression System also allows for accurate measurement of the gas
and liquid rate, and by controlling the total mixture flow rate and the pressure in the small
separator, the system can be stabilized. Kovalev et al., (2003) report that the S3 system has
been successfully implemented at the North Cormorant and Brent Charlie platforms in the
North Sea.
The use of riser topside pressure measurement as a variable for severe slugging control has
been reported with diverging views. The controllability analysis reported by (Storkaas 2001)
showed that the riser top pressure alone is not a good variable for riser-pipeline instability
control. This is since the zeros of the corresponding transfer function are in the right half-
Dynamic choke is a choke manipulated by active control based on real time changes of
system variables. The choking position is not fixed but adjusted based on a measured variable
for achieving stability. Riser base pressure, riser top pressure and flow rate are commonly
systematic analysis of the riser-pipeline system using control theories. The analysis also
30
included the assessment of the stability characteristics of the system using the riser top valve
opening as the manipulated variable. Based on their analysis, they identified the riser base
pressure as the best variable for stabilizing riser-pipeline system (Storkaas et al., 2004).
Jones et al., (2014) stated that the most effective mitigation approach to slugging is riser top
valve choking (topside choking). Jansen et al., (1996) agreed with Schmidt et al., (1979) that
‘choking eliminates severe slug by increasing the back pressure and acting as a flow
resistance proportionally to the velocity of the liquid slug in the riser’. This meant that
choking could potentially balance and maintain the multiphase flow with ‘minimal back
pressure’. However, Ogazi et al., (2011) argued that an inherent disadvantage with this
approach is the extra back pressure induced on the pipeline and recommended the use of an
active feedback control (dynamic choke) that could attenuate the slug flow and increase
production. Tengesdal (2002) used this novel approach to model the mitigation of severe slug
at the riser base. The approach was not considered to need any additional gas injection from
the platform and was therefore termed ‘self-gas lifting’ (Tengesdal, 2002). This approach
appeared to be quite beneficial as any extra-cost needed to compress external gas for
mitigation of severe slugs, to transport the gas, and to store it on platforms topside, could all
Havre et al (2000), report the first industrial implementation of an anti-slug controller. Who
presents an anti-slug control system for the Hod-Valhall pipeline and illustrates its
performance with both simulations and actual field data. The simulation results illustrate an
interesting fact; by turning the control system off and keeping the same valve opening as was
implemented (on average) by the control system, the riser slugging returns in the system. This
proves that the control system stabilizes an unstable operating point. This unstable operating
31
point, where the flow in the pipeline is steady, exists at the same boundary condition as
would normally result in riser slugging. Havre and Dalsmo (2002) give a more detailed
The cyclic behaviour of riser slugging is illustrated schematically in figure 2.3. It can be
broken down into four parts. First, gravity causes the liquid to accumulate in the low point
(Step 1), and a prerequisite for severe slugging to occur is that the gas and liquid velocity is
low enough to allow for this accumulation. The liquid blocks the gas flow, and a continuous
liquid slug is formed in the riser. As long as the hydrostatic head of the liquid in the riser
increases faster than the pressure drop over the riser, the slug will continue to grow (step 2).
When the pressure drop over the riser overcomes the hydrostatic head of the liquid in the
Slug, the slug will be pushed out of the system and the gas will start penetrating the liquid in
the riser (step 3). Since this is accompanied with a pressure drop, the gas will expand and
further increase the velocities in the riser. After the majority of the liquid and the gas has left
the riser, the velocity of the gas is no longer high enough to pull the liquid upwards. The
liquid will start flowing back down the riser (step 4) and the accumulation of liquid starts
again. A more detailed description of the severe slugging phenomenon can be found in for
example Taitel (1986). It is well known that riser slugging may be avoided by choking
(decreasing the opening Z) of the valve at the riser top. To understand why this is the case,
positive perturbation in the liquid holdup in the riser is then introduced. Initially, the
increased weight will cause the liquid to “fall down”. This will result in an increased pressure
32
a) The upstream pipeline pressure increases both due to compression and less gas
b) The pressure at the top of the riser decreases because of expansion of the gas. The
increased pressure drop will increase the gas flow and push the liquid back up the
riser, resulting in more liquid at the top of the riser than prior to the perturbation.
