Shell Multiphase Flow Experience

Marine Pipelines - Hydraulics - 3 Topics

History & Trends

Shell Multiphase Flow Experience
Examples of Multiphase Transportation Systems:
Study examples
Gert van Spronsen - Pipelines Validation / Impact Multi-phase Models
Results of Dynamic Simulations
Shell Global Solutions International (SGSI) - Rijswijk
Operational issues
Email : Gert.vanSpronsen@shell.com
Tel : +31 70 447 3427 2
2009 Shell Global Solutions International B.V. All rights reserved. Do not distribute without consent of copyright owner
Shell Multiphase Flow Experience

Multiphase Flow Technology in Shell Trends in Multi-phase Flow Technology

70's - 2-phase pressure drop & hold-up; empirical correlations only
Shells extensive experience with multi-phase flow
- First Two-phase lines of moderate length
First large multiphase lines designed in mid -end 70s
- UK FLAGS, 450 km, 36 - Sarawak MLNG-1, 120 km, 36 - The need for accurate Two-phase models recognised
- NL WGT, 120 km, 36 - Australia N-Rankin, 135 km, 40 - Liquid hold-up 0.5 - 1.0 %
80's - Two-phase models based on first principles available
Traditionally a large effort on in-house development
- Sophisticated steady state design of two-phase pipelines
Multi-phase pressure drop & hold-up models, incl. corrosion aspects
Multiphase control and remediation systems - Liquid hold-up up to 4 %
90's - Transient Two-phase calculations possible
In-house proprietary methods developed
Steady state calculations - Pipesim (TWOPHASE)
- Multi-phase systems larger and more complex
Dynamic calculations - Compas & Compas-UniSim link (Traflow, Hyflow) - Extensive Dynamic simulations as part of design
00s - Multiphase Transport Option Mature Technology
Large test facility built in the 80s to verify and further - Development ongoing to extend Multiphase application envelope
develop models based on first principles
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Recent Trends & Changes
Examples:
4

Long distance wet gas operation

- GoldenEye (UK)
New Production through existing
- Pearl (Qatar)
infrastructure
Larger variation in throughput - Dev. In Gulf of Mexico (USA)

Lower flowrates - increased liquid hold-up - Condensate spiking in gaslines 5

3
2
More difficult terrain and deeper water - Malampaya (Philipines)
More extreme elevation profiles
Ormen Lange (Norway)
1
-
Operation in/or near Hydrate region
Waxy oil in two-phase pipelines

5 Shell - E&P Pipeline systems

Shell Multiphase Flow Experience

Applications of Multiphase Flow Technology Woodside Production System

Offshore - 2 fields
- Gas/Cond. Production
- CGR - upto 65 bbl/mmscf
1. Woodside North West Shelf - Complex Optimisation - Gas Re-injection
Pipelines - 40, 135 km
2. Sarawak Malaysian LNG Production system Shells largest - 30, 25 km
Onshore - LNG plant
- Liquid stab.
3. Sabah SMDS and Full well stream - Concept - LPG
- Dom. Gas

4. Norway Ormen Lange, deepwater & S2b - Start-up Liquid hold-up

Production
Station 8,000-25,000 m3 (7-22 %)
5. Philippines Malampaya Ops. Hold-up variations
up to 10,000 m3
Deepwater & Dom.Gas
Export lines Slug catcher volume
5,000 m3 (in use <2000 m3)
Interfield line
Extensive Optimisation
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Woodside Slug catcher - 5000 m3
Comparison of different Multiphase Correlations
100 20
Pressure drop Woodside NRA Pipeline - Pressure Drop & Hold-up
90 Hold-up 18

15,800
80 15,400 16
14,000
70 14

Pressuredrop (bar)

Hold-up (m3)
60 55.0 56.1 12
53.3 53.9

50 46.6 10
41.8 41.3 8,400 8,400
40 8

30 6
4,600

20 4

???
10 2

0 0
Field test 95
Field Test 95 Shell
SRTCA Pipesim1
B&B Pipesim2
B&B-TD Pipesim3
B&J-rev Pipesim4
MB Pipesim5
OlgaS

