Considering the Effect of Crude Oil Viscosity on Pumping Requirements _ Campbell Tip of the Month

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26/11/13 Consider ing the effect of crude oil viscosi ty on pumping requi rements | Campbel l Tip of the Month

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Considering the effectof crude oilviscosity on pumping

requirements

In the August 2009 Tip of the Month (TOTM), it was shown that pumping power requirement varies as the

crude oil API changes . Increasing API or line average temperature reduces the crude oil viscosity. The

viscosity reduction caused higher Reynolds number, lower friction factor and in effect lowered pumping

power requirements. Since the objective of the Augus t 2009TOTM was to studythe effect API and the lineaverage temperature have on thepumping power requirement, the effect of crude oil viscosity on pump

performance was ignored and inthe course of calculation aconstant pump efficiency of =0.75 was

used for all cases. In this TOTM, we will consider the crudeoil viscos ity effect ona selected pump

performance. The Hydraulic Institute Standards [1] procedures and the guideline presented in the August

2006 TOTM written by Honeywell were applied to correct thepump efficiency.

As in the Augus t 2009 TOTM, we will study crude oil API and the pipeline average temperature and how

these effect the pumping requirement. For a case study, we will consider a 160.9 km (100 miles) pipeline

with an outside diameter of 406.4 mm (16 in) carrying crude oil with a flow rate of 0.313 m3/s or 1,126

m3/h (170,000 bbl/day or 4958 GPM). The pipeline design pressure is 8.963 MPa (1300 psia) with a

maximum operating pressure of 8.067 MPa (1170 ps ia). The wall thickness was es timated to be 6.12

mm (0.24 in). The wall roughness is 51 microns (0.002 in) or a relative roughness (e/D) of 0.00013. The

procedures outlined in the March 2009 TOTM were used to calculate the line pressure drop due to friction.

Then corrected pumping efficiency was used to calculate the required pumping power. Since the objective was to

study the effect API and the line average temperature have on the pumping power requirement, we will ignore elevation

change. The change in pum ping power requirements due to changes in crude oil API and line average temperature for

this case s tudy will be dem onstrated.

Viscosity Effect on Centrifugal Pump PerformanceThere are several papers investigating and presenting procedures for correcting centrifugal pump curves [2-3].

According to Turzo et al.[2], three models are available for correcting performance curves: Hydraulic Ins titute, Stepanoff,

and Paciga. Turzo et al.[2] also presented a com puter applications for correcting pump curves for viscos ity effect. In

this review, the Hydraulic Institute [1], HI, procedure was applied and is described briefly here.

HI uses a performance factor, called ParameterBwhich includes terms for viscosity, speed, flow rate and total head.

The method uses a new bas is for determining the correction factors CH, CQ, and C . The basic equation for

Parameter Bis given as Equation 1.

B= Performance factor

K= 16.5 for SI units

= 26.5 for USCS (FPS)

vis= Viscous fluid Kinematic viscosity cSt

HBEP-W

= Water head per s tage at BEP m (ft)

QBEP-W= Water flow rate at BEP m3/h (gpm)

N= Pump shaft speed rpm

Correction factors are applied to capacity (CQ), head (CH), and efficiency (C ). Calculation of these Correction Factors

is dependent on the calculated value of Parameter B. For the cases considered in this study, the Bvalues were less

than 1; therefore, based on the HI guideline, the correction factors for head and capacity were set equal to 1 and the

correction factor for e fficiency,C , was calculated by Equation 2.

BEP-W= Pump efficiency at BEP

Vw= Water kinematic viscos ity cSt

Figures 1 and 2 present the water-based pum p curves used in this study. For computer calculations, these two curves

were fitted to polynomials of degrees 3 and 2 for head vs capacity and efficiency vs capacity, respectively.

In Equations 3 and 4, His in m (ft) and Qis in m3/h (GPM). For this pump:

HBEP-W=323m=1060ft, QBEP-W=1726 m3/h= 7600 GPM, N=1780 rpm, and BEP-W=83.4.

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Case Study 1: Effect of Line Average Tempera ture (Seasonal Variation)

To study the effect of the line average temperature on the pumping power requirement, an in house computer program

called OP&P(Oil Production and Processing) was used to perform the calculations outlined in the March 2009 TOTM.

For a 35 API crude oil in the pipeline described the required pumping power was calculated for line average

temperature ranging 21.1 to 37.8 C (70 to 100 F). For each case, the parameter Bwas calculated by Equation 1 and

since its value was less than 1, the efficiency correction factor was calculated by Equation 2. Then, the pump efficiency

calculated by Equation 4 was multiplied by the correction factor for the subsequent calculations. The corrected efficiency

ranged from 0.70 to 0.72. The required pumping power was compared with an arbitrary base cas e (85 F or 29.4 Cand constant = 0.75) and the percentage change in the pumping power requirement was calculated. Figure 3

presents the percent change in power requirement as a function of line average temperature. There is about 5%

change (for constant =0.75) and more than 8% change (for corrected efficiency) in the pumping power requirem ent for

the temperature range considered.