Now, if the valve opening is larger than a certain critical value Zcrit, too much liquid will
leave the system, resulting in a negative deviation in the liquid holdup that is larger than the
original positive perturbation. Thus, we have an unstable situation where the oscillations
grow, resulting in slug flow. For a valve opening less than the critical value Zcrit, the
resulting decrease in the liquid holdup is smaller than the original perturbation, and we have a
Severe slugging has become a major challenge to gathering crude oil from the fast depleting
oil reservoirs. With deep-water exploration up to 2000m becoming common, many risers will
be required in the coming decade, all of which will become vulnerable to severe slugging if a
sustainable solution is not found. A number of severe slugging control techniques have been
This section reviews these severe slugging control techniques and their objectives based on
the underlying technologies. The current control techniques can be classified into two, based
on the underlying scientific and/or technological principles employed. The two classifications
are changing flow condition and riser outlet downstream adjustment. A typical severe slug
flow condition is identified using one major characteristic of the pressure profile. This is the
differential pressure (DP) across the riser during severe slugging. During the slug production
stage as shown in Figure 1.1, the entire riser column is completely filled with liquid, such that
33
the liquid volume fraction is equal to one, but when the maximum differential pressure across
the riser is less than 1.08 barg. This implies the stages of the slug cycle, and the condition in
which the riser is filled with liquid at the production stage does not occur (Ogazi, 2011).
This approach focuses on altering the flow, pressure conditions and the structure of the flow
line upstream (sub-sea) of the riser. Current practical approaches Includes the design
modification of upstream facilities, riser base gas lift, gas re-injection (self-lifting),
34
Design modification of upstream facilities: This method involves applying changes
to the existing facilities upstream of the riser. The common concepts are changing
Changing flow line internal diameter: In order to mitigate the severe slugging
occurring in a production system, the pipeline size can be changed with targets on
increasing or reducing the internal pipe diameter, depending on the type of slug
prevalent in the system. Reducing the pipe diameter, will reduce the cross sectional
area of the pipe thereby increasing the fluid velocity. This concept generates a flow
regime with low gravitational pressure drop in the riser; a condition necessary for
avoiding liquid accumulation at the riser base, which is prevalent in low velocity
terrain, induced severe slugging. Increasing the pipe diameter increases the cross
sectional area of the pipe. This may produce a low velocity stratified flow in the flow
line, a condition necessary for avoiding hydrodynamic slug. This implies that while
increasing pipe diameter may remove hydrodynamic slug, it may initiate terrain-
Fargharly concluded in a study of severe slugging in the Upper Zakum oil field that optimum
sizing may alleviate (mitigate) the severe slugging problem but it will not eliminate severe
slugging completely. However, optimal sizing will depend on other production factors, which
could be difficult to determine precisely. One disadvantage of this method is that changing
flow line diameter is capital intensive and it may introduce other operational problems. This
35
2.6.2 Riser base gas lift
Riser base gas lift system is a slug attenuation strategy in which compressed gas is injected
into the riser base to lift the liquid. Riser base gas injection can attenuate slug formation by
the following interrelated fluid, flow and pressure mechanisms, decreasing the pressure in the
flow line, increasing the flowrate and changing the flow regime in the riser, decreasing the
Alvarez and Al-Malki reported the attenuation of a hilly terrain induced slugging encountered
in an 11.4km long large diameter pipeline by increasing GOR through riser base gas injection
(Alvarez, 2003). Meng and Zhang also discussed the possibility of attenuating severe
slugging by increasing GOR through increased well gas injection (Meng, 2001). Jansen and
Shoham showed through experimental studies conducted using a 9.1m pipeline and 3m
higher riser system that it is possible to stabilize severe slugging by gas injection, (Jansen,
1994). However, riser base gas injection is not a straightforward process, as it requires
accurate flow regime assessment. Introducing riser base gas injection into a stratified flow
regime can cause flow instability. There have been industrial reports of riser base gas
Kuwait.
