Petrotech-2010

31 October-3 November 2010, New Delhi, India

Paper ID- 20100556

Flow Assurance Problems of Waxy Crude oil in Mumbai Offshore:
Case studies
S.C.Agrawal, G.C.Sundriyal, N.Shelat, A.K.Jain, and K.L.Mehrotra
Regional Geoscience Laboratory ,WOB, ONGC, Panvel, Navi Mumbai-410221
Email : [email protected]
Abstract:
Flow assurance of waxy crude oil is essential for its smooth transportation from well head up to
custody transfer and is a big challenge. The problems associated with waxy crude oils include
crystallization and deposition of wax in flow lines affecting overall production and transportation and
thus increased operational cost.
Present paper deals with recent case of wax associated problems in transportation of crude oil of ZA
and ZB risers of ICP process platform in Mumbai offshore . The crude oil has a very high pour point
(36C) and wax content (~24 %). Complex emulsion being formed due to increase in water cut during
crude oil production. There is a significant fall in temperature at the risers ZA and ZB at ICP process
platform as compared to well head temperature. The temperature falls from 55 to 27 C for ZA-ICP
line and from 65 to 30C for ZB-ICP line. Problem of high back pressure is being observed frequently
in ICG-ICP line.
Characteristics of these crudes and the chemical solutions necessary for improving the flow in these
production lines have been studied. Out of all the methods available for pumping waxy crude oil, use
of pour point depressant (PPD) is preferred economically. Performance evaluation of different flow
improvers under static and dynamic conditions showed that flow properties of crude oils could be
considerably improved by treatment with a suitable flow improver and the problem of high back
pressure in ICG-ICP line can be tackled by judicious use of Demulsifier along-with pour point
depressant. There is a remarkable decrease in the plastic viscosity, yield value and pour point
indicating increase in wax dispersion , thus facilitating good flow at lower temperatures.
Introduction:
Flow assurance of waxy crude is a challenging task. Most of the crude of Mumbai High are waxy.
Initially wax is in equilibrium in the reservoir under certain temperature-pressure conditions. Once
this equilibrium is disturbed by production and change in temperature pressure conditions, wax
deposition may occur. This deposition reduces the effective diameter of pipes. As a result there is a
decrease in well production /increased pressures at the receiving platform and require frequent
pigging of flow lines. This problem has been experienced in a few well fluid lines from producer wells
to collector lines at platform in Mumbai High and problem of high back pressure has been observed
frequently in ICG-ICP flow line.
The present study was taken up with an objective to provide solution to the frequent high back
pressure problem at ICP process platform. Four oil samples from IU, WB, ZA platforms and a
composite sample of ICP line were studied in detail. The affect on viscosity profile and flow
characteristics by additives such as demulsifier and pour point depressant with varying doses,
independently or in combination at varying temperatures as observed in the field, i.e. , >50C to 27C
temperature range, on these crudes was studied . The pour point often is used as a total indicator of a
crude oil's flow properties. The effect of different wax dispersants and flow improver/ crystal
modifiers (Pour Point Depressants) on ZA& ZB risers crude oils of ICP process platform, having high
pour point of 360C, have been evaluated for improving the flow ability .
Experimental:
Samples Detail :
Crude oils: Representative crude oil samples were provided by Surface Chemistry group of Mumbai
High Asset of ONGC. Water and entrained solids were removed from crude oils by heating in water
bath ensuring minimum loss of lighter fraction before performing experiment. Standard procedures
were followed for determination of physicochemical properties of crude oils. The crude oils of ZA and

