SPE 15656

Pipeline Transportation of High Pour Point New Zeaiand Crude

Using Pour Point Depressants

by Grant Slater, Petroleum Corporation of New Zealand Limited, and

Ann Davis, NL Treating Chemicals/NL industries, Inc.

SPE Member

copyright 19S6, Society of Petroleum Enginwrs

This paper was prepared for presentation at the 61st Annual Technical Conference and Exhibitionof the society of Petroleum Engineers hold in New
Orlaana, LA October S-S, t 9SS.

This paper wee selected for prasentatiin by an SPE Program Committw followingraview of informationcontained in en abatracl submittedby the
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~ at S$% mwfinga am subject to pubkatbn review by Editorial Committees of lhe Society of Patroleum Engineers. Parmiaaion to aopy is
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where and by whom the paper ia prewnted Write Pubfiitiia Manager, SPE, P.O. Sox S33S3S, Richardson, TX 7SOSWS3S, Telex, 7S0SS9SPEDAL,

ABSTRACT sible to devise a management plan whkh minimizes diffi-

The Petroleum Corporation of New zealand Limited dis-
covered New Zealands first major oil fieki in 1980. Ro-
duction is currently 1590 m3/d (10,000 bpd), which
represents about 14% of the countrys requirements.
The crude has a high pour point (32C) and a high wax
level (35%). A major factor in development of the field
was the selection of appropriate technology to overcome
transportation problems via a 40 km pipeline from the
process plant to port storage with ground temperatures of
11 C (52F). Technical and economic considerations
resulted in the selection of a chemical pour point depres-
sant rather than thermal cracking, dilution with conden-
sate, or maintaining the crude oil temperature above its
pour point,
Selection of a suitable pour point depressant was made
using laboratory studies done by various prospective sup-
pliers, Product performance was based on pour point and
yield value for the crude using a simple simulation of pipe-
iine cooling.
The first year of pipeline operation was essentially trouble-
free and the foliowing key points were noted. The actual
pipeline dosage rate was considerably lower than labora-
tory predicted rates. By careful experimentation during
pipeline shutdowns of varying duration, it has been pos-
cultiesduring start-up.
The paper discusses how the adoption of pour point
depressant technology, in conjunction with pipeiine
design, has resulted in an eesenthlly trouble-free system
which enables the crude to be successfullytransported by
pipeline.
INTRODUCTION
The Petroleum Co~oration of New Zealand Ltd. (Petro-
corp) discovered New Zealands first major oil field during
1980, The field is located onshore in high value farming
Iand in the countrys North Island, near New Piymouth
(Fig, 1),
Production of crude oil commenced in October 1984 with
795 m3/d being produced from four wells. This has been
subsequently increased to 954 ins/d and beginning in
November 1986, production will be 1590 m3/d from
twelve wells.
The marketing strategy was based on buik storage at New
Plymouth with dispatch to markets within New Zealand
and overseas by tanker. Transportation of crude from the
production station to port storage was recognized as a
problem during initial pianning because of the high pour
point of the crude,

The foilowing options were evaluated in detail:

