Experimental investigation of viscous oil-water-sand flow in horizontal pipes: Flow patterns and pressure gradient

Abstract

Fluid production from unconsolidated reservoirs often leads in sand production, which poses a number of issues. Sand deposition in flowlines can result in significant pressure dips, pipe and facility damage, and obstructions that decrease productivity. More research is needed to understand the movement and deposition of sand in oil-water-sand (O-W-S) fluxes. This article focuses on O-W-S flows in a 6-meter-long horizontal pipe with an inner diameter of 0.0381 m. The study looks at the flow behavior of high viscosity oil-water (O-W), water-sand (W-S), and oil-water-sand (O-W-S) flows. Experiments were carried out at 250 psig pressure in a laboratory flow test facility using various heavy synthetic oils (viscosities ranging from 3500 cP to 7500 cP at 25°C) and tap water. The sand concentration varied from 1% to 10%, with an average sand particle diameter of 145 μm and material density of 2630 kg/m³. Water cuts ranged from 0.0 to 1.0. The experimental results revealed a minor change in pressure gradient between (O-W) and (O-W-S) flows. However, increasing the sand concentration in (O-W-S) flow resulted in higher pressure losses. The reduction factor of pressure gradient indicated that the highest decrease in pressure drop occurred at higher superficial oil velocities. Furthermore, a direct relationship was observed between the reduction factor and the decrease in water cut. The results also showed that the minimum required transportation velocity for sand slurry decreased with increasing superficial oil velocity, while the minimum transportation condition increased with higher sand concentration. The comparison between the expected pressure gradient from Bannwart and McKibben et al. and the actual experimental data demonstrated significant accuracy for the oil viscosities and superficial oil velocities used in the study.

Keywords

Slurry velocity / Flow pattern / Pressure gradient / High viscosity / Minimum transport condition

Declaration of competing interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

Acknowledgments

The author extends heartfelt appreciation to the Oil and Gas Research Centre for their invaluable support in facilitating and contributing to the successful completion of this research. Their assistance and collaborative efforts were instrumental in achieving the study's objectives.

References

[1] E. Zorgani, H. Al-Awadi, W. Yan, S. Al-Lababid, H. Yeung, C. Fairhurst, Viscosity effects on sand flow regimes and transport velocity in horizontal pipelines, Exp. Therm. Fluid Sci. 92 (2018) 89-96, https://doi.org/10.1016/j.expthermflusci.2017.08.024.

[2] D. Dall'Acqua, M. Benucci, F. Corvaro, M. Leporini, R.C. Grifoni, A. Del Monaco, et al., Experimental results of pipeline dewatering through surfactant injection, J. Pet. Sci. Eng. 159 (2017) 542-552, https://doi.org/10.1016/j.petrol.2017.08.068.

[3] G. Giacchetta, M. Leporini, B. Marchetti, A. Terenzi, Numerical study of choked two-phase flow of hydrocarbons fluids through orifices, J. Loss Prev. Process Ind. 27 (2014) 13-20, https://doi.org/10.1016/j.jlp.2013.10.014.

[4] D. Barnea, O. Shoham, Y. Taitel, Flow pattern characterization in two phase flow by electrical conductance probe, Int. J. Multiph. Flow 6 (5) (1980) 387-397, https://doi.org/10.1016/0301-9322(80)90001-4.

[5] Prediction of dispersion viscosity of oil/water mixture flow in horizontal pipes,in: A. Martinez, S. Arirachakaran, O. Shoham, J. Brill (Eds.), SPE Annual Technical Conference and Exhibition, Society of Petroleum Engineers, 1988, https://doi.org/10.2118/18221-MS.

[6] N. Brauner, D.M. Maron, Flow pattern transitions in two-phase liquid-liquid flow in horizontal tubes, Int. J. Multiph. Flow 18 (1) (1992) 123-140, https://doi.org/10.1016/0301-9322(92)90010-E.

[7] J. Trallero, C. Sarica, J. Brill, A study of oil-water flow patterns in horizontal pipes, SPE Prod. Facil. 12 (3) (1997) 165-172, https://doi.org/10.2118/36609-PA.