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Shell Multiphase Flow Experience

Comparison of different Multiphase Correlations Woodside 1st Trunkline - Capacity Predictions

100% 100%
Pressure drop Woodside NRA Pipeline - Pressure Drop & Hold-up
Hold-up 89 % NRA only GWA + NRA
84 % 50
75% 75%
Variation vs Fieldtest / SRTCA method

66 %
Test: 7-1995 GWA only
40
50% 50%
Pressure drop (bar)
34 % NRA production only
32 %
28 % 29 % 30

25% 25%
11 %
20
?? -1 % 0%
0% 0%
Field Test
Field test 95
95 Shell
SRTCA Pipesim1
B&B Pipesim2
B&B-TD Pipesim3
B&J-rev Pipesim4
MB Pipesim5
OlgaS 10
NRA only
GWA + NRA
Onshore pressure 66.6 bara GWA only
-25% -25%
0
-45 % 10 20 30 40 50 60 70
Hold-up compared to SRTCA calculations
Throughput - Total Massflow (kt/d)
-50% -50%
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

Sarawak - MLNG Transport Systems Shell method vs. others - MLNG-Dua
100 50
MLNG-Dua:

Thousands
MLNG-Dua system
48,100
90

Offshore - 2 fields 80
Pressure drop 40,700
40
Hold-up
CGR - upto 60 bbl/mmscf
Pipelines - 38, 160 km 70

- 2 x 36, 120 km

Pressuredrop (bar)
60 30

Hold-up (m3)
Onshore - LNG plant 24,000 48.6 51.7 46 25,900
- Liquid stab 50
36.3
Liquid hold-up 40 20

25,000-80,000 m3 (7-20 %)
30
Ops. Hold-up variations
up to 20,000 m3 20 10

Slug catcher volume 10

2,000 m3
0 0

Operational constraints Shell

SRTCA Pipesim1
BBM Pipesim2
MB Pipesim3
MBE
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

Pipeline Profile / Operations Induced Liquid Surge Concept Study - Example Project
KME

KMNW 24 x 25 Km
50
24 x 13 Km KBB (Operating Hub)
25
M1 E11
M1 start-up
MLNG 24 x 15 Km
0
KMSW ?? x 120 Km Limau
-25
Elevation (m)

-50
M3 EW
-75 Usukan Bay
-100

KK
-125

-150
0 25 50 75 100 125 150 175 200 225 250 275 300

Distance (km)
SM
KNDP-A
NOT TO SCALE
M3 - Subsea injection
Injection point slopes down to M1
M3 production & M1 shutdown Phase I - KBB field to shore, 120 km
M3-M1 leg fills-up with M3 liquid
Large scale Gas to Liquid plants SMDS
Liquid plug formed of 25 km 38 (18,000 m3) Base plan Full well stream transport to plant
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Project Details Full Wellstream issues SMDS Operational Issues

Gas / Condensate / water Security of Supply

Two SMDS trains + Domgas
One SMDS train 325 mmscf/d No formation water ? Complex plant at remote location
Domestic gas 200 mmscf/d
Elevation Profile Hydrates - no issue due to high Loss of feed - uncontrolled shutdown
20
ambient temperature Start-up takes upto 6 days
Gas 850 mmscf/d 0
Corrosion management requires Additional gas supply options
Condensate 25 kbbl/d -20
regular pigging !! Gas from pipeline linepack

Elevation (m)
-40
Water 800 bbl/d -60 Unmanned Platform LNG peakshaving plant
CO2 2.5 % -80
Increased reaction time to problems
-100
Maintenance
Reduced Availability
-120 Only one SMDS train in operation for
-140
some 30 days a year
0 20,000 40,000 60,000 80,000 100,000 120,000
Distance (m)

Note; Production rates are notional, for presentation example only

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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