Illustrations at end of paper,

 PIPELINE TRANSPORTATION OF HIGH POUR POINT NEW ZEALANDCRUDE
2 USINGPOURPOINTDEPRESSANTS
1, The formation of an oil-in-water emulsion or the injec-
tion of a water layer to line the pipe wall, then piping to
port storage.
2, Thermal conditioning to reduce apparent viscosity of
the crude by giving it a specific thermal history prior to
piping.
3, Trucking the crude oil horn production station to port
storage facilities.
4. Piping the stabilized crude oil through an electrically
heat traced and thermally insulated pipeline to the port
storage facility.
5, Thermal cracking of the oil to reduce its pour point
before piping to the port storage in an uninsulated line.
6, Blending of the crude oil with low pour point conden-
sate from a nearby gas/condensate field.
7. Tnating the oil with wax crystal modifiers and then
piping to port storage.
The use of wax crystal modifiers to reduce the crude pour
point was eventually adopted as it was expected to lower
the pour point to an acceptable level, minimize the yield
point to a level compatible with the pipehne design to assist
in the management of pipeline shutdowns, and reduce the
apparent viscosity.
This has proven to be an acceptable method with two
years successful operation now complete. This paper
describes as a case study the reasons why the use of pour
point depressants was adopted. It also describes the pipe-
line design and the selection of a suitable pour point
depressant along with a comparison of the design predic-
tions with the resultsof two years of operation.
CRUDE CHARACTERISTICS
The crude oil has a moderate API gravity (38 to 40) and
a high pour point of 30C (86F) to 32C (90F). The
crude has a very low sulfur content (0.066% wt.), low
conradson carbon residue (0.277% wt.), vanadium (less
than 0.5 ppm) and nickel (less than 0.1 ppm) contents.
The crude ISa mixed base of paraffins and naphthenes, but
it also has a sizablearomatic content. The heavy cuts of the
crude are waxy and have high pour points with the overall
wax level about 35% wt. The crude h dmllar In composi-
tion to some of the Indonesian crudes. The crude oil char-
actertsttcsare summarised in Table 1.
The transport properties of t$e crude can be described in
terms of (1) ASTM pour point, (2) viscosity at various
shear rates and temperatures, and, (3) yield point.
SPE15S5S
The pour point, when determined strictly in accordance
with ASTM D97-66, IS 30C (86F) for both the max-
imum and minimum values. The yield stress for crude
unclosed with pour point depressant has never been mea-
sured consistently; one measurement made was at 11C
(52F) and with the crude cooled statically gave a yield
value of 8250 Pa and 12 Pa if cooled under shear. The
rheologtcal behavior is dependent on both shear rate and
temperature. Above the pour point the viscosity ranges
from 0.020 Pas at 33C (91F) down to 0.005 Pass at
43C (110F), Below the pour point the viscosity natu-
rally increases substantially to 0.150 Pas at 28C (83F)
and 0.500 Pas at 13C (55F).
FEASIBILITY STUDIES FOR VARIOUS
PIPELINING METHODS
The Initial conceptual and feasibility studies for the field
clearly identified the high wax content as presenting diffi-
culties in both production and transportation. The investi-
gations covered all possible options for transporting crude
from the production station to port storage, a distance of
some 40 km. The various options considered, and their
eventual reasons for rejection, are discussed.
1. WatorlCrudo $ystoms
Both emulsion and water layer systems were consid-
ered and rejected during the conceptual design phase.
The limited availability of water at the production sta-
tion, the prevailing environmental climate which would
have required the water to be treated to a very high
quality before discharge, and the potentta! difficulties in
obtaining permission to discharge such high quantities
of treated water were considered sufficient reasons to
reject this OPtbil.
2. Thermal Conditioning
The use of thermal conditioning to reduce the apparent
viscosity by fliving the crude a specific thermal history
was rejected cm the grounds of capital cost, process
complexity, and limited space at the production station
for installation of the aquipment,
3, Trucking
While having a relatively low capital cost, the annual
operating costs made this uneconomical, and the
potential plannlng applications associated with trucking
crude oil through the adjacent rural farming and urban
areas also made it undesirable as an option.
4. Insulated Plpallne
The options of a thermally insulated plpellne, together
with either conventional electric heat tracing, skin effect
current tracing, or a preheated crude were all consid-
ered. The costs for a system that maintained flowing
temperatures were slgniflcani$ higher than for some
SPE 15656 GRANT SIATER and ANN DAVIS
other options, without including the additional costs of
a system to reheat the crude after a shutdown.
At this stage in the investigations, it became evident from
the marketing studies that a number of the potential buyers
would insist on a permanent reduction in pour point to
about 15C (59F) due to refinery crude handling limita-
tions, With this limitation now clearly identified, the fol-
lowing three options were studied in more detail, as all
three resulted in a permanent reduction in pour point
which suited both the market and engineering require-
ments for tr.msporting crude in an uninsulated line.
5, Thermal Cracking
The use of thermal cracking to break down the long
chain molecules was considered in detail and eventu-
ally rejected for a combination of reasons that included:
a. Difficulties in determining the plant size as initial
production was 636 m3/d but expansion up to 1590
m3/d was possible.
b. Effluent treatment and disposal in what is an envi-
ronmentally sensitivearea, and finally,
c. The limited hydrotreating capacity at New Zealands
only refinery which was expected to process most of
the crude.
6. Dilutlonwith LowPour PointCondensate
