Condensate Pipeline Case Study Page 1 of 13

Condensate Pipeline Case Study

A subsea pipeline is to be designed to transport condensate from a satellite platform to a
processing platform. Compositional analysis of the condensate has been obtained. The engineer is
asked to perform the following tasks :-

l Develop a compositional model of the hydrocarbon phases.

l Add the aqueous phase to the compositional model and identify the hydrate envelope.
Hydrates are tobe avoided by operating the pipeline above the hydrate formation
temperature.
l Select a pipeline size.
l Determine the pipeline insulation requirement.
l Screen the pipeline for severe riser slugging. Severe riser slugging is to be avoided.
l Size a slug catcher.
l Engineering data.

Task 1. Develop a Compositional Model of the

Hydrocarbon Phases
A compositional fluid model allows the fluid physical properties to be estimated over the range of
pressures and temperatures encountered by the fluid. The fluid model is made up of individual pure
library components such as methane, and petroleum fractions. Petroleum fractions are used to
estimate the behavior of groups of heavier pure components. The hydrocarbon phase envelope can
be plotted on pressure and temperature axes. The following steps are to be carried out:

l Add the pure hydrocarbon components.

l Characterize and add a petroleum fraction.
l Generate the hydrocarbon phase envelope.

1. After starting PIPESIM use the <File/New/pipeline and facilities model> menu to open a new
model and save this in the training directory (for example as file c:\training\ps02.bps).
2. Use the <Setup/compositional...> menu to enter the pure components given at the end of
the case study.
3. Select the pure hydrocarbon components from the component database. Multiple selection is
possible by holding down the control key.
4. When all pure hydrocarbon components have been selected, press the Add>>button.
5. When the number of moles of the pure components have been added, select the Petroleum
Fractionstab and characterize the petroleum fraction "C7+" by entering the BP, MW, and
SG in row 1.
6. Then press the Add to composition>>button and enter the number of moles for C7+
under the Component Selectiontab.
7. Generate the hydrocarbon phase envelope by pressing the Phase Envelopebutton. The
following plot should be obtained:

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Task 2. Identify the Hydrate Envelope

Certain fluid compositions show a tendency to form hydrate compounds in the presence of water.
These compounds can cause line blockages. The tendency to form hydrates is dependent also on
pressure and temperature. In this study, hydrate formation is to be avoided by operating above the
hydrate formation temperature at all times. The following steps are to be carried out:

l Add the aqueous component.

l Generate the hydrate envelope.

First it is necessary to add the aqueous component, pure water.

1. Use the <Setup/compositional...> menu to select water and press the Add>>" button.
2. Enter the water concentration of 10% volume ratio (bbl/bbl).
3. Generate the aqueous phase envelope and the hydrate formation line by pressing the Phase
Envelopebutton. The following plot should be obtained:

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Note that hydrates tend to form in the region on or to the left of the hydrate line. In this study,
hydrate formation will be avoided by operating the pipeline at temperatures above 75 °F at all
times.

Task 3. Select a Pipeline Size

Find the smallest pipeline I.D. that will allow the design flowrate of 10,000 STB/d of condensate to
be transported from the satellite platform whilst maintaining an arrival pressure of not lower than
1,000 psia at the processing platform. The pipeline sizes available are 8", 10", or 12" I.D. as
described in the data section at the end of the case study. This can be determined as follows:

l Use the pressure temperature profiles operation to calculate the pressure drop for each of
the three pipeline size options.

First it is necessary to add a source to the model.

1. This is done by pointing and clicking on the source button at the top of the screen and then
pointing and clicking in the work area. A source appears as shown below. Alternatively the
wizard feature can be used.

source button source

2. To enter data relevant to the source double click on the object. Enter the inlet pressure of
1,500 psia and the inlet temperature of 176 °F.
3. Now add a boundary node to represent the arrival point at the processing platform.

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boundary node button boundary node

4. Then add nodes to represent each end of the pipeline:

node button node

5. Connect the model together by pointing, clicking and dragging using the riser and flowline
buttons:

6. riser button flowline button

Completed Model
Note that the red outline indicates that essential data is missing for that component.

