E i T ti Erosion Testing

& CFD Erosion Modellingg

John Peters, NEL ,
29 January 2014
National Measurement System (NMS) National Measurement System (NMS)
NMS is a network of laboratories and processes p
Maintains national measurement infrastructure
Represents position of UK measurement Represents position of UK measurement
NEL (Scotland, UK) ( )
UK National Standard for Fluid Flow and Density
Measurement
A global centre of excellence in flow measurement,
flowsystems and fluid dynamics. flow systems and fluid dynamics.
World class research, development, modelling,
calibration consultancy measurement and testing
Energy, Oil & Gas Low Carbon Technologies Environment
calibration, consultancy, measurement and testing
(Particle) Erosion (Particle) Erosion
A major issue world-wide in oil & gas exploration
d d ti i i t and production piping systems
Causes major wear damage to piping Causes major wear, damage to piping,
equipment, components
Potential damage, significant errors in
flowmetering systems g y
Contents Contents
(Particle) erosion basics
Factors which affect erosion
NEL erosion testing
CFDerosion modelling CFD erosion modelling
Benefits of combined testing &modelling Benefits of combined testing & modelling
Summary
(Particle) Erosion Basics
Erosion- (Sand) Particle Erosion Damage Erosion (Sand) Particle Erosion Damage
Eroded hole-
originally
4mm wall
Erosion in a hydrocyclone
Flow
Erosion in a hydrocyclone
Erosion in a 50mm bend
downstream of a valve
Choke valve severe wear
Erosion Damage at base of coupon/ probe fitting
New fitting
Particle Erosion Particle Erosion
Sand particle hits a metal/hard surface
Material removed Material removed
t
In This Presentation..
Particle Erosion - impingement of particles on Particle Erosion - impingement of particles on
material surfaces, removal of material
Abrasion Wear - particles rubbing across
f b t i t i t b i surfaces, between moving parts, into bearings
ONLY
DO NOT CONFUSE WITH .
Cavitation erosion - collapse of bubbles on
surfaces surfaces
Liquid jet erosion - high velocity liquid jets
impinging on a surface impinging on a surface
Droplet erosion - liquid droplets in a high velocity
t i i i f gas stream impinging on a surface
. NOT COVERED IN THIS PRESENTATION
ALL THESE EROSION MECHANISMS REMOVE MATERIAL!
Compound Particle Wear Mechanisms Compound Particle Wear Mechanisms
The potential for compound wear should also be p p
considered. One mechanism may be more
dominant than the other, or two stage such as: , g
Particle erosion AND corrosion
Particles and multiphase flows
Sand induced corrosion -
e.g. interference/removal corrosion inhibitor film
Erosion then corrosion Erosion then corrosion -
e.g. failure of Inconel lining
Erosion Sand Particle Erosion Damage Erosion Sand Particle Erosion Damage
lmpingement of high fluid/particle velocities,
d id ( t i l l) produces rapid wear (material removal)
Rapid, severe levels of damage, wear:
Safety issues, hazards
Loss of pressure containment - pipe rupture
B d t ll d th h Bends, tees, wall erodes through
Component breaks up, e.g. choke internals
Internal wear of down-hole equipment Internal wear of down-hole equipment
New vs worn
View of badly worn chokes !
Factors Which Affect Factors Which Affect
Erosion
Erosion- How Much Sand ?? Erosion How Much Sand ??
Do not need much sand. (sand + high velocity)
Sand production varies significantly - often small
fraction % by weight
< 0.01% can cause major erosion problems
e.g. ..... 0.2 kg for 1 MMSCF gas,
or 2 kg per 1000 barrels
Sand particle size varies widely
From 25-40 microns (flour) to ...150...300450+
Particle Erosion Basics Particle Erosion Basics
Erosion highly dependant upon impact velocity g y p p p y
Small particles < 60 microns (m) are often less
erosive than bigger particles >150 microns erosive than bigger particles >150 microns
Most steels, Inconel & Stellite - similar resistance
Ceramics & Tungsten Carbide 10-100 times better
BUT they are brittle y
Factors Affecting Erosion g
Fluid velocity: Wear = f (velocity)
2.6
Quantity (mass) of sand Quantity (mass) of sand
Average particle size e.g. 250 microns, typical
Sand shape, sharpness, hardness
Fluid flow regime - liquid, gas, multiphase g q , g , p
Piping configuration, flow path profile, shape
Equipment component design Equipment, component design
Materials of construction
Angle of impingement
Wear-rate vs Impingement Angle
M i E i O i Diff t L ti Maximum Erosion Occurs in Different Locations
1
0 7
0.8
0.9
0.5
0.6
0.7
Tungsten Carbide
Ductile Metal
0.2
0.3
0.4
Ductile Metal
0
0.1
0.2
0 20 40 60 80 100 0 20 40 60 80 100
Angle (degrees)
Nature of Erosion Nature of Erosion
May be evenly distributed all-over
Often very localised erosion hot-spots
Often small steps up/down, changes in internal p p , g
bore, surface irregularities trigger local vortices,
sand becomes trapped within, rotating pp , g
grinding wheel !........an erosion crater develops
Once an erosion scar starts, it keeps digging Once an erosion scar starts, it keeps digging
Can be unstable and rapid, complex process
Often not well managed or understood Often not well managed or understood
Abrasion Wear
Abrasion - Sand Particles
Sand particles get between surfaces and cause
abrasive wear abrasive wear
Badly scored ball Badly scored ball
Gate valves sliding surfaces
Abrasion (Wear) - Sand Particles
Into bearings and seals
Leaking seals valve seats Leaking seals, valve seats
Higher friction, higher operating forces/torques
E i f i f t Excessive forces - seizure of parts
Downhole equipment
Often short operating life
Erosion testing verifies performance Erosion testing verifies performance
Erosive Flow Tests: Valves (Abrasion) Erosive Flow Tests: Valves (Abrasion)
Sand in ball valve seat assembly Seat leakage
NEL Erosion Testing
Typical Sand Particle Size Distribution Typical Sand Particle Size Distribution
Used by NEL for Testing
Particle Size
Aperature/Mesh size
microns
% Retained by Weight to
BS 410