This would have involved diluting the crude with a
nearby condensate in the ratio of 60:40 crude/
condensate to obtain a product with an acceptable pour
point. This method was rejected for cost, logistical and
marketing reasons:
a, The storage and pipeline for the condensate would
have been substantial as the condensate was avail-
able no closer than the pipeline discharge area (40
km), and,
b. The buyers indicated that they would prefer to
receive New Zealands crudes and condensates as
separate materials,
This method was, however, reserved as a possible backup
option.
7, Uae of Chemical Pour Point Depressants
While having a relatively high annual operating cost,
this method was adopted as it achieved the following
objectiveswhich no other option could offer:
a. The crude could be easily transported by pipeline
and restarting after a shutdown would be relatively
easy.
b, The crude achieved the marketing pour point
requirement of 15C (59F) and the use of these
materials was acceptable to the crude oil buyers,
c. The system was very flexible in regard to capacity
changes,
3
The decision was made at this stage to use a chemical pour
point depressant as preliminary studies had indicated that
suitable products for this crude ex;sted and that the costs
would be acceptable. At this stage detailed investigations
of suitable products commenced with the detailed pipeline
design undertaken simultaneously as suitable laboratory
results became available, The pipeline design was under-
taken by the Ministry of Works and Development in New
Zealand in conjunction with an independent pipeline
design firm. The laboratory evaluation of pour point
depressants was undertaken by a numbei of potential sup-
pliers as Petrocorp had neither suitable laboratory facilities
nor suitably experienced personnel.
The costs of a thermally insulated pipeline, trucking
untreated crude, chemical dosing with pour point depres-
sant and thermal cracking were investigated in some detail.
The costs are summarized in Table 2, with the costs given
for 477 m/d of production and in New Zealand dollars,
first quarter 1983. The net result is that for a 10 percent
rate of return over a 10 year life, the present value of
chemical dosing ISthe lowest cost option.
PIPELINE DESIGN
In the design of the pipeline the following constraintswere
specified:
1. The required capacity was 1590 m3/d to allow for
future (and at that time unknown) expansion from the
existing knc wn production of 636 to 795 m3/d.
2. Intermediate pumping for normal operation was con-
sidered undesirable since the length was only 40 km.
3, The crude temperature at the inlet to the pipeline
would be about 60C (140F), which reflected proc-
essingtemperatures.
4. The ground temperatures ra,~ged from a 20-year
recorded low of 11C (52F) to a hig!~of about 18C
(64F), The pipeline passed under a number of small
rivers and one large river with a 20-year low of 5C
(41F).
5, The Taranaki region (and New Zealand in general) is
very sensitive to environmental concerns and reduction
in pollution risk was a significant concern both at the
production station along the plpellne route and at the
receiving tank farm.
6, ANSI B 31,4 was to be the design code as required by
Government legislation in New Zealand,
 PIPELINE TRANSPORTATION OF HIGH POUR POINT NEW ZEALANDCRUDE
4 USINGPOURPOINTDEPRESSANTS
7. Pour point, viscosity and yield data would be available
only from laboratory trials conducted by pour point
suppliers. Because the McKee crude is a complex rheo-
logical system, it was anticipated that laboratory data
would vary based upon the instruments used to carry
out the measurements.
With these constraints, the pipeline designers considered
both 4-inch and 6-inch diameter lines, with the latter being
chosen to satisfactorily meet all design requirements and
maintain a good level of flexibility,
Following are the main features of the pipeline design:
1. The hydraulic calculations had to be based or. a range
of values which reflected the various laboratory predic-
tions as a preferred pour point depressant had yet to be
identified, This was further compounded by the shear
thinning nature of the crude. The variation in viscosity
measurements and the design viscosities adopted are
given in Figure 2. Viscosity measurements ranged from
0.004 to 0.020 Pas at 66C (150F), 0.007 to 0.030
Pas at 21C (70F) and 0.050 to 0.190 Pas at llC
(52F).
2. The pipeline was designed for shear rates which corre-
sponded to throughputs from 477 m3/d to 1590 m3/d.
3. The pumping facilities for 795 m3/d consisted of a SUC.
tlon booster pump and a multistage centrifugal shipping
pump with 100% standby for each unit, Increases in
capacity were allowed for by adding additional booster
and shipping pumps operating in parallel. The piping
arrangement allowed for series operation of the ship-
ping pumps to provide higher pressures after extended
pipeline shutdowns,
The hydraulic design showed that the pumping pres-
sure was not only sensitive to capacity, but also to the
assumed viscosity. For this reason, it was necessary to
use a pump with a sufficiently flexible design curve to
cope with a range of viscosities,
4, Yield values were measured by the pour point depres-
sant suppliers laboratories which resulted in the pipe-
line being designed for a yield value of 4,0 Pa for the
crude at llC (52F),
5. Storage tanks at the Inlet to the pipellne provided for
477 msof intermediate storage between the production
processplant and the pipeline to minimise the need for
frequent shutdowns,
6, Considerable attention was paid to the need for turbu-
lent operation to mlnlmIse or prevent wax crystal depo-
shion in the pipeline.
15s5s
The use of regular (daily) pigging to remove wax
caused either by dropout or by deposition on the pipe
wall was included in the design.
7. The pour point depressant injection system provided
for substantial storage (117 m) which at the design
stage represented some 60 days use. The pour point
depressant tank was heated with hot circulating water
and insulated to allow for the use of pour point depres-
