Black Gold Production Company was established in 2014 with the aim of transferring new oil technologies from European countries to Iran. The company has a full range of additives for use in pipelines, the most important of which is the friction reducing material ([1] DRA) for use in crude oil and product transmission lines.
This product, which is a polymer from the alpha-olefins family with high molecular weight, has had very favorable effects in reducing manufacturing and operating costs in the oil industry. Crude oil pipeline is considered a product. DRA injection at very low concentrations of [2] ppm in crude oil and product pipelines reduces the pressure drop caused by friction. Decreasing the frictional pressure drop can lead to a decrease in the output pressure [3], followed by an increase in the capacity of the pipeline.
Results from DRA injection:
1. Stimulation of DRA material to reduce operating pressure or remove a number of electric pumps or turbopumps in the oil pumping system
By injecting DRA, the operating pressure of the pumps and turbines is reduced. In some cases, you can also turn off a number of pumps or booster pumps [4] or even a roadside pumping station, resulting in significant savings in the cost of repairing and maintaining the crude oil and product pumping system.
A) Turn off the electric pumps in the 8-inch and 52-kilometer pipeline
Injection rate DRA(Lit/Hr) |
Number of electromotors in the circuit | Pressure at the beginning of the pipeline (psi) | Flow ( BPD) | |
0 | 3 | 430 | 21500 | Before DRA injection |
6 |
1 | 185 | 21500 |
After DRA injection |
Injection rate DRA(Lit/Hr) |
Number of turbopumps in the circuit | Pressure at the beginning of the pipeline (psi) |
Flow ( BPD) |
|
0 | 3 | 660 | 105000 | Before DRA injection |
25 | 2 | 267 | 108000 | After DRA injection |
The conditions of turbopumps before and after injection were as follows:
Turbopump number | Rotational speeds of the gas producer rotor (NGP) | |
Before DRA injection | After DRA injection | |
1 | 92% | 78% |
2 | 86% | It was turned off |
3 | 83% | 75% |
C) Remove the pump house and increase the transmission capacity of the product in the 12-inch and 60-kilometer pipeline
Injection rate DRA(Lit/Hr) |
Number of pump houses | Pressure at the beginning of the pipeline (psi) | Flow ( BPD) | |
0 | 2 | 506 | 48320 | Before DRA injection |
10 | 1 | 500 | 53600 | after DRA injection |
Before DRA injection | ![]() |
after DRA injection | ![]() |
2. Increase Flow on crude oil pipelines and products
By injecting DRA into the pipeline, the reduced frictional pressure drop can be converted to an increase in fluid flow.
a) Increase in oil flow in the pipeline 24 inches and 150 kilometers
Injection rate DRA(Lit/Hr) |
Pipeline end pressure (psi) | Pressure at the beginning of the pipeline(psi) |
Flow ( BPD) |
|
0 | 60 | 230 | 105800 | Before DRA injection |
28 | 60 | 180 | 179000 | after DRA injection |
3. Safety and prevent premature wear of pipelines
By injecting DRA into the pipeline, a decrease in the frictional pressure drop and consequently a decrease in the outlet pressure of the pipeline is observed.
a) Reduce the outlet pressure in the pipe line by 8 inches and 97 kilometers
Injection rate DRA(Lit/Hr) |
Pipeline end pressure (psi) | Pressure at the beginning of the pipeline(psi) |
Flow ( BPD) |
|
0 | 30 | 1050 | 16800 | Before DRA injection |
6 | 30 | 675 | 18000 | after DRA injection |
4. Increasing the exploitation of oil wells by injecting DRA into overhead pipelines
Due to the DRA injection, it is possible to use low pressure oil wells and sometimes increase the operation of existing wells.
a) Increase in oil production from low pressure wells through DRA injection in 6-inch and 27-kilometer pipeline
Injection rate DRA(Lit/Hr) |
The number of wells that can produce | Pressure at the beginning of the pipeline(psi) |
GOR SCF/STB |
Flow ( BPD) |
||
0 | 2 | 1390 | 1600 | 14000 | Before DRA injection | |
20 | 3 | 1190 | 1600 | 20000 | after DRA injection |
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Flexible pipeline design according to limitations and needs
In the design and construction of crude oil and product transmission pipelines, DRA injection has led to a decrease in frictional pressure drop and thus a reduction in pipeline outlet pressure, which can be used in the design of transmission routes. Considering the reduction of the output pressure in the design leads to a decrease in the diameter and thickness of the transfer pipes. In addition, the use of pumps and turbines has been reduced, reducing the cost of investment and energy consumption.
The table below shows an example of the design of a hinged line that can be modified using the DRA material, and depending on the costs, limitations, and capacity required to transfer the fluid, different concentrations of the DRA material can be used. Dad.
Pipeline design using DRA
800 km of pipeline in 5 parts of 160 km Grade B seamless pipe, cSt 5 oil viscosity, crude oil with API 35 Pipeline capacity 250,000 barrels per day |
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Diameter pipe(inches) | Wall thickness(inches) | [5]MAOP (psi) | Number of pump houses | The length of each section of pipeline(Km) |
Injection rate DRA (ppm total) |
Design variables | ID |
24 | 0.375 | 788 | 5 | 160 | 0 | Basic design | 1 |
24 | 0.312 | 656 | 5 | 160 | 9 | Reduce wall thickness | 2 |
24 | 0.281 | 591 | 5 | 160 | 15 | Reduce wall thickness | 3 |
22 | 0.375 | 859 | 5 | 160 | 20 | Reduce the diameter of the pipeline | 4 |
20 | 0.375 | 945 | 5 | 160 | 50 | Reduce the diameter of the pipeline | 5 |
24 | 0.375 | 788 | 3 | 267 | 22 | Reduce the number of pump houses | 6 |
[1] Drag Reducing Agent
[2] parts per million
[3]Discharge Pressure
[4] Booster Pump
[5] Maximum Allowable Operating Pressure