This platform had no slugging problem until riser base gas injection was introduced. It can be
explained that the riser base gas injection changed the flow regime from stratified flow to
slug flow. Another crucial issue is the trade-off between the optimum point for gas injection
and the amount of gas required to stabilise the system as shown in differing reports by Jansen
and Shoham (Jansen, 1994), it was concluded that through their experiment that a high
amount of gas is required to eliminate severe slugging in just a 3m high riser. Pots et al also
36
reported that an unrealistically large volume of gas is required to achieve stability by riser
CHAPTER 3
3.1 Overview
Review of literature in the previous chapter has shown that the methods of riser slugging
mitigation can be classified into two (2); change of conditions of flow and riser outlet
downstream adjustment. A typical severe slug flow condition is identified using one major
characteristic of the pressure profile. This is the differential pressure (DP) across the riser
during severe slugging. For the purpose of the investigations to be done in this thesis, two
mitigation techniques have been selected for performance evaluation, in order to identify
3.2 Materials
The primary materials needed for the performance evaluation to be done in this work are;
i. Input data: Field data is quintessential to be able to perform analyses. The kinds of
data to be utilized include; production field data for the deep offshore location, riser
geometry and design properties and gas injection schedule for the gas lift.
ii. Software: The industry based numerical simulator often utilized for this kind of
37
3.3 Method/Workflow
To initialize the analysis, the riser system would be designed using simulator, based on
design parameters gathered - this would serve as the base case model. Two different
alterations of this base case model would then be simulated for the two mitigation
techniques being considered in this research. Analysis would then be conducted on the
A comparative analysis approach would then be adopted for the performance evaluation by
OLGA was developed based on two (2) key governing equations of engineering fluid
δ ( V g ρg ) −1 δ ( A p V g ρ g u g )
= +ψ g +G g (3.1)
δt Ap δt
( )
δ ( V L ρ L) −1 δ ( A p V L ρL u L ) VL
= +ψ g −ψ e +ψ d +G L (3.2)
δt Ap δt V L+ V D
( )
δ ( V D ρL ) −1 δ ( A p V D ρL u L ) VD
= +ψ g +ψ e−ψ d +GD (3.3)
δt Ap δt V L +V D
38
d) Gas phase equation;
1 δ ( A p V g ρ g ug )
2
δ ( V g ρ g ug )
δt ( )
=−V g
∂P
∂z
−
Ap δz
1
−λ g ρ g|u g|u g .
2
Sg
4 Ap
1
−λi ρg|ur|ur .
2
Si
4 Ap
+V g ρ
(3.4)
1 δ ( A p V D ρ L uD )
( )
2
δ ( V D ρL u D )
δt ( )
=−V D
∂P
∂z
−
Ap δz
+V D ρ L g cos θ−ψ g
VD
u +ψ u −ψ e uD + F D
V L+ V D a e i
(3.5)
1 δ ( A p V L ρL u L )
2
δ ( V L ρ L uL )
δt ( )
=−V L
∂P
∂z
−
Ap δz
1
2
S
4 Ap
1
2
S
− λ L ρL|u L|u L . L −λ i ρ g|ur|ur . i +V L ρL g cos θ
4 Ap
(3.6)
1 δ ( A p V L ρ L uL + A p V g ρg u g )
2 2
δ ( V g ρg ug +V L ρ L uL )
δt ( )
=−( V g +V d )
∂P
∂z
−
Ap δz
1
2
S
−λ g ρ g|ug|u g . g −λi
4 Ap
1
2
(3.7)
liquid droplet.
39
S = wetted perimeter; ur = relative velocity; λ g = gas friction coefficient; λ L= liquid friction
reduce a larger system into elemental units, in order to capture the intricacies associated
with the elemental sections and then integrate this into the overall computation. For OLGA,
discretisation is achieved by sectioning the pipeline-riser system such that the length-to-
section ratio recommended to have neighbouring section lengths that are between greater
than 0.5 times the preceding section and less than 2 times the next section.
u Δt
C= ≤C max (3.8)
Δx
Δ t = time-step
x = section-length.
40
41
CHAPTER 4
42