sant products which had above-ambient melting points
and which had to be added to the crude at elevated
temperatures. The pour point depressant injection
pump had 100% standby and the flow rate was mea-
sured. Injection was between the booster and shipping
pumps to ensure the pour point depressant was well
mixed into the crude, This limited use to pour point
depressants which were stable under high shear.
The addition of pour point depressant should be con-
trolled so that the crude pour point remains below that
of the ground temperature at all times, with the min-
imum ground temperature being 11 C.
8. In addition to the mainline block valves at the start and
end of the pipeline, additional block valves, high preS-
sure injection valves and check valves were installed at
spacings which ranged from 6.5 km to 10.5 km.
The design concept allowed the mainline pumps to be
able to restart the pipeline flow provided the crude yield
value remained at or below 4 Pa. In the event that the
crude yield increased above 4 Pa, then high pressure
injection pumps (96.5 bar) with low capacities (1,3 to
1.6 1/s) could be used to inject condensate at the block
valve stations, If the crude yield value did not exceed
41.3 Pa, then the positive displacement pump would
be able to restart the flow without exceeding the allow-
able pressuresfor the ANSI 600 pipe,
LABORATORY STUDIES FOR SELECTING
THE POUR POINT DEPRESSANT
Laboratory studies for selecting the most suitable product
were undertaken by a number of supplier laboratories,
This section of the paper describes the studies for the
product currently in use,
Two types of pour point tests were used to evaluate potrm-
tial pour point depressants. The first type followed the pre-
cedure descrtbed in ASTM D97-66. The oil samples were
subjected to the preliminary treatment described for OIIS
having pour points above 32C (90 F). The oil was
heated to 46C (115F) in a bath, without stirring. The
samples were treated with chemical, shaken 100 times and
returned to 46C (115F) where they were allowed to sta-
SPE15656 GRANT SIATER and ANN DAVIS
bilize for 30 minutes, The temperature of the samples was
lowered and movement of the oil was noted at 3C (5F)
intervals.
The second type of pour point test was a modified version
of ASTM D97-66 in an effort to duplicate predicted pjpe-
line coo!!ng rates. Prior to each test, the crude sample was
reheated to a bottom-hole temperature of 85C (185F)
and held there for one hour. This was an attempt to return
the crude to reservoir condition and is called the benefi-
ciation treatment. This thermal treatment should destroy
any thermal history and restore the crude oil to its original
pour point condition. (Note that beneficiation was not
done on the ASTMD97-66 test). The beneficiated sam-
pies were allowed to cool to 65C (149F) and stabilized
for 30 minutes. The pour point depressant was added, fol-
lowed by 100 hand shakes. Untreated samples were also
agitated the same number of times. The samples were sta-
bilized for 30 more miriutes at 65C (149F). Afterwards
they were cooled according to the predicted pipeline
cooling rate shown in Table 3.
Several pour point depressants were tested and Additive A
gave the most significant reduction in pour point. The
results in Table 4 show that 2000 ppm of Additive A was
required to reduce the pour point to 1 lC (52F) using
the modified cooling curve. The ASTM D97-66 test at
2000 ppm of Additive A only reduced the pour point to
18C (64F) .
In order to explain the difference in results between the
two tests, it is necessary to have a theory on the mecha-
nism of wax crystallization. Since crude oil is a complex
mixture, there are many factors which affect its pour point,
However, this simplistictheory is offered to give some idea
of how a pour point depressant affects the pour point.
Photomicrographic studies have shown that wax gradually
crystallizesin the form of needles. As more and more wax
crystahzes, an organized network forms throughout the oil
resulting eventually in the solidification of the crude, A
pour point depressant retards the growth of these networks
by modifying the natural wax crystal to a smaller crystal
which is more dense. It is not certain whether this occurs
by co-crystallization or by absorption. The modified crystal
is not as likely to form the organized network; therefore,
the pour point of the oil is reduced. With this in mind, the
reason for the difference In results between the two pour
point testsISexplained below.
There are two main differences between the ASTM D97-
66 test and the modified test: pour point depressant dosing
temperature and cooling rate, The temperature of the
crude oil when the pour point depressant IS added is an
Important factor determining its performance. If this tem-
perature is too low, wax crystals will already be present,
5
reducing the effectiveness of the treatment. Since the
modified test was dosed at 65C (149F) and the ASTM
D97-66 test was dosed at 46C (115F), this could have
accounted for some of the difference.
Anothet determining factor in the performance of the pour
point depressant is the cooling rate. When a waxy crude is
cooled slowly, the wax crystallizesat a slower, controllable
rate. If the cooling process is faster, the amount of wax
crystals increases rapidly in proportion to the pour point
depressant present, In this case, more pour point depres-
sant is needed to control the crystal formation. The ASTM
D97-66 test has a faster cooling rate than the modiiied test;
therefore, the pour point depressant requirements
increase.
Based upon the results of the pour point screening, Addi-
tive A was chosen for theological studies.
1. ApparentVlscoslty
A Brookfield Syncholectric LVT coaxial cylinder visco-
meter with a small sampler adaptor was used in the vis-
cosity evaluations. Temperatures werecontrolled with a
Haake circulator and temperature programmer. The
viscosity/temperature studies were conducted under
dynamic test conditions using the predicted cooling