Petrotech-2010
31 October-3 November 2010, New Delhi, India
ZB riser are highly waxy (~24%) and have high pour point (36C).The temperature range for ZA-ICP
and ZB ICP flow lines is 55 to 27C and 65 to 30C respectively. Low temperature attained by
these flow lines at ICP end is the main causative for flow assurance problem. For study of high back
pressure in ICG-ICP line, Four oil samples from IU, WB, ZA risers and a composite sample of ICP line
were taken for the study of viscosity profile .
Wax Dispersants : To identify suitable wax dispersant/inhibitor for ZA&ZB crude oils, Surface
Chemistry group of Mumbai High Asset of ONGC provided nine samples to RGL, received from
globally established suppliers. Physical state and miscibility of dispersants with xylene was tested at
25C. Only five samples: A,B,C,D&E were found suitable for further evaluation.
Flow Improver / Pour Point Depressant : Pour Point Depressant sample collected from bulk sample
supplied to Mumbai High Asset of ONGC.
Demulsifier : Samples collected from bulk sample supplied to Mumbai High Asset of ONGC.
Methodology :
Doping of crude oils:The crude oils of ZA and ZB were heated to 482C and
treated with
dispersants/depressant at different doses i.e. 100, 300, 350,500, 700, 900, 1050,1400 and 1750
ppm.
Pour Point and Rheological Parameters :Pour point was determined by Pour Point apparatus.
Plastic Viscosity(PV) and Yield value(YV) of treated and untreated oils were measured by Fann VG
Meter at 20C . The other set kept at 251Cfor 14 days and again measured at 20C. In one another
set of experiments, effect of samples have been examined after doping and cooling to 30C.
Wax deposition study: Wax deposition tendency was evaluated in static condition . ZA and ZB crude
oil samples treated with different doses of wax dispersants and depressant were taken in 100 ml
Stoppard measuring cylinders and cooled to 271C(room temperature) for 24 hours. After that the
cylinders were shaken mildly (i.e.7- 8 strokes) and the treated oil was poured out till it flow out it self
from the cylinder on inverting it. The wax deposit (%) was determined.
Wax Inhibition Evaluation : Cold finger testing ranks chemical performance based on the weight of
wax deposited over a three hours period. Cold probe was maintained at 301C for ZB crude(6530C).After completion of the circulation through a copper coil (length 5.5 ft, ID- 5mm,OD-8mm ) with
peristaltic pump, the coil is flushed with diesel till the clear diesel comes out from the other end of
the coil. The coil is then inverted to drain the diesel and is dried overnight at room temperature.
The coil is then flushed with chilled acetone to remove loose oil if any. Percentage of wax inhibition is
calculated after running a blank experiment under similar condition.
Viscosity profile evaluation : Emulsion samples from IU, WB, ZA risers and a composite sample of
ICP line were treated with varying doses of demulsifier and PPD to determine their synergetic affect
on viscosity profile at temperature range 50C to 27C. Viscosity studies were carried out on RV-1
Haake Viscometer at a constant shear rate 511 s-1.
Results and Discussion :
Physico-chemical properties of crude oils collected from ZA and ZB riser oil lines are indicated in
Table-1. The composite emulsion of ICP ICG line have high wax 24% Resin content 6.8% and Pour
point is 360C. High pour point is indicative of high viscosity at lower temperature. Being similar in
nature most of the experiments were performed on ZB crude. Performance evaluation of five wax
dispersants i.e. A,B,C,D,E and one depressant (PPD) are mainly based on pour point and rheology
at 20C and 30C .
Table-1.
S.N.
1
2
3
4
5
6
7
8
9
10

General Characteristics of crude oil of #ZA & #ZB riser

Results
Parameters
ZB
ZA
Density (15C)
0.8430
0.8445
Specific Gravity (60/60 F)
0.8434
0.8449
API gravity
36.27
35.97
Kinamatic Viscosity at 37.8C (cst)
5.1
4.99
Water content (% vol)
Traces
1.0
BS&W ( % vol)
0.1
1.1
Asphaltene (% wt)
1.79
1.12
Resin (% wt)
2.93
2.90
Wax ( % wt)
23.86
24.7
Pour Point (C)
36
36

Petrotech-2010
31 October-3 November 2010, New Delhi, India

20C is the required temperature for performance evaluation of PPD / flow improver currently in use
at Mumbai High asset whereas 30C is the desired temperature of ZB-ICP line. Requirement as per
ONGC specification for treated crude with 350 ppm dose of PPD at 20C is PV=15CP(max),YV=10.2
Dyne/sq.cm(max) and Pour point = 18C (max) . Results at 20C and 30C are briefly discussed
below.
Rheological studies at 20C : Plastic Viscosity of neat crude was 53CP at 20C.After 14 days this
increased to 60 CP. Plastic Viscosity of the crude oil was reduced marginally on treatment with 350
ppm wax dispersants (it varied from 43-50 CP) which further increased on ageing the treated oil for
14 days. The Pour Point was not affected by the treatment and remained same i.e. equal to neat
crude oil. The crude oil treated with PPD indicated 30% decrease in Plastic Viscosity (PV-I ).No
change was observed on ageing for14 days( PV-II).17%decrease in Pour Point have been noted, it
also remained same on ageing ( Fig 1).

