6th European Sand Management Forum, March 2014, Aberdeen

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6th European Sand Management Forum, 26-27 March 2014, Aberdeen Erosion

1 6th European Sand Management Forum, March 2014, Aberdeen Erosion Management- Using Erosion Testing Combined with Erosion Modelling John Peters, NEL, UK

NEL Holds UK National Standards for fluid flow & density

measurement, flow systems and fluid dynamics World class

consultancy, measurement and testing Energy, Oil & Gas Low

2 NEL Holds UK National Standards for fluid flow & density measurement A global centre of excellence in flow measurement, flow systems and fluid dynamics World class research, development, modelling, calibration, consultancy, measurement and testing Energy, Oil & Gas Low Carbon Technologies Environment SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 2

3 Presentation Contents (Particle) Erosion Basics Factors Which Affect Erosion NEL Erosion Testing CFD Erosion Modelling Benefits of Testing & Modelling Combined Summary SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 3

4 (Particle) Erosion A major issue world-wide in oil & gas exploration & production piping systems Causes major wear, damage to piping, equipment, components Potential damage, significant errors in flow metering systems Possible Loss of Containment SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 4

5 Erosion (Sand) Particle Erosion Damage Eroded Holeoriginally 4 mm wall Flow Erosion in a hydrocyclone Erosion in a 50 mm bend downstream of a reduced-bore ball valve SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 5

6 New vs worn View of badly worn choke parts! SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 6

7 Particle Erosion Damage Around Probe Base New Wear at base of coupon / probe fitting SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 7

8 (Particle) Erosion Basics SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 8

9 In THIS Presentation... Particle Erosion t Sand particle hits a metal/hard surface Material removed SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 9

10 ... and Abrasion Wear... ONLY Sand particles go between surfaces and cause abrasive wear: Between seats, seals, into bearings Sliding surfaces - Gate Valve Rotating surface - Ball Valve SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 10

11 ... NOT TO BE CONFUSED WITH Cavitation erosion - collapse of bubbles on surfaces Liquid jet erosion - high velocity liquid jets impinging on a surface Droplet erosion - liquid droplets in a high velocity gas stream NOT COVERED IN THIS PRESENTATION ALL THESE EROSION MECHANISMS REMOVE MATERIAL SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 11

12 Compound Wear Mechanisms The potential for compound wear should also be considered One mechanism may be more dominant than the other, or two stage, such as: Particle erosion AND corrosion Sand induced corrosion: e.g. interference/ removal of corrosion inhibitor film Erosion then Corrosion: e.g. Failure of Inconel lining SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 12

13 Erosion Sand Particle Erosion Damage Impingement of high fluid/particle velocities, produces rapid wear (material removal), severe damage: Safety Issues, Hazards Loss of pressure containment- pipe rupture, Bends,Tees, wall erodes through Component breaks up, e.g. choke internals Severe wear of flow paths SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 13

14 Factors Which Affect Erosion SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 14

15 How Much Sand? Do not need much sand to give high wear:... sand + high velocity Sand production varies significantly - often small fraction % by weight < 0.01% can cause major erosion problems e.g. 0.2 kg sand for 1 MMSCF gas, or 2 kg per 1000 barrels Sand particle size ~ varies widely From microns (flour) to Typical UK North Sea... ~ 250 microns SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 15

16 Erosion Basics Particle Velocity Erosion highly dependent upon particle impact velocity... E = K.f V 2.6 SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 16

17 Erosion Basics Particle Size Generally, small particles, < 100 microns (µm) are less erosive For a given fluid, operating conditions a. Small, light particles b. Medium particles c. Large, heavy particles - few impacts on wall - more impacts, abrasion - lot of impacts and deflections SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 17

18 Erosion Basics Materials, Erosion Resistance Most steels, Inconel & Stellite - similar resistance Ceramics & Tungsten Carbide ~ times better BUT they are brittle SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 18