Completing the component

1. Double click on Riser_1to enter the riser details that is horizontal distance and elevation
difference (length is automatically computed), I.D., roughness, overall heat transfer
coefficient and ambient temperature.
2. Repeat this for Flowl_1and Riser_2.
3. Select the <Operations/Pressure-temperature profiles...> menu and set up the operation so
that the calculated variable is outlet pressure.
4. Set the Inlet pressure 1,500 psia and the Liquid Rate to 10,000 STB/d. The sensitivity
variable is Pipeline ID with values of 8", 10", and 12".
5. Set the component as Flowline_1, the variable as IDand enter the sizes.
6. Press the Run Model button when all the data has been added.
The following plot should be obtained (the axis may have to be changed to show Total
Distance versus Pressure ):

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It can be seen that a 10" is the smallest pipeline size that will satisfy the arrival pressure condition
of at least 1,000 psia.
Note: Do not forget to now set the flowline ID to 10" for all subsequent simulations.

Task 4. Determine the Pipeline Insulation Requirement

Find the smallest thickness of thermal insulation that can be used to insulate the pipeline and
maintain an arrival temperature of not less than 75 °F. This minimum arrival temperature is
required to prevent the formation of hydrates. The insulation has a thermal conductivity of 0.15
Btu/hr°ft/°F and a thickness of 0.75" or 1". This can be determined as follows:

l Use the pressure temperature profiles operation to calculate the temperature profile for the
design and turn down flowrate cases with 0.75" thermal insulation thickness.
l Re-run the model with 1.0" thermal insulation thickness and compare the temperature
profiles.

1. Double click on Flowl_1.

2. Select the Heat Transfertab, and then select the Calculate Usub-tab.
3. Enter the heat transfer data given at the end of the case study, and add a layer of insulation
with a thermal conductivity of 0.15 Btu/hr/ft/°F and a thickness of 0.75".
4. Press the OKbutton.
5. Select the <Operations/Pressure-temperature profiles> menu and set up the operation so
that the calculated variable is outlet pressure, and the sensitivity variable is System
data/liquid rate with values of 5,000 and 10,000 STB/d.
6. Run the model and configure the output to obtain the following plot:

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7. Re-run the model using a thermal insulation thickness of 1".

8. Configure the output to obtain the following plot:

It can be seen that 1" insulation is required to maintain an arrival temperature of 75 °F.

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Note: Do not forget to now set the insulation thickness to 1" for all subsequent simulations.

Task 5. Screen the Pipeline for Severe Riser Slugging

Severe riser slugging is likely in a pipeline system followed by a riser under certain conditions. The
elements leading to severe riser slugging are:

1. The presence a long slightly downward inclined pipeline prior to the riser.
2. Fluid flowing in the "stratified" or "segregated" flow regime (as opposed to the usual "slug"
or "intermittent" flow regime).
3. A slug number (PI-SS) of lower than 1.0.
4. The PI-SS number can also be used to estimate the severe riser slug length from the
equation:
slug length = riser height/PI-SS number.

Severe riser slugging is to be avoided in this case. The necessary information can be extracted
from the model as follows:

l Configure the model output such that slug information, and flow regime maps are printed for
the fluid at the riser base.

1. Select the <Setup/Define output...> menu and check the slug output pagesbox.
2. Set Number of cases to printto 2.
3. Add a report tool to the model in place of node N2. This can be done by first selecting a
report tool and placing it in the work area.

report tool button report tool

4. Then reconnect Flowl_1to the report tool by first clicking on the middle of Flowl_1. You
will see that highlight boxes appear at either end of the flowline.
5. Move the mouse over the right hand highlight box, and the mouse pointer changes to an "up
arrow" shape. The line can then be dragged from N2and dropped onto the report tool as
shown below.