curve shown in Table 3. Each sample was beneftciated
as described before. Several shear rates were used to
show the shear-thinning (pseudoplastic) behavior of
the crude. The dose temperature was 60C (140F) at
several dose rates.
Based upon the test results, a dose rate of 2000 ppm
Additive A was chosen for the pipeline commissioning.
This dosage rate would be reduced as the flow condi-
tions in the pipeline stabilized. Table 5 shows the vis-
cosity of the crude treated with 2000 ppm of Additive
A at shear rates of 8, 16 and 40 see at varying tem-
peratures. The viscosity/temperature relationships are
shown graphically in Figure 3.
2. Yield Valuo$
Yield values were determined using the Farm Model 35
viscometer with the No. 1 spring and the standard rotor
and bob (R1-B1).
It was anticipated that the yield value would vary along
the length of the p{pelfne with the two extremes being:
(a) The crude 011at the start of the pipellne which is
cooled statically from 65C (149F) to 1 lC
(52F), and,
(b) The crude oll at the discharge end of the pipellne
which has been cooled dynamically (under shear)
to llC (52F).
 PIPELINETRANSPORTATION
OF HIGHPOURPOINTNEWZEALANDCRUDE
USINGPOURPOINTDEPRESSANTS
Using the predicted cooling curve in Table 3, one
sample was cooled statically (no shear) to 11C (52F)
and held for 12 hours at that temperature. Another
sample was cooled dynamically at 8 see-l to 1lC
(52F) and held for 12 hours at that temperature.
Yield values were obtained after 12 hours according to
Farm operating instructions. Yield values obtained
using 2000 ppm of Additive A after static and dynamic
cooling conditions were 3.5 Pa and 2,5 Pa, respec-
tively,
Applicationof LaboratoryData
This laboratory data, together with that from the other lab-
oratories, was used in the design of the pipeline, The yield
data resulted in the pipeline being designed for the crude
having a maximum yield value of 10 Pa under normal con-
ditions. The apparent viscosity data adopted for design,
shown in Figure 3, is a compilation of all such data
obtained during the laboratory studies.
REFINERY TRIAL
Crude produced from the plant was initially refined by the
New Zealand Refining Company at Marsden Point, Prior
to accepting the crude, the refinery operators requested
that the selected pour point depressant be processed. This
was to determine (1) if the pour point depressant would
cause foaming or foullng in the pre-heat train of the Crude
Distillation Unit (CDU), (2) if breakdown of the pour point
depressant adversely effected the crude distillation unit
rundown prochds, or, (3) if residual pour point depressant
had any beneficial effects on the pour/cloud points of the
rundown streams.
As the crude was not available for the refinery trial, the
selected pour point depressant was doeed to Kapuni con-
densate, This waxy condensate is produced from onshore
wells In Taranaki, approximately 60 km from the crude
plant, The pour point depressant was injected into the con-
densate at 800 ppm, 1600 ppm and 3200 ppm using a
positive displacement metering pump. The product was
dosed for 3 hours at each rate.
During the trial, foaming tendencies were monitored using
a foam level recorder in the pre-flash vessel, Pressure
levels in the CDU were closely monitored to determine if
foaming or foullng was occutrlng. At the end of each test
period samples of residue, heavy gas oil, and automotive
gas 011were taken. These were tested in the laboratory for
pour point and total acid number.
Obsewations are summarised below:
1, No problems were experienced In the CDU during the
trial pertod.
SPE
15858
2. A slight increase in foaming was noted in the pre-flash
vessel. However, this higher foaming level was main-
tained in the vessel on completion of the trial when
unclosed Kapuni condensate was being charged,
3. The pour point depressant had no residual effect on the
pour points of the rundown products. Temperatures in
the pre-heat train and the CDU ensured complete dis-
sociation of the polymer product.
As a result of the plant trial the New Zealand Refinery
Company concluded that treated crude would cause no
process upsets in the refinery and would have no detri-
mental effects on refined products.
PIPELINE COMMISSIONING
On November 5, 1984, crude began flowing into the pro-
duction station storage tank. At this stage, the pour point
depressant was being injected into the crude tank inlet line
at approximately 2000 ppm, When the McKee storage
tank was nearly filled, the pour point depressant injection
was shifted to Its permanent position, between the booster
and shipping pumps.
Shipping commenced on November 7, 1984. Pour point
depressant was injected at approximately 2000 ppm into
the crude, As the pipeline was filled with hydrotest water, a
pig train was run ahead of the crude to minim&e admixing.
The pour point and rheology of the pipelined crude was
monitored on a 24-hour basis for the next 7 days. A Farm
Model 35 viscometer was used to monitor the rheology. By
calculating arrival times, it was possible to obtain samples
of the initial crude as it reached each block valve station.
When the first crude arrived at the Omata tank farm on
November 8, 1984, testing showed it to have excelient
theological properties and a pour point of below -5C
(23F) .
Results obtained during the commissioning period showed
that the pour point depressant performed significantly
better in actual pipeline conditions than in laboratory
testing, In the following two months a concerted effort was
made to optimize the dose rate of the product, By closely
monitoring pipeline pressures, crude rheology and pour
points, it was possible to reduce the pour point depressant
dose rate to 960 ppm by December 25, 1984 (summer in
New Zealand).
REVIEW OF DESIQN
Following commissioning, It has been possible to review
the performance of the pipeline using a pour point depres-
sent In the crude to determine the extent to which the !abo-
ratory Mals and pipeline design were applicable to this
SPE 15656 GRANT WATER and ANN