19 Erosion Basics Impact Angle Erosion Rate v Impact Angle Maximum Erosion Rate occurs in different locations SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 19

20 Factors Affecting Erosion Levels Particle velocity; wear = f (velocity) 2.6 Average Particle size, e.g. 250 microns, typical Materials of construction Impact Angle Quantity (mass) of sand Sand shape, sharpness, hardness Fluid flow regime - liquid, gas, multiphase Piping configuration, flow path profile, shape, complexity Equipment, component design SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 20

Nature of Erosion May be evenly distributed all-over Often small steps up/ down, changes in internal bore, surface irregularities trigger local vortices, sand becomes trapped within, rotating

21 Nature of Erosion May be evenly distributed all-over Often small steps up/ down, changes in internal bore, surface irregularities trigger local vortices, sand becomes trapped within, rotating grinding wheel!... an erosion crater rapidly develops Often very localised erosion hot-spots Once an erosion scar starts, it keeps digging HOLE Can be unstable and rapid, complex process Often not well managed or understood 90 bend- hole on inside radius of bend SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 21

22 Erosion at weld beads SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 22

23 Rotating Vortex at weld-bead FLOW Rotating vortexwith sand Erosion down-stream of a weld bead, - crater often develops SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 23

24 Abrasion Wear SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 24

Abrasion (Wear) Sand Particles Sand particles go between surfaces and cause abrasive wear: Gate valves ~ sliding surfaces Ball valves ~ rotating surfaces Into bearings and seals Leaking seals, &

25 Abrasion (Wear) Sand Particles Sand particles go between surfaces and cause abrasive wear: Gate valves ~ sliding surfaces Ball valves ~ rotating surfaces Into bearings and seals Leaking seals, & damaged seats Higher friction, higher operating forces/ torques Excessive forces, seizure of parts. Short operating life, unreliable An erosive flow test is often the only way to verify equipment s abrasion performance SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 25

26 NEL Erosion Testing SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 26

27 Typical Sand Size Distribution Used by NEL for Testing Particle Size Aperature/Mesh size microns % Retained by Weight to BS < Average size 275 microns SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 27

28 NEL Erosive Flow Facility (Sand / Water) Computer 3-D image of NEL Erosive Flow Facility (sand/water) with various flowmeters installed SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 28

29 NEL Erosive Flow Testing Controlled erosive flow conditions 20 years experience erosion testing, wear assessments Test Fluid - Water/sand, - Water /sand + viscosifier ( API slurry) - Gas/sand Different erosive wear characteristics and patterns in piping and components Accelerated testing techniques: High sand concentrations Comparison materials- hard, soft, reference materials Higher velocities Sand particle size, hardness? Scaling Wear - component life-prediction / How long to test? How much wear? SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 29

30 Erosion Testing, Wear (Material Loss) Detect, measure, assess wear (quantify/qualify) A balance, sufficient wear (measurable) v test duration Before, during and after tests Visual Inspection, photos Dimensional Measurements Vernier calipers, micrometer Co-ordinate measurements (CMM) Laser 3-D scanning -Profilometry Ultrasonic wall thickness measurements Weight Loss of components - Precision weighing Coupon Material Erosion tests SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 30

31 Benefits of Erosive Flow Testing A good performance on test is a good omen for a good performance in the field. Testing is essential to test seals, bearings and all moving parts Accelerated erosion tests are simulated under controlled conditions Testing quickly identifies any design weak points Testing identifies local erosion hot-spots Testing may show surprises, not evident from CFD SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 31

32 CFD Erosion Modelling SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 32

33 Example Erosion Equation e.g. DNV RPO501- Bend erosion equation erosion m sand. F( ).sin( ). C. A t pipe l. G. K. U n n.~ 2.6 mass of sand bend geometry Particle velocity particle size effect material properties SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 33

34 CFD Erosion Modelling Basics The flow paths are predicted using CFD SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 34

35 CFD Erosion Modelling Basics The path of sand particles is modelled SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 35