710
500

0.7
3.9 500
355
250
180
3.9
16.2
44.8
28.4
125
<125

5.5
0.5


Average size 275 microns
C t 3 Di f NEL E i Fl F ilit ( d/ t ) Computer 3-D image of NEL Erosive Flow Facility (sand/water)
with various flowmeters installed.
Water-Sand Erosion Facility Water-Sand Erosion Facility
Facility design, development supported by Facility design, development supported by
National Measurement System (NMS)
Currently undertaking NMS flowproject to Currently undertaking NMS flow project to
assess the performance of different flowmeters in
erosive flowconditions erosive flow conditions
Compare before and after test results, findings
Present results at a flow conference
NEL Erosive Flow Testing NEL Erosive Flow Testing
Definitive erosion performance data p
Independent tests, controlled conditions
Design development work Design, development work
Performance testing, evaluation
Endurance, valve cyclic testing
Product verification testing
API slurry testing - with viscosifier
NEL Erosion Testing g
Controlled erosive flow conditions,
similar to/simulate field conditions similar to/simulate field conditions
Fluid - water/sand or gas/sand
Diff t i h t i ti d tt i Different erosive wear characteristics and patterns in
piping and components
Accelerated testing techniques: Accelerated testing techniques:
High sand concentrations
Soft materials, hard materials, reference materials
Higher velocities Higher velocities
Sand particle size
Scaling wear g
Erosion Testing- Wear (Material Loss) g ( )
Detect, measure, assess wear (quantify/qualify)
Abalance sufficient wear (measurable) vs time A balance, sufficient wear (measurable) vs time
Before, duringand after tests
Visual inspection, photos
Dimensional measurement
Vernier calipers micrometer Vernier calipers, micrometer
Co-ordinate measurements (CMM)
Laser 3-d scanning - profilometry
Ult i ll thi k t Ultrasonic wall thickness measurement
Precision weighing
Comparison materials Comparison materials
Coupon erosion tests
UT matrix on a pipe elbow
Benefits of Erosive Flow Testing
Good performance on test = good in the field
Testing essential to test seals bearings and all Testing essential to test seals, bearings and all
moving parts
Accelerated field conditions simulated under Accelerated field conditions - simulated under
controlled conditions
T ti id tifi Testing identifies
Design weak points
L l i h t t Local erosion hot-spots
Show surprises, not evident from CFD
CFD Erosion Modelling
Erosion Equations os o quat o s
n
l
d
U K G
C F
m erosion . . .
). sin( ). (
.

=

pipe t
sand
U K G
A
m erosion . . .
.
.

Erosion Equations os o quat o s
e.g. DNV RPO501 bend erosion equation
C F ) i ( ) (

n.~ 2.6
f d
n
pipe t
l
sand
U K G
A
C F
m erosion . . .
.
). sin( ). (
.

ti l l it
mass of sand
p p

bend geometry
particle size effect
particle velocity
material properties
CFD Example: Check Valve
Calculation process
FLOW
Define Geometry
Mesh Velocity magnitude
Define Geometry
Mesh Velocity magnitude
CFD Example: Check Valve
Streamlines
CFD Example: Check Valve
Particle path prediction
Small Particles Large Particles
CFD Example: Check Valve
Contours of erosion
Health & Safety Executive: Health & Safety Executive:
Failed Piping Investigation Erosion?