situation. The following design and performance parame-
ters have been reviewed and are further described below:
1. Pour point of the crude at the pipeline discharge point
2,
2. Pumping pressure which reflectsthe hydraulic design in
general and the design viscositiesin particular
3. Temperature profile h the pipeline under operating
conditions
4, Pipeline restart after short shutdowns in the pipefine
4 apparent viscosityof around 50%.
5. General mechanical design
3.
6. The logistical implications of using pour point depres-
sant
7. Wax buildup
8. Pour point depressant dose rate
The only major design factor which has not been reviewed
is the restart of the pipeline after an extended shutdown
which would reflect the reliability of yield value predictions.
This k simply because there have been no extended shut-
downs and, quite obviously, it is hoped that this parameter
will never be tested. In addition, it has only been possible 4.
to fully review the performance at low rates of 795 to 954
m3/d, as higher and lower rates have only been used for
short periods.
1. PourPoint
The pour point of the crude is measured both to meet 5.
sales specifications and as an aid in the pipeline dis-
charge, as part of the pipeline management plan, in
order to determine the pour point depressant dose
rate, The pour point is measured in the storage tanks to
ensure that the crude meets its sales specifications.
During initial operation of the pipeline, the pour point
was measured strictly in accordance with ASTM D97-
66. h rapidly became evident that this was not the most
suitable method of measuring pour point as the results
of this test were giving pour points greater than the
actual pour point cf the crude both at pipeline dis-
charge and In the bulk tank. From both a pipeline man-
agement viewpoirlt and salesrequirement, the actual
pour point is of more interest since in both cases the
true requirement ISfor a crude that can be transported 6.
by pipeline from a bulk tank at 15C (59F) without
going solid, After negotiations with the crude oil buyer,
the ASTM D97-66 test was amended for our use by
deleting the requirement to reheat the crude as this was
obviously destroying the previous temperature and
shear history of the crude, The use of pour point
depressant has exceeded laboratory predictions with
DAVIS 7
actual pour points of less than 5C (41 F) being
easily obtained at acceptable dosage rates (refer to sec-
tion 8 below),
Hydraulic Design
The pumping pressuresrequired to transport the crude
in the pipeline have been substantially less than those
predicted, with pressures of 17 bar being required to
transfer 795 m3/d whereas vaiues of 24 bar had been
predicted. The only dgn{f(cant variable likely to have
changed is the apparent viscosity with the reduction in
pumping pressure representing a reduction in average
TomperaturaProfile
The design was based on a calculated temperature pro-
file along the pipeline which was used in both the labo-
ratory simulations for viscosity determinations and in
the pipeline design. Figure 4 shows this temperature
profile compared with that which has been estimated
based on temperature measurements at sampling
points. The major difference is in the suddencodng
caused by a rivercrossing which has had a far greater
effect than that predkted. This has probably had an
effect on the wax crystal growth and thus may explain
some of the variances in viscosityand pour point.
Restart After Short Shutdowns
Following shutdowns ranging from a few hours to days,
it has been possible to restart the pipellne using only the
shipping pumps with restart pressures no higher than
normally encountered,
Mechanical Daslgn
The mechanical des{gn of the pipeline has been excel-
lent with the following features having been noted:
a, The installation of sampling points is essential for
monitoring of performance so that actual pour
points and temperatures can be measured.
b, Pressure monitoring h essential for estimating vls-
cosity and detecting the passage of unclosed slugs
of crude.
c, The use of stub welded valves ISnot recommended
since a waxy crude is more Ilkely to interfere with
the sealing of valves, necessitating their replace-
ment which is obviously easier with flanged connec-
tions.
Logl$tlcal lmpllcatIon8
The use of a chemical pour point depressant requires
that adequate stocks of a high value product be main-
tained, With a lengthy supply route, as in this case, this
can mean that substantial working capital is tied up In
the product. in addition, the operation is totally depen-
dent on the avallablllty of the pour point depressant
and it is impossible to continue production without It.
 PIPELINETRANSPORTATION
OF HIGHPOURPOINTNEWZEALANDCRUDE
8 USINGPOURPOINTDEPRESSANTS
-. ----
Provided careful stock control is practiced this is not a
Iarge problem.
7, Doposltlonor $ettllng
The design of the pipeline and seiection of a pour point
depressant had not included detailed consideration to
wax deposition on the pipeline walls or to wax settling
under Iaminar flow. The experience of the pour point
depressant suppliers combined with some laboratory
work indicated this was not a major problem. Provision
for continuous pigging was, however, included in the
management plan for the pipeline.
Examination of pigs has shown that wax buildup is not
a major probiem, provided sufficient pour point
depressant is injected with the dose rate being a func-
tion of ground temperature. As the ground tempera-
ture falls, the rate of wax deposition increases and
additional pour point depressant must be added to
overcome this. The pipeline operation has seldom
been in laminar flow, other thbn for short durations,
and it has not been possible to evaluate the effects of
wax settling duting Iaminar flow.
8. PourPoint D8p~$S@nt008. Rat.
The laboratory simulations had indicated that a dose
rate of 1200 ppm would be required to achieve a pour
point of 15C (59F) (sales specification) and 2000
ppm to achieve 1 lC (52F), this being the winter
ground temperature. At these dose rates the yield