36 CFD Erosion Modelling Basics Erosion Damage caused by each particle wall collision is calculated SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 36

37 Potential Erosion Areas Down-hole equipment Wellhead Flow paths, chokes, Piping, bends Flowmeter system & inlet piping config. Piping configurations - Bends, Tees, Reducers SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 37

38 CFD Model Piping Configuration FLOW Flow Streamlines Gas Flow

39 CFD Model Piping Configuration Erosion Rate Gas Flow

40 Choke Piping Configuration With 5 Bends! Pipe 1 Choke Valve Pipe 2 FLOW Pipe 3 SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 40

41 CFD Example: Choke Body Erosion Erosion Areas SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 41

42 Erosion Scar Around a Port in a Choke Valve Cage SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 42

43 Choke Plug Accelerated Wear Test! SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 43

44 CFD View: Cone Flowmeter Water/Sand Erosion Test CFD SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 44

45 Benefits of Testing & Modelling Combined Testing often reveals erosion hot-spots not identified by the CFD. Testing can be used to validate CFD erosion model predictions Erosive Flow Testing in conjunction with CFD erosion modelling is a powerful design package to optimise component design for minimum wear Use validated CFD model to predict field wear-life of components, equipment, pipelines Form part of the tool-kit for risk management: optimising production, managing wear levels, developing sand management and maintenance strategies. SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 45

46 Summary SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 46

47 Summing Up: CFD Erosion Modelling & Testing Benefits- Erosion is a complex wear regime, many factors affect wear; high velocities give rapid wear Testing is essential to test seals, bearings, moving parts Test data validates CFD erosion model; gives increased confidence in modelling field conditions Predict the wear life of components in field conditions Design optimisation for minimal wear Part of the tool-box for pipeline integrity, risk and maintenance management. SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 47

48 Thank You for Listening Any Questions? John Peters, NEL Contact: SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 48

49 Forthcoming NEL Training Courses & Conferences Multiphase & Wet-Gas Flow Measurement Training Course; April 30 th 2014, Principles and Practice of Flow Measurement Training Course; May 13 th 2014 Produced Water & Environmental Conference; June 10 th 2014 Please visit our web-site for latest details: SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 49

50 NEL Contacts Switchboard : +44 (0) Audit & Allocation Alick MacGillivray amacgillivray@tuvnel.com CFD John Dods jdods@tuvnel.com Densitometers Norman Glen nglen@tuvnel.com Erosion John Peters jpeters@tuvnel.com Flow Consortium Phil Mark pmark@tuvnel.com Heavy Oil Chris Mills cmills@tuvnel.com Calum Hardie chardie@tuvnel.com Measurement Consultancy Craig Marshall Chris Mills cmarshall@tuvnel.com cmills@tuvnel.com Measurement Uncertainty Alick MacGillivray amacgillivray@tuvnel.com Meter Diagnostics Craig Marshall cmarshall@tuvnel.com MeterVue Phil Mark pmark@tuvnel.com Multiphase Terri Leonard tleonard@tuvnel.com PPDS Lynn Hunter lhunter@tuvnel.com Single Phase Metering Bob Belshaw bbelshaw@tuvnel.com Training Helen Tulloch htulloch@tuvnel.com Umbilicals Janice MacLeod jmacleod@tuvnel.com Valve Testing John Dods jdods@tuvnel.com Wet Gas Emmelyn Graham egraham@tuvnel.com For general queries contact the Sales Team on sales@tuvnel.com SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 50

51 Contact us + 44 (0) info@tuvnel.com SPE-SME - 6th EUROPEAN SAND MANAGEMENT FORUM Slide 51

Erosion Testing & CFD Erosion Modelling. John Peters, NEL, 29 January 2014

Erosion Testing & CFD Erosion Modelling John Peters, NEL, 29 January 2014 National Measurement System (NMS) NMS is a network of laboratories and processes Maintains national measurement infrastructure