Note that as the line average temperature increases the power requirement decreases. This can be explained by

referring to Figure 4 in which the oil viscosity decreases as the temperature increases . Lower viscosity results in higher

Reynolds (i.e. Reynolds number which is the ratio of inertia force to viscous force); therefore, the

friction factor decreases (refer to the Moody friction factor diagram in the March 2009 TOTM).
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Case Study 2: Effect of Variation of Crude Oil API

In this case, the effect of crude oil API on the total pump power requi rement for three different line average

temperatures was studied. For each line average temperature, the crude oil API was varied from 30 to 40 and the total

pumping power requirement was calculated and compared to the base case (35 API and average line temperature of

29.4C=85F).

For each case the percent change in total power requirement was calculated and is presented in Figure 5. As s hown,

when API increases the total power requirement decreases . This also can be explained by referring to Figure 4 in

which the crude oil viscosity decreases as API increases. The effect of viscosity is more pronounced at lower line

average temperature (i.e. 21.1 C or 70F). Figure 5 also indicates that there is about 30 % change in total powerrequirement as API varies from 30 to 40 API. This is a s ignificant variation and sugges ts that it should be considered

during design of crude oil pipelines.

Discussion and Conclusions

The analysis of Figures 3 and 5 indicates that for the oil pipeline, the pumping power requirement varies as the crude

oil API changes. Increasing API or line average temperature reduces the crude oil viscosity (see Figure 4). The

reduction of viscosity results in higher a Reynolds num ber, lower friction factor and in effect lowers pumping power

requirements.

For the cases studied in this TOTM, the effect of crude oil viscosity on the performance of pump was considered. It was

found that no correction was required for the capacity and head but a correction factor in the range of 0.95 to 0.98 was

required to adjust the pump efficiency for crude oil applications.

A sound pipeline design should cons ider expected variations in crude oil API and the line average temperature. In

addition, the pump performance curves should be corrected for the effect of viscosity.

To learn more about similar cases and how to minimize operational problems, we s uggest attending ourME44

(Overview of Pumps and Compressors in Oil and Gas Facilities), ME46 (Compressor Systems Mechanical Design

and Specification), PL4 (Fundamental Pipeline Engineering), G40 (Process/Facility Fundamentals), G4 (Gas

Conditioning and Processing), and PF4 (Oil Production and Processing Facilities)courses.

By: Dr. Mahmood Moshfeghian
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References:

ANSI HI 9.6.7-2004, Effects of Liquid Viscos ity on Rotodynamic (Centrifugal and Vertical) Pump Performance,

2004.

Turzo, Z.; Takacs, G. and Zsuga, J., Equations Correct Centrifugal Pum p Curves for Viscos ity, Oil & Gas J., pp.

57-61, May 2000.

Karassik, I.J., Centrifugal Pumps and System Hydraulics, Chem. Engr. J., pp.84-106, Oct. 4, 1982

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Posted on October 1, 2009 at 3:30 pm

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Written by Dr. Mahmood Moshfeghian

Dr. Mahmood Moshfeghian is an instructor and consultant with John M Campbell and Company (JMC). He is the author

of most of Campbell Tips of the Month and develops technical software for JMC. He has 35 years teaching experiencein universi ties (Oklahoma State University, University of Shiraz, University of Sydney and University of Qatar) as well as

for oil and gas industries. Dr. Moshfeghian joined JMC in 1990 as a part time consultant and then as full time

instructor/consultant in 2005. Previous to joining JMC, Dr. Moshfeghian was a Senior Research Scientist at Kuwait

Institute for Scientific Research and Professor of Chemical Engineering at Shiraz University. Dr. Moshfeghian is a

senior mem ber of AIChE and has published numerous technical papers on thermodynamic properties, and Process

Engineering. Dr. Moshfeghian has presented invited papers in international conferences. He holds a B.S., an M.S. and

a Ph.D. in Chemical Engineering, all from Oklahoma State University.

View all posts by: Dr. Mahmood Moshfeghian

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9 Responses to Considering the effect of crude oil viscosity on pumping

requirements

1. P K Sahasays:

April 26, 2012 at 7:42 am

Effect on pump power understandable. Would like to know what crude oil temperature should be ass umed

when ambient temperature is sub-zero say minus 10-15 degree C. What is viscosity at (-) 12 degree C for say

API 32.5 crude oil? Will any heating be required to main tain flowability and reduce power requirem ent especially

if friction loss is not a substantial percentage of total dynamic head for the pump?

Reply

2. james waghornsays:

January 5, 2013 at 7:27 am

i hope you like my case s tudy

Reply

3. Christiano Ronaldosays:


YaYa YaYa YaYa Kolo Kolo YaYa

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