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SPE 15103

Prediction of Slug Length in Horizontal, Large-Diameter Pipes 15103 Scott, Stuart L.,* SPE, Shoham, Ovadia, SPE, and Brill, James P., SPE, U. of Tulsa August 1989 Summary. The prediction of slug characteristics for large-diameter pipes is studied with data collected from flowlines in the Prudhoe Bay field in Alaska. A 3-mile [5-km] -long pipeline was fully instrumented with nuclear densitometers, insert turbine meters, flowmeters, pressure and temperature sensors, and separator level indicators. During these tests, more than 19 million data points were collected on 12-, 16-, 20-, and 24-in. [30-, 41-, 51-, and 61 -cm] -diameter pipes. These data were used to construct a data base that can be accessed interactively or by FORTRAN applications programs. The data show such slug characteristics as slug length, bubble length, and holdups. Data analysis revealed that the liquid slugs do not maintain a constant length and that the slugs tend to grow as they flow through the pipeline. An existing slug-length correlation was modified with these new data, and a term was added to account for the observed slug growth. Introduction When a pipeline is operated in slug flow, the prediction of the liquid flow rate that can be expected at the end of the pipeline is important in the design of separator facilities. During slug flow, the liquid phase exists as aerated liquid slugs and as liquid films on which the gas phase occurs as a bubble. Because most of the liquid exists in the fast-moving slugs, an a priori knowledge of the average slug length is essential for proper design of separator facilities. Correlations exist for the prediction of slug frequency and slug length, but these correlations were developed in small-diameter pipes. The correlations predict slug lengths an order of magnitude less than slug lengths observed in large-diameter pipes. Extensive

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SPE 15103

data were collected for large-diameter pipes at Prudhoe Bay from 1978 to 1981. Some of these data from 16- and 24-in. [41- and 61-cm) -diameter pipes were used to develop correlations to predict slug lengths in large-diameter pipes. These latter correlations predict the slug lengths in large-diameter pipes much more accurately than the earlier small-diameter pipe correlations. These correlations can be improved, however, by analysis of additional data. The Prudhoe Bay data include tests on 12-, 16-, 20-, and 24-in. [30-, 41-, 51-, and 61-cm] -diameter flowlines. Only a portion of the 16- and 24-in. [41- and 61-cm] data has been included in the development of the large-diameter correlations. These data lie in a narrow range of flow rates and have limited applicability at other flow rates. Therefore, a broadening of the data base used to develop these correlations is necessary. Also, it is evident from the ex-perimental data that slugs tend to grow as they flow through pipeline. No previous correlation accounts for such a slug-growth phenomenon. This effect becomes increasingly significant with increasing pipe diameter. A new correlation can be developed to include these improvements to estimate slug length better. The intent of this paper is to present an improved correlation to predict the average slug length and slug growth in large-diameter pipes. First, slug flow is described to convey the importance of the slug length in the characterization of slug flow. Next, the various methods currently available to predict slug length are presented. A description is then given of the Prudhoe Bay data. Finally, the new slug-length and slug-growth correlation is presented. Description of Slug Flow Fig. 1 shows an idealized slug unit, which consists of four zones: the mixing zone, the slug body, the film, and the bubble. The flow mechanism is that of a fast-moving slug of high liquid holdup overriding a slow-moving film ahead of it. The slug scoops the slow-moving liquid film and accelerates it to the velocity of the slug in the mixing zone. Liquid is shed from the tail of the slug to a trailing film, which moves at a velocity much less than the slug-body velocity. Most of the pressure drop in slug flow occurs in the liquid slug. The acceleration of the scooped film causes a large pressure drop in the mixing zone. The pressure drop resulting from friction is also much larger in the slug than in the bubble and film region. Thus, the overall pressure drop depends greatly on the slug length. Slug-Length Prediction

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The numerous methods that exist for the prediction of slug length fall into two categories: correlations and mathematical models. Most of the correlations were developed in small-diameter pipes and are not usable for estimating slug length in large-diameter pipes. The two correlations based on the large-diameter Prudhoe Bay data perform reasonably well but do not use all the data taken at Prudhoe Bay. The mathematical models have difficulty in that the physics governing slug length and slug growth is not fully understood. Small-Diameter Correlations. Gregory and Scott presented a slug-frequency correlation based on CO2 and water flowing in 0.75-in. [2-cm] -diameter pipe. Use was also made of the data collected by Hubbards in 1.5-in. [4-cm] -diameter pipe. These two data sets were correlated with the slug Froude number: (1) where (2)

Greskovich and Shrier presented a similar correlation based on the mixture Froude number. They based this correlation on data from 1.5-in [4-cm] -diameter pipe and performed some experiments using 6-in. [15-cm] -diameter pipe. Both of these correlations perform adequately for small-diameter pipes, but when applied to the Prudhoe Bay data, they failed to scale up accurately for larger-diameter pipe. Predictive Models. The pioneering work on modeling slug flow was presented by Dukler and Hubbard. The model defines the different interactions found in slug flow and allows calculation of velocities in the slug unit, lengths of the four zones, and pressure drop. Unfortunately, the input parameters required by this model include not only fluid properties, pipe diameter, and flow rates, but also holdup in the liquid slug and slug frequency. The model depends heavily on the slug frequency used. For example, the pressure drop predicted is almost directly proportional to the slug frequency. The model also assumes a steady-state representation of the slug unit in which the slug length is constant and the amount of liquid scooped at the head of the slug is equal to the amount of liquid shed at the tail. Therefore, slug growth is not considered in this model. Taitel and Dukler presented a model to predict slug frequency based on six dimensionless groups. The basis of their analysis is the conditions required for slug formation. This analysis assumes a steady-state slug that neither increases nor decreases in length and treats slug formation as strictly an entrance phenomenon. The model compared favorably with the small-diameter data of Dukler and Hubbards and Gregory and Scott ; therefore, scale-up to larger-diameter pipes is questionable. SPEPE P. 335