[8] P. Angeli, G. Hewitt, Flow structure in horizontal oilewater flow, Int. J. Multiph. Flow 26 (7) (2000) 1117-1140, https://doi.org/10.1016/S0301-9322(99)00081-6.

[9] The tools of sand management,in: J. Tronvoll, M. Dusseault, F. Sanfilippo, F. Santarelli (Eds.), SPE Annual Technical Conference and Exhibition, Society of Petroleum Engineers, 2001, https://doi.org/10.2118/71673-MS.

[10] M. Açikgöz, F. Franca,R. Lahey Jr., An experimental study of three-phase flow regimes, Int. J. Multiph. Flow 18 (3) (1992) 327-336, https://doi.org/10.1016/0301-9322(92)90020-H.

[11] T. Ganat, M. Hrairi, S. Regassa, Experimental investigation of gaseoilewater phase flow in vertical pipes: influence of gas injection on the total pressure gradient, J. Pet. Explor. Prod. Technol. 9 (4) (2019) 3071-3078, https://doi.org/10.1007/s13202-019-0703-0.

[12] T. Ganat, S. Ridha, M. Hairir, J. Arisa, R. Gholami, Experimental investigation of high-viscosity oilewater flow in vertical pipes: flow patterns and pressure gradient, J. Pet. Explor. Prod. Technol. 9 (4) (2019) 2911-2918, https://doi.org/10.1007/s13202-019-0677-y.

[13] Y. Taitel, D. Barnea, J. Brill, Stratified three phase flow in pipes, Int. J. Multiph. Flow 21 (1) (1995) 53-60, https://doi.org/10.1016/0301-9322(94)00058-R.

[14] X.Z. Chen, X.J. Chen, F. Zhou, Phase holdups and frictional pressure gradient of oil-gas-water three phase bubbly flow in vertical upward pipes, in: 6th Miami Int. Symp. On Heat and Mass Transfer, 1990.

[15] Identification and classification of new three-phase gas/oil/water flow patterns,in: C. Keskin, H.-Q. Zhang, C. Sarica (Eds.), SPE Annual Technical Conference and Exhibition, Society of Petroleum Engineers, 2007, https://doi.org/10.2118/110221-MS.

[16] O. Rodriguez, A.C. Bannwart, C. De Carvalho, Pressure loss in core-annular flow: modeling, experimental investigation and full-scale experiments, J. Pet. Sci. Eng. 65 (1-2) (2009) 67-75, https://doi.org/10.1016/j.petrol.2008.12.026.

[17] M. Kassai, Experimental investigation on the effectiveness of sorption energy recovery wheel in ventilation system, ExHT 31 (2) (2018) 106-120, https://doi.org/10.1080/08916152.2017.1397815.

[18] T.J. Danielson (Ed.), Sand Transport Modeling in Multiphase Pipelines. Offshore Technology Conference, Offshore Technology Conference, 2007, https://doi.org/10.4043/18691-MS.

[19] P. Ayazi Shamlou, Hydraulic transport of particulate solids, Chem. Eng. Commun. 62 (1-6) (1987) 233-249, https://doi.org/10.1080/00986448708912062.

[20] Sand flow regimes in slightly upward inclined gas-liquid stratified flow,in: R. Dabirian, R. S. Mohan, O. Shoham, G. Kouba (Eds.), ASME 2016 Fluids Engineering Division Summer Meeting Collocated with the ASME 2016 Heat Transfer Summer Conference and the ASME 2016 14th International Conference on Nanochannels, Microchannels, and Minichannels, American Society of Mechanical Engineers Digital Collection, 2016, https://doi.org/10.1115/FEDSM2016-7729.

[21] K. Najmi, B.S. McLaury, S.A. Shirazi, S. Cremaschi, The effect of viscosity on low concentration particle transport in single-phase (liquid) horizontal pipes, J. Energy Resour. Technol. 138 (3) (2016), https://doi.org/10.1115/1.4032227.

[22] R. Tebowei, M. Hossain, S.Z. Islam, M.G. Droubi, G. Oluyemi, Investigation of sand transport in an undulated pipe using computational fluid dynamics, J. Pet. Sci. Eng. 162 (2018) 747-762, https://doi.org/10.1016/j.petrol.2017.11.003.