Fig 1.Effect of PPD treatem ent on PV

F ig .2 E f f e c t o f P P D t r e a t m e n t o n Y V

40

200

35

180
160

PV-I

30

PV-II

Y ie ld V a lu e
( D y n e s /s q .c m .)

PV (CP)

25
20
15
10
5
0
0

500

1000

1500

Y V -1

140
120
100
80
60

Y V -2

40
20
0
0

2000

500

1000

1500

2000

D o s e (p p m )

DOSE (ppm )

Yield Value of neat crude was 214.2 dynes/sq.cm at 20C and which further increased to 270.3 after
ageing for 14 days. There was an increase in Yield value from 10 to 90% on treatment with wax
dispersant samples, after 14 days the trend was observed to be same. The yield value ( YV-I ) of the
oil decreased to 173.4 (~20%) on treatment with PPD. It i.e. YV-II further reduced to 147.9 dynes
/sq.cm after 14 days. (i.e. a reduction of 45% w.r.t. neat crude). Treatment with higher dose i.e.1050
and 1750 ppm was not found effective with studied wax dispersants. While in the case of PPD at 1050
ppm dose, Plastic viscosity was reduced to 17 CP , Yield Value 10.2 dynes/sq.cm( Fig2) and Pour
Point 21C . Here reduction in Pour Point was observed almost 60% of the neat crude. After ageing
for 14 days, the value of Plastic Viscosity was further decreased to 15 CP while Yield value and Pour
Point remained same. Further increase in treatment dose to 1750 ppm proved to be of no advantage.
Rheological studies at 30C:Performance Evaluation of wax dispersant samples on ZB crude have
also been studied at 30C ( being the temperature of receiving end of flow line) with lower treatment
doses i.e. 100, 300 and 500 ppm. Main observations are:

Plastic viscosity of treated crude remained almost same as that of neat crude. However
partial decreasing trend was observed in most cases except the crude treated with dispersant
sample no. D where an increasing trend was noticed (Fig 3 ).

No significance change in Yield value was observed except the crude treated with dispersant
sample no D and E. (Fig 4 )

Pour Point was unchanged i.e. equal to neat crude oil with dispersant (Fig 5. ).

Oil treated with PPD shows a decreasing trend is observed in PV,YV and Pour point (Fig3, 4
& 5).

Petrotech-2010
31 October-3 November 2010, New Delhi, India
F ig .4 - E ffe c t o f W a x D is p e r s a n ts o n
Y ie ld V a lu e

F ig .3 - E ffe c t o f W a x D is p e r s a n ts o n
P la s tic v is c o s ity
35
30

Y v (D y n e s /
sqcm )

A
B

25
20
15
10

P V (c P )

C
D
E

5
0

PPD
0

200

400

160
140
120
100
80
60
40
20
0

A
B
C
D
E
PPD
0

600

400

600

D o se i n p p m

D o se i n p p m

200

Flow improver/ PPD was found most effective in relation to other studied dispersant hence its
performance test carried out at different concentrations i.e. 100,300, 500, 700, 900and 400
ppm to optimize the dose for ZA and ZB crudes. Results indicated in Table- 2 shows that
1. Plastic Viscosity decreased with increase of dose and stabilized at a value~8.
2. Yield Value decreased to 10.2 in ZB oil and 5.1 in ZA oil at 500 ppm which further
decreased to 5.1 on increasing the dose to 700ppm in ZB oil but remained stable on
further increase of treatment level.
3. Pour point also showed decreasing trend ((Fig 6 ). At 500 ppm dose, the pour point
was 27C of ZB oil and 24C of ZA oil , which are within the temperature range
required in the field for ZB-ICP line i.e.65 30 C and for ZA-ICP line i.e.5527C.
Table 2. Effect of Flow Improver / PPD Treatment on Crude oil of ZB and ZA riser

S.N.

1.
2.
3.
4.
5.
6.
7.

Dose
(ppm)

Neat crude
oil
100
300
500
700
900
1400

Parameters on Dosing of PPD

Rheology at 30C
Pour Point
Wax Dispersion(%)
(C )
at 27 1C
PV
YV
ZB
ZA
ZB
ZA
ZB
ZA
ZB
ZA
25
28
127.5
137.7
36
36
No flow
No flow
20
16
14
11
9
8

19
12
9
8
9
8

66.3
20.4
10.2
5.1
5.1
5.1

51.0
25.5
5.1
5.1
5.1
5.1

36
33
27
24
24
21

36
30
24
24
21
21

No flow
No flow
98.5
98.8
99.1
99.5

No flow
No flow
99.0
99.2
99.5
99.7

PV = Plastic Viscosity ( CP) ; YV = Yield Value ( Dynes /sq.cm.)