values and viscositieshad also been measured. The fol-
lowing observations can be made about the dose rate of
pour point depressant:
a, Overall a substantially lower dose rate, 720 to 1280
ppm, is required to achieve an actual pour point of
11C (52F). The pour point is usually 5C (41F)
at these dose rates. This was, however, anticipated
based on other pipeline experiences.
b, The dose rate has to be varied from summer to
winter which reflects the changing ground tempera-
ture and thus the cool-down rate and pipe wall tem-
perature. Summer dose rates where the ground
temperature is 16C (61F) to 21C (70F) are as
low as 720 ppm and the winter rates as high as
1120 to 1280 ppm when ground temperatures fall
to 12C (54F) to 16C (61F),
c, The controlling factors in determining the dose rate
are wax deposition on the pipe wali, which
increases as temperature drops, and actual pour
point at the pipeline discharge,
PIPELINE MANAGEMENT PLAN
As a result of one years successful operation, a plan for
operating the pipeline has been developed to reflect the
RPF 1
W, - 0
various parameters described in this paper. The main fea-
tures of this plan areas follows:
1. The pipeline is continuously pigged to remove wax
buildup. Inspection of the pig determines the degree
of wax deposition on the pipe wall which becomes
one major factor in determining the dosage rate.
Because of varying ground temperatures (12 to
21C), the degree of wax deposition varies for a con-
stant dosage rate,
2, The temperature of the crude is measured on an inter-
mittent basis at the various sampie points aiong the
line. This is being done both to improve the knowl-
edge of the actual pipeline cooling rate and as a minor
input to determining the pour point depressant dose
rate.
3, The pour point of the crude is measured on a daily
basis at the pipeline discharge to provide a direct feed-
back on pour point depressant performance whkh is
used as a major input in determining the pour point
depressant dosage rate. The method used to deter-
mine the pour point is based on ASTMD97-66butis
modified by deleting the requirement to reheat the
sample so that an actual pour point is obtained.
4. The pour point of the crude is measured on a daily
basis in the stock tanks to ensure compliance with
sales specifkations and to provide an indication of any
Iongterm trends in pour point which can be used in
assessingthe dose rate.
5. The pipeline pressures at the start of the line and at
various intermediate points are measured and
recorded on a chart recorder. Alarms are installed to
alert operators of any sudden problems. The pres-
sures are used as an indication of viscosity or restric-
tions in the line.
6. For normal operations, the pour point depressant
dose rate is determined by considering the following
factors:
a, Sufficient pour point depressant must be added to
maintain the actual pour point in the bulk tanks at
15C (59F) .
b, Sufficient pour point depressant must be added to
maintain the actual pour point at the pipeline dis-
charge just above the ground temperature which is
taken as 15C (59F) during the summer and
1 lC (52F) in the winter.
c. Sufficient pour point depressant must be added to
keep wax deposition within acceptable limits. The
aim is to have minimal wax buildup on the pigs.
SPE15656 GRANTSLATERandANNDAVIS
The effect of this is that the dose rate varfes from
about 720 ppm in summer to 1280 ppm in winter
with the controlling factor being wax deposition in
summer and autumn but with actual pour point
becoming more important during the winter,
7, For long-term monitoring of performance, the actual
pour points in the bulk tank and at sampling locations,
as well as pumping pressures, can be used to modify
the normally accepted dose rates.
8, The approach to pipeline shutdowns depends on
whether the shutdown is planned, For planned shut-
downs, the dose rate is increased to 2000 to 2400
ppm for about 8 hours to lower the pour point as
much as possible, and flow rates are held to a max-
imum to ensure that wax deposition is minimized. The
bulk storage tank at the pipellne inlet is maintained as
full aspossible and sufficient space is held at the dis-
charge end of the line to accommodate this volume,
This provides about 12 hours of crude supply at
normal pumping rates. Depending on the duration of
the shutdown if known, the line ISthen pumped inter-
mittently at high rates (1431 m3/d) for between 20
minutes and 1 hour, Under this regime, the restart
pressures do not change significantly from the normal
operating pressures.
TABLE1
CHARACTERISTICSOF NEW ZEALANDCRUDE
Nature
Gravity, API
Sulfur Content, % wt,
Wax Content, % wt,
ASTM pour point, C
Shear Stress, Pa
9
[fan unplanned shutdown of a duration longer than 1
day was to occur In the future, the approach will be to
apply this same procedure as closely as possiide, Pour
point depressant would bc injected at about 2400
ppm and the pipeline would be kicked at high veloci-
ties for a short period of time as often as possible,
9, The dosage of pour point depressant must be continu-
ously monitored to ensure that pipeline operation
without pour point depressant does not occur. Despite
motor interlocks, a flow switch and flow meter, there
has been one instance of a zero injection rate for a few
hours, This occurred because the flow meter was out
of service for repair, the flow switch failed and the
pump relief valve failed to shut causing pour point
depressant to be recycled around the pump,
10, The stocks of pour point depressant must be closely
monitored to ensure that adequate product is avail-
able considering stock en route, the production pro-
gram and the need to minimize working capital.
ACKNOWLEDGEMENTS
The permission of the Petroleum Corporation of New
Zealand Limited and NL Treating Chemicals/NL lndus-
tries, Inc., to publish this paper isgreatly appreciated,
Paraffinic
38 to 40
0,066
35
30-32
0,2 at 43C (llOF)
0,7 at 33C (91F)
4,8 at 28C (83F)
19,5 at 13C (55F)
 = 15656
TABLE2
SUMMARYOF TRANSPORTOPTION COSTS, FIRSTQUARTER12S3,NEWZEALAND$