Full Wellstream issues SMDS Operational Issues Multiphase Pipeline Options

Gas / Condensate / water Security of Supply

Pressure drop & capacity - a 30 is OK
No formation water ? Complex plant at remote location
Hydrates - no issue due to high Loss of feed - uncontrolled shutdown
ambient temperature Start-up takes upto 6 days
Linepack considerations - a 36 is required
Corrosion management requires Additional gas supply options
regular pigging !! Gas from pipeline linepack
What are consequences for pipeline operation and
Unmanned Platform LNG peakshaving plant
slugcatcher
Increased reaction time to problems Maintenance Ramp-up from one to two train operation
Reduced Availability Prolonged operation at one train (w/wo Domgas)
Only one SMDS train in operation for
some 30 days a year Pigging operation

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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Pressure drop & Operational Envelopes Liquid Management & Operational Modes
30,000
24 inch
30 inch 36 inch - Liquids
100 36 inch
36 inch - water
25,000
30 inch - Liquids
One SMDS Train One SMDS Train 30 inch - water
24 inch - Liquids

Liquid Volume (m3)

20,000
Inlet Pressure (bar)

Two SMDS Trains Two SMDS Trains

90

15,000
Two SMDS Trains + Dom gas Two SMDS Trains + Dom gas

10,000
80

5,000

70 0
0 5 10 15 20 25 0 5 10 15 20 25
Throughput (m m sm 3/d) Throughput (mmsm3/d)
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

Multiphase Pipeline & Slugcatcher Multiphase Pipeline & Slugcatcher

Costs (MMUS$) Costs (MMUS$)

36 inch Hydraulic in-stable, NOT acceptable 36 inch - Hydraulic in-stable, NOT acceptable
34 inch Slugcatcher - 6000 m3 34 inch 245 Slugcatcher - 6000 m3
32 inch Slugcatcher - 4000 m3 32 inch 195 Slugcatcher - 4000 m3
30 inch Slugcatcher - 2000 m3 30 inch 165 Slugcatcher - 2000 m3

2 x 24 inch Slugcatcher - 1500 m3 2 x 24 inch 195 Slugcatcher - 1500 m3

- Total Installed Cost of Pipeline & slugcatcher in 2001

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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Multiphase Pipeline & Slugcatcher Conclusions & Recommendation

Costs (MMUS$)
36 inch - Hydraulic in-stable, NOT acceptable
Adequate solution for secure supply for SMDS plant available
34 inch 245 Slugcatcher - 6000 m3 - limited linepack
32 inch 195 Slugcatcher - 4000 m3 - limited linepack
30 inch 165 Slugcatcher - 2000 m3 - no linepack Only an Integrated approach between Upstream & Downstream
Will result in a good match of production system and Plant
Avoid systems which are very difficult to operate
2 x 24 inch 195 Slugcatcher - 1500 m3 - Adequate Linepack
- Selected option
Integrated Upstream & Downstream project
resulted in optimum solution
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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

Malampaya Deep Water Gas to Power Project Malampaya Challenges

Maintain high availability of export gas in combination with a

difficult deepwater production system

Hydrate management under flowing and non-flowing conditions

- High availability of methanol regeneration

Liquid hydraulics and management in flowlines with steep inclines

- Potential for slugging
- No slugcatcher included in topsides

Liquid flowback into the well (after unplanned shutdown) is not acceptable

No planned intervention of subsea system

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Shell Multiphase Flow Experience Shell Multiphase Flow Experience

 Conclusions

Multiphase Flow Pipeline Systems widely applied in the Oil & Gas
Industry

Continuing drive to further extend reach of Multiphase applications

gas/condensate, oil/gas & full well streams @ extreme conditions

Field experience & feedback to modelling tools is vital for progressing the
extended reach

Early input from Operations play a key role in optimising complex

multiphase developments Shell Global Solutions is a network of independent technology companies in the Shell Group. In this presentation the expression 'Shell' or 'Shell Global Solutions' is
sometimes used for convenience where reference is made to these companies in general, or where no useful purpose is served by identifying a particular company.

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Shell Multiphase Flow Experience Shell Multiphase Flow Experience