Wax deposition
Results on wax deposition tendency of crude oil of ZB riser in static condition (24 hours) at
27C (room temperature) for different doses of dispersants indicate no flow after inversion of
cylinders having crude treated with different wax dispersants (A,B,C,D,E) irrespective of
doses. Similar results were also found with PPD treated crude when100 and 300 ppm dose
was applied. However at 500 ppm dose ~1.5% deposition was observed which further
decreases marginally on increase of treatment level. Almost similar results were found with
crude oil of ZA riser(Table.2). Performance evaluation (cold finger test) of wax dispersant
under dynamic condition is indicated in Table-3. Copper tube choked when circulation was
stopped after completion of experiment with neat crude oil and A,B,C,D and E dispersant
samples . Among the studied chemicals, PPD/Flow improver is found most effective chemical
as wax inhibitor/ dispersant/depressant.

Petrotech-2010
31 October-3 November 2010, New Delhi, India
Table 3. Performance Evaluation
by cold finger test
( Dose : 500 ppm , Duration : 3hours,
Volume : 800ml ,Temp:6530 C )
S.N. Sample Weight of
%
wax
Inhibiti
deposited
on
(gram)
1
Neat
52.86
oil-ZB
2
A
51.70
2.2
3
B
46.36
12.2
4
C
49.50
6.3
5
D
50.30
4.8
6
E
52.40
0.8
7
PPD
3.90
92.8

Fig.6 Effect of PPD on Pour Point

Fig 5.Effect of Dispersant on

Pour Point

40
35

40

Pour Point ( C)

30
25
20

A
B
C
D
E
PPD

30

15
ZB

10

ZA

20
100

300

500

Dose (ppm )

500

1000

1500

D o se ( p p m)

Viscosity Profile:
Viscosity profile of emulsions is given in Fig 7. Viscosity of untreated emulsions is found to be in the
range 9.8 to 3.2 cP at 50 0C and 95 to 33 cP at 270C. Higher viscosity at lower temperature may be
due to decrease in solubility of waxes in crude oil with decreasing temperature which may lead to
crystallisation of waxes. Emulsion treated with 20 ppm dose of demulsifier and 300 ppm dose of PPD
0
0
together has good effect on viscosity profile. It ranges between 3.5 3.1 cps at (50 C-35 C) and 3.5
0
0
7.4 cps at lower (35 C-27 C) temperature range.(fig. 8).There is no effect of demulsifier dosage on
pour point of crude emulsion alone or in combination with PPD .

Fig-7 : VISCOSITY PROFILE OF UN-TREATED EMULSIONS

Fig-8: VISCOSITY PROFILE WITH 20 PPM DEMULSIFIER

& 300 PPM PPD

100
90

20

WB

18

ZA

70

IU

16

ICG-ICP Comp.

WB

ZA

IU

ICG-ICP Comp.

14
V is c o s ity c P

80

V is c o s it y c P

60

12

50

10

40

30

20

10

2
0

0
50C

45C

40C

35C

33C

30C

50C

27C

45C

40C

35C

33C

30C

27C

Conclusion:
On the basis of present studies following conclusions have been drawn :

The wax dispersants A,B,C.D & E exhibited insignificant effect on rheological parameters,
viscosity and pour point.

Treatment with PPD has been found to be effective at a dose of 500 ppm for both the crude
oil samples of ZA and ZB riser of ICP platform , as all the parameters i.e.. Plastic Viscosity,
Yield Value, Pour point and wax deposition /dispersion tendency were within required /desired
limit.

Petrotech-2010
31 October-3 November 2010, New Delhi, India

Problem of high back pressure in ICG-ICP line can be tackled by judicious use of Demulsifier
(20ppm) along-with pour point depressant (300ppm).

Further studies need to be continued for identification of an effective pour point depressant
which can reduce pour point effectively.

Acknowledgement :
Authors are grateful to ED, Western Offshore Basin , Mumbai for inspiration , encouragement ,
motivation and continued support through out the present study. Authors are also thankful to Head,
Surface chemistry, Mumbai High Asset for providing valuable inputs, suggestions and guidance .

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