[23] O.T. Fajemidupe, A.M. Aliyu, Y.D. Baba, A. Archibong-Eso, H. Yeung, Sand minimum transport conditions in gasesolideliquid three-phase stratified flow in a horizontal pipe at low particle concentrations, Chem. Eng. Res. Des. 143 (2019) 114-126, https://doi.org/10.1016/j.cherd.2019.01.014.

[24] M. Leporini, B. Marchetti, F. Corvaro, G. di Giovine, F. Polonara, A. Terenzi, Sand transport in multiphase flow mixtures in a horizontal pipeline: an experimental investigation, Petroleum 5 (2) (2019) 161-170, https://doi.org/10.1016/j.petlm.2018.04.004.

[25] R. Durand, The Hydraulic Transportation of Coal and Other Materials in Pipes, Colloqium of National Coal Board, London, England, 1952.

[26] E. Condolios, E.E. Chapus, Transporting solid materials in pipelines, Chem. Eng. 70 (13) (1963). https://trid.trb.org/view/19615.

[27] K. Bello, B. Oyeneyin, Experimental investigation of sand minimum transport velocity in multiphase fluid flow in pipes, Niger. J. Technol. 35 (3) (2016) 531-536, https://doi.org/10.4314/njt.v35i3.9.

[28] D. Ercolani, F. Ferrini, V. Arrigoni, Electric and thermic probes for measuring the limit deposit velocity,of the 6th Int. Conf. on the Hydraulic Transport of Solids in Pipes, 1979, pp. 27-42.

[29] P. Doron, D. Granica, D. Barnea, Slurry flow in horizontal pipesdexperimental and modeling, Int. J. Multiph. Flow 13 (4) (1987) 535-547, https://doi.org/10.1016/0301-9322(87)90020-6.

[30] M. Toda, H. Konno, S. Saito, Simulation of limit-deposit velocity in horizontal liquid-solid flow, J. Chem. Eng. Jpn. 13 (6) (1980) 439-444.

[31] K. Wilson, Analysis of contact-load distribution and application to deposition limit in horizontal pipes, J. Pipelines 4 (3) (1984) 171-176.

[32] D.J. Wood, Pressure gradient requirements for re-establishment of slurry flow, 6th Int. Conf.on the Hydraulic Transport of Solids in Pipes, 1979, pp. 217-228.

[33] R. Durand, Basic relationships of the transportation of solids in pipesexperimental research, in: Intern Assoc Hydr Res, 5th Congr Minneapolis, 1953, 1953.

[34] P. Stevenson, R.B. Thorpe, Energy dissipation at the slug nose and the modeling of solids transport in intermittent flow, Can. J. Chem. Eng. 81 (2) (2003) 271-278, https://doi.org/10.1002/cjce.5450810213.

[35] D.G. Thomas, Transport characteristics of suspensions: part IX. Representation of periodic phenomena on a flow regime diagram for dilute suspension transport, AIChE J. 10 (3) (1964) 303-308, https://doi.org/10.1002/aic.690100307.

[36] K. Spells, Correlations for use in transport of aqueous suspensions of fine solids through pipes, Trans. Inst. Chem. Eng. 33 (2) (1955) 79-82.

[37] A. Archibong-Eso, Y. Baba, A. Aliyu, Y. Zhao, W. Yan, H. Yeung, On slug frequency in concurrent high viscosity liquid and gas flow, J. Pet. Sci. Eng. 163 (2018) 600-610, https://doi.org/10.1016/j.petrol.2017.12.071.

[38] J. Shi, L. Lao, H. Yeung, Water-lubricated transport of high-viscosity oil in horizontal pipes: the water holdup and pressure gradient, Int. J. Multiph. Flow 96 (2017) 70-85, https://doi.org/10.1016/j.ijmultiphaseflow.2017.07.005.

[39] H. Al-Awadi, Multiphase Characteristics of High Viscosity Oil (PhD thesis), Cranfield University, UK, 2011, http://dspace.lib.cranfield.ac.uk/handle/1826/13902.

[40] K.H. Bendiksen, M. Langsholt, L. Liu, An experimental investigation of the motion of long bubbles in high viscosity slug flow in horizontal pipes, Int. J. Multiph. Flow 104 (2018) 60-73, https://doi.org/10.1016/j.ijmultiphaseflow.2018.03.010.