Tmcedl Trucking Chomlcals

Insulated Untreated Dosing Thermal
Pipeiine MCKSSCrude 100/OMcKeeCrude Cracking

Capitai Costs
Buried 6-inch Line 6,500,000 6,500,000 6,500,000
Pipe insulation/Tracing 7,900,000
Power Line Interconnects Unknown
Loading Stations 1,000,000
Heavy Duty Site Paving 300,000
Dispatchers OffIce 50,000
Upgrading Public 8km Road 2,000,000
Additional Crude Storage 250,000
Chemical Warehouse 650,000
Forklift Truck 50,000
Thermal Cracker 8,900,000
Support infrastructure For Thermal Cracker 4,000,000

TOTALS 14,400,000 3,600,000 7,200,000 19,400,000

Annuai Opmting Costs

(Bassdon 477 mld)
Trucking Costs 3,400,000
Utilities 190,000 Negligible Negligible 300,000
Publlc Road Maintenance 250,000
Labor 480,000 120,000 360,000
Chemicals 1,770,000
Plant Maintenance/Overhead Unknown Negligible Negligible 300,000

TOTALS 190,000 4,130,000 1,890,000 gljo,oo(j

TABLE3 TABLE4
PREDiCTEDPiPELiNE COOLiNQ RATE Comparison OF ASTM D97966WiTH THE
MODiFiED POURPOiNT TEST
Temperature
Oc PourPoint, C
Time, hr F
AdditiveA, mm ASTM D9746 Modified
o 65 149
1 44 111 30 30
2 32 90 40: 28 20
3 25 77 800 24 18
4 20 68 1200 22 14
5 17 63 1600 20 13
6 15 59 2000 18 11
7 14 57
8 13 55
9 12 54
10 11 52
11 9 48
 TABLE5
McKEECRUDEVISCOSITYTEMPERATURE
STUDIESWITH ADDITIVEA(2000 ppm)

Vlscoslty,PM
NORTH
Shear Rate, ses 8 18 40 ISLAND
Temperature,C
43 0,004 0.002 0.003 New Plymouth
38 0,004 0,002 0.004
33 0.004 0!003 0.004
28 0.004 0.004 0.005
23 0,007 0+007 0.006
18 0,026 0.012 0.013
13 0,056 0.034 0,025
11 0086 0,046 0,035

Flguro 1 - Now Zealands flrot maJor 011flold

Iooatodonshorenear Now Plymouth

0.100
0.080

0.080

0.040

*. 0.030
~
E 0.020

! 0.016
!5

0.010

0.006
0.004
0.003
65 66 46 3s 30 26 20 16 11
TCmpar@ura, C

Figura2- Aotualvlscosltlosvorausdaslgnviscooltlosat flow rat. of 888mld

 #E 15656
0.08

0.08
Shear Rat., sot-
0.0? -8
A-1$
9 0.08 0-40
8

!
s
0.06

0.04

0.03

0.02

0.01

0
10 16 20 2s 30 36 40 46
~mporatura, C

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