FLOW




FLOW

50mm nb
reduced bore
ball valve
Elbow 1
(eroded in field) (eroded in field)
Piping Configuration Piping Configuration
Eroded hole
Flow
Original Wall
thickness
approx. 4mm
S ti f 50 b i lb Section of 50mm bore pipe elbow
Air-Sand Tests - Effect of the Reduced-Bore Valve
1 2
1.4
Without valve
1
1.2
With valve
0.6
0.8
0.4
0
0.2
0 10 20 30 40 50 60 70 80 90
Angle (degrees)
CFD Model of Valve & Bend: Wet Sand/Gas vs Dry Gas/Sand
mm/year mm/year
Wet Gas/Sand Dry Gas/Sand
Investigation Concluded
Fitting a bend on the outlet of reduced bore valve
caused sand particles to be concentrated into p
smaller impingement area on the bend
Erosion pattern observed on the wall of the bend Erosion pattern observed on the wall of the bend
not like dry gas pattern (NEL tests); like the wet
gas CFD prediction gas CFD prediction
NEL produced HSE Erosion Review Document
Erosion in Elbows in Hydrocarbon Production Erosion in Elbows in Hydrocarbon Production
Systems: Review Document. HSE 2003
Research Report 115 Research Report 115
Potential Erosion Areas
Wellhead Flow
paths, chokes,
Down-hole
equipment
p
Piping, bends
q p
Piping
configurations -
Flowmeter system
&
Bends, Tees,
Reducers
&
inlet piping config.
Piping Configuration
FLOW FLOW
Meter Piping Configuration Meter Piping Configuration
FLOW
CFD Example: Choke Body Erosion CFD Example: Choke Body Erosion
FLOW
Erosion areas
Erosion Scar Around a hole in a Choke
Valve Cage
Choke Plug Accelerated Wear Test ! Choke Plug Accelerated Wear Test !
Cone Flow Meter - Water/Sand Erosion Cone Flow Meter Water/Sand Erosion
Test
FLOW
CFD
NEL Erosion Testing & CFD Modelling NEL Erosion Testing & CFD Modelling
Extensive knowledge & experience - g p
Design, develop test programme, fabricate test
fixture, piping configuration
Determine test parameters
Undertake erosion test programme
Inspect measure and assess wear levels throughout Inspect, measure and assess wear levels throughout
Determine CFD erosion model predictions
Compare, validate CFD model with test data Compare, validate CFD model with test data
Report wear findings
Use CFD model to predict field wear-life
Benefits of Testing & Modelling Combined Benefits of Testing & Modelling Combined
Testing can validate CFD erosion model
di ti predictions
Powerful design combination- to optimise
component design for minimum wear
Validated CFD model - simulate and predict field p
wear-life of components & pipelines
Tool-kit Tool kit
Optimise production, minimise wear
Risk Assessment & management - develop sand
management & maintenance strategies.
Sand Management
Sand Management g
Minimise and eliminate sand production
I t ll d h l Install down-hole screens
Gravel packs
Install sand traps
Optimise production rates
Sand Management g
Sand tolerant system
D i d ti i t i i t Design, production equipment, piping system
Understand erosive flow regimes
Install sand monitors, monitor sand production
Wear-life prediction, maintenance programme
On-line Sand Monitoring
Different types of monitors
Intrusive Intrusive
Non-intrusive
Optimise production minimise sand rate Optimise production - minimise sand rate
Measure sand rate, quantify sand over time
Use to estimate material loss
Monitor critical wear areas, wear rate
prediction
On-line Sand Monitoring
Factors influencing performance
Design process conditions flowregime Design, process conditions, flow regime,
liquid/sand/multiphase
Piping configurations, location, installation
Set-up/calibration, operation, reliability,
repeatability, accuracy
Summary
Summing Up
Erosion is a complex wear regime: small
changes can significantly affect wear levels g g y
Erosive flow testing is essential to understand the
wear characteristics of components and validate wear characteristics of components and validate
equipment performance
CFDerosion models need to be validated with CFD erosion models need to be validated with
test data to have confidence in modelling field
conditions conditions
Summing Up g p
Erosion Testing often identifies an erosion hot-
spot which CFDmodel doesnt show! spot, which CFD model doesnt show!
CFD can optimise designs for erosion: predict the
wear life of components in field conditions wear life of components in field conditions
Part of the tool-box for pipeline integrity, risk and
i t t maintenance management
Thank you for listening Thank you for listening
Any questions? Any questions?
Forthcoming NEL Erosion Presentations Forthcoming NEL Erosion Presentations
Subsea UK, Aberdeen
