Sand Erosion Experiments and Model Development for UNS N06625 Cladding and UNS S32750

Zhang, Yongli; Gharaibah, Emad; Friedemann, John D.; Kulkarni, Guruprasad; Devi, R. Ganga; Dasan, B.; Mathew, P. Mani

doi:10.4043/23356-ms

Cited by 5 publications

(1 citation statement)

References 7 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The parameters in the material response model are typically derived from sand-blast tests performed on small coupons and different models have been developed for different materials (e.g. Zhang et al, 2012). In SPPS and RPO501 the material response model parameters can be changed, so that erosion can be predicted in components made of different materials.…”

Section: Erosion Prediction Methodsmentioning

confidence: 99%

Improving Erosion Assessment Through High-Fidelity CFD Simulation Methods

Barton¹,

Lewis²,

Emmerson³

2015

All Days

View full text Add to dashboard Cite

Pipework erosion is becoming an increasing issue within the oil and gas industry. New, high-rate subsea wells and associated topsides tie-ins are particularly vulnerable to erosion, and the consequences of failure are considerable.Accurate prediction methods can be used to improve pipework design, inspection regimes and operating limits. This paper assesses the accuracy of erosion predictions made using simple equations, conventional computational fluid dynamics (CFD) erosion simulations and high-resolution CFD methods.Correlation-based prediction methods, such as those in DNV RPO501, are effective for screening purposes, but they only deal with simple pipe fixtures such as single bends. CFD is often used to assess more complex layouts such as manifolds or flow lines. However, the standard CFD approach typically assumes a steady state flow and a homogeneous multiphase mixture. Recent comparison with large-scale tests has shown that CFD can effectively predict the flow-induced vibration forces caused by liquid-gas mixtures. In this work, the same liquid-gas modelling techniques have been used, with an additional sand particle phase, to assess pipework erosion.In wet gas flow, a thin annular liquid film typically coats the pipe walls. Test work has shown that wall-films can significantly reduce erosion rates by slowing and redistributing sand impacts. The homogeneous approach used in most correlations and typical CFD studies ignores this effect and these methods tend to over-estimate erosion rates. This ultimately results in overly-conservative pipework design and production limits. It was found that high-fidelity CFD simulations that explicitly model the liquid, gas and sand correctly predict a reduction in erosion when a liquid film is present. The predicted flow regime is consistent with physical observations and the gas-liquid-sand model more closely predicts experimental test results.This work demonstrates the benefits of explicitly modelling separate gas, liquid and sand phases, comparing predictions with published test data and showing the effects of higher-resolution simulations in a typical subsea pipework configuration.

show abstract

Section: Erosion Prediction Methodsmentioning

confidence: 99%

Improving Erosion Assessment Through High-Fidelity CFD Simulation Methods

Barton¹,

Lewis²,

Emmerson³

2015

All Days

View full text Add to dashboard Cite

show abstract

Use of Computational Fluid Dynamics Model for Evaluating Performance of High Pressure High Temperature Wells

Yuan

Bello

2014

All Days

View full text Add to dashboard Cite

The importance of performance monitoring is growing as the number of high-pressure, high-temperature (HPHT) wells continues to increase in deepwater and ultra-deepwater fields. Accurate prediction of HPHT well performance is essential for enhancing deepwater oil and gas production operations. Applying computational fluid dynamics (CFD) modeling to three- phase gas-oil-water flow in HPHT well conditions is an emerging concept. Multiphase flow in HPHT wells is extremely complex and depends on a multitude of effects including the properties of gas/oil/water, well geometries and configurations, operating pressures and temperatures, and multiphase flow patterns. In this work, simulations have been performed for three-phase flow in HPHT wells using CFD modeling techniques. The calculated results for phase velocity, pressure and temperature distribution are discussed in detail. The CFD simulation results are compared with measured field data and a finite difference-based mechanistic model. Reasonable agreements are achieved. Extensive parametric analysis of the three-phase flow system is performed to validate the viability of the CFD model as a predictive tool. The CFD model is demonstratively capable of predicting pressure drop and multiphase flow profiles in the HPHT well throughout various simulated production conditions. The experience gained from the CFD model studies can potentially improve the operations of HPHT wells in terms of increased productivity and enhanced reservoir management. In addition, results demonstrate the capability of the CFD model to predict various multiphase phenomena associated with HPHT well operations.

show abstract

Sand Management and Erosion Prediction Models for Oil and Gas Applications - Experimental and Numerical Validation Studies

Gharaibah

Zhang

2016

Day 2 Tue, September 27, 2016

View full text Add to dashboard Cite

Due to the recent drop of the oil prices, the oil and gas industry is experiencing tremendous pressures to reduce costs. This is especially true for both oil and gas production systems (OGPS) development and operations to ensure profitability while meeting increasing regulatory requirements. Sand production and erosion can present rigorous challenges during the design and production phases of the OGPS and lead to significant increase in the CAPEX and OPEX. Thus, the accurate prediction of the erosion rates, location of erosion hotspots and expected sand accumulation zones in production system is a key task during the design, as well as for the development of sand monitoring systems used during the production phase. In the recent years, simulation of multiphase flows including sand management and erosion prediction has become a powerful engineering tool in the oil and gas industry. It can be applied to conduct virtual experiments to help designing the OGPS during the project design phase. There have been many significant improvements to the modelling approaches including more details of the flow physics, rapid development of the computational resources, and the adaption of modelling methodologies from other industries such as aviation and automobile. However, the generic simulation models and tools must be validated and tested before they can be used in the design, product development or monitoring systems of the oil and gas specific applications. In addition, high fidelity flow and erosion simulations can minimize the cost of the production system design and operation optimization as they enable sensitivity studies for large number of design variations and production condition sets – provided they present an industrial application in terms of short simulation runtime and low resource effort. Recently, GE Oil & Gas made an effort for examining the validity of existing erosion prediction correlations and modelling approaches in commercial Computational Fluid Dynamics (CFD) software. Sand particles transport and erosion laboratory experiments – on different materials as well as for OGPS-like flow loop configurations with test conditions close to the actual OGPS operation conditions – were performed to gather test data that can be used for the validation of the numerical simulations. The objective of this paper is to present part of the effort, focusing on the geometry and piping elements' arrangements (in particular bends arrangements) impact on the erosion rates and erosion hotspot locations, the validation results of 1D tools and 3D CFD erosion prediction models and the comparison to the test data. Furthermore, future development required to enhance the accuracy of the modelling results and the uncertainties are addressed. The major challenges to all methods are 1) erosion prediction for very small sand (<50 μm), 2) lack of quality field data for validation and improvement, 3) high level of uncertainty due to the complexity of the erosion process. Significant inconsistency between the erosion predicted by different models was the driver for the effort. Choosing one or the other in certain applications is not always obvious and can be difficult to justify, yet they can give very different results. The community needs to fully understand the situation and look for a solution.

show abstract

Sand Erosion Experiments and Model Development for UNS N06625 Cladding and UNS S32750

Cited by 5 publications

References 7 publications

Improving Erosion Assessment Through High-Fidelity CFD Simulation Methods

Improving Erosion Assessment Through High-Fidelity CFD Simulation Methods

Use of Computational Fluid Dynamics Model for Evaluating Performance of High Pressure High Temperature Wells

Sand Management and Erosion Prediction Models for Oil and Gas Applications - Experimental and Numerical Validation Studies

Contact Info

Product

Resources

About