Reconnecting the flowline to the report tool

1. Similarly reconnect Riser_2to the report tool.

2. Delete "N2", and reposition the report tool as shown below.

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Modified model
1. Double click on the report tool and check the option flow map.
2. Select the <Operations/Pressure-temperature profiles> menu and re-run the model.
3. Select the <Reports/view output> menu and check the PI-SS number at the riser base for
both flowrate cases. It can be seen that the PI-SS number is higher than 1.0 at the riser
base in both cases. In the turndown flowrate case the PI-SS number is 1.18 as shown
below:

4. Check the riser base flow regime maps in the output file to see if the flow is in the
"stratified" or segregated region. It can be seen that flow is in the intermittent (normal
slugging) flow regime. The turndown case flow map is shown below:

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It can be seen that the segregated region has been avoided and the likelihood of severe riser
slugging is reduced.
Note: Do not forget to save the final model!

Task 6. Size a Slug Catcher

Having established that normal slug flow is expected, it is now necessary to size a slug catcher.
The size will be determined by the largest of three design criteria:

1. The requirement to handle the largest slugs envisaged (chosen to be statistically the 1/1000
population slug size).
2. The requirement to handle liquid swept in front of a pig.
3. Transient effects, that is the requirement to handle the liquid slug generated when the
production flow is ramped up from 5,000 to 10,000 STB/d.

This can be achieved as follows:

l Review the simulation output to establish the slugcatcher volume required for each of the
three design criteria and select the largest volume.

1. Review the output file and it can be seen that the turndown case generates larger slugs.

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As shown above, the 1/1000 slug length is 1,781.2 ft, which gives a slug volume of 971.5 ft
3
.
2. Now select the <Reports/view summary> menu and check the liquid swept in front of a pig
("liquid by sphere" ).

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It can be seen that the turndown case gives the larger volume of 279.1 bbl or 1,567 ft 3.
3. Now calculate the liquid generated when the flow is ramped up from 5,000 STB/d to 10,000
STB/d. This is the difference in total holdup between the two cases, that is 692 - 623 = 69
bbl or 522 ft 3.

Therefore the pigging volume of 1,567 ft 3is the determining design case.

Data Available
Layout
Condensate flows down a 400 ft x 10" ID riser from the satellite platform to the seabed, along a 5
mile pipeline, and up a 400 ft x 10" ID riser to the processing platform.

Boundary Conditions

Fluid inlet pressure at satellite platform

1,500 psia
Fluid inlet temperature at satellite platform
176 °F
Design liquid flowrate
10,000 STB/d
Maximum turndown
5,000 STB/d
Minimum arrival pressure at processing platform
1,000 psia
Minimum arrival temperature at processing platform
75 °F.

Pure Hydrocarbon Components:

Component Moles
Methane 75
Ethane 6
Propane 3
Isobutane 1
Butane 1
Isopentane 1
Pentane 0.5
Hexane 0.5

Petroleum Fraction
Name Boiling Point (°F) Molecular Weight Specific Gravity Moles
C7+ 214 115 0.683 12

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Aqueous Component

Component
Water
Volume ratio (%bbl/bbl)
10

Pipeline Sizes Available

I.D.(") Wall thickness (") Roughness (")
8 0.5 0.001
10 0.5 0.001
12 0.5 0.001

Pipeline Data

Height of undulations
10/1000
Horizontal distance
5 miles
Elevation difference
0
Wall thickness
0.5"
Roughness
0.001"
Ambient temperature
50 °F
Overall heat transfer coefficient
0.2 Btu/hr/ft 2/°F

Pipeline Insulation Study Data:

Pipe thermal conductivity

50 Btu/hr/ft/°F
Insulation thermal conductivity
0.15 Btu/hr/ft/°F
Insulation thickness available
0.75" or 1.0"
Ambient fluid
water
Ambient fluid velocity
1.64 ft/sec

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Burial depth
0 (half buried)
Ground conductivity
1.5 Btu/hr/ft/°F

Data for Risers 1 and 2

Horizontal distance
0
Elevation difference (Riser_1)
-400 ft
Elevation difference (Riser_2)
+400 ft
Inner diameter
10"
Wall thickness
0.5"
Roughness
0.001"
Ambient temperature
50 °F
Overall heat transfer coefficient
0.2 Btu/hr/ft 2/°F

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