[41] M. Basha, S.M. Shaahid, L.M. Alhems, Effect of viscosity on pressure drop of oil-water two phase flow in 6” horizontal and inclined stainless steel annulus pipe, J. Adv. Res. Fluid Mech. Therm. Sci. 69 (2) (2020) 156-167.

[42] G. Sotgia, P. Tartarini, E. Stalio, Experimental analysis of flow regimes and pressure drop reduction in oilewater mixtures, Int. J. Multiph. Flow 34 (12) (2008) 1161-1174, https://doi.org/10.1016/j.ijmultiphaseflow.2008.06.001.

[43] A new method for predicting friction losses and solids deposition during the water-assisted pipeline transport of heavy oils and co-produced sand,in: M. McKibben, S. Sanders, R. Gillies (Eds.), SPE Heavy Oil Conference-Canada, Society of Petroleum Engineers, 2013, https://doi.org/10.2118/165480-MS.

[44] M.J. McKibben, R.G. Gillies, C.A. Shook, A laboratory investigation of horizontal well heavy oildwater flows, Can. J. Chem. Eng. 78 (4) (2000) 743-751, https://doi.org/10.1002/cjce.5450780417.

[45] L.P.M. Colombo, M. Guilizzoni, G.M. Sotgia, Water holdup estimation from pressure drop measurements in oil-water two-phase flows by means of the two-fluid model, J. Phys. Conf. Ser. 923 (2017) (2017), https://doi.org/10.1088/1742-6596/923/1/012012.

[46] W. Wang, J. Gong, Experiment research of phase inversion in mineral oil water two-phase flow in horizontal pipe, J. Energy Resour. Technol. Trans. ASME 131 (4) (2010), https://doi.org/10.1115/1.4000324.

[47] G.C. Yeh, F.H. Haynie Jr. R. A. Moses, Phase-volume relationship at the point of phase inversion in liquid dispersions, AIChE J. 10 (2) (1964) 260-265, https://doi.org/10.1002/aic.690100224.

[48] An analysis of oil/water flow phenomena in horizontal pipes,in: S. Arirachakaran, K. Oglesby, M. Malinowsky, O. Shoham, J. Brill (Eds.), SPE Production Operations Symposium, Society of Petroleum Engineers, 1989, https://doi.org/10.2118/18836-MS.

[49] S. Decarre, J. Fabre, Phase inversion behavior for liquid-liquid dispersions, J. Inst. Fr. Pet. (1997) 415-424, https://doi.org/10.2516/ogst:1997050.

[50] N. Brauner, A. Ullmann, Modeling of phase inversion phenomenon in twophase pipe flows, Int. J. Multiph. Flow 28 (7) (2002) 1177-1204, https://doi.org/10.1016/S0301-9322(02)00017-4.

[51] G. Jing, Q.-p. Li, H.-y. Yao, Y. Da, A model for predicting phase inversion in oilwater two-phase pipe flow, J. Hydrodyn. Ser B. 18 (3) (2006) 310-314, https://doi.org/10.1016/S1001-6058(06)60008-5.

[52] A. Bensakhria, Y. Peysson, G. Antonini, Experimental study of the pipeline lubrication for heavy oil transport, Oil Gas Sci. Technol. 59 (5) (2004) 523-533.

[53] D. Strazza, B. Grassi, M. Demori, V. Ferrari, P. Poesio, Core-annular flow in horizontal and slightly inclined pipes: existence, pressure drops, and hold-up, Chem. Eng. Sci. 66 (12) (2011) 2853-2863.

[54] A.R. Oroskar, R.M. Turian, The critical velocity in pipeline flow of slurries, AIChE J. 26 (4) (1980) 550-558, https://doi.org/10.1002/aic.690260405.

[55] J. Davies, Calculation of critical velocities to maintain solids in suspension in horizontal pipes, Chem. Eng. Sci. 42 (7) (1987) 1667-1670, https://doi.org/10.1016/0009-2509(87)80171-9.

[56] A.C. Bannwart, Modeling aspects of oilewater coreeannular flows, J. Pet. Sci. Eng. 32 (2-4) (2001) 127-143, https://doi.org/10.1016/S0920-4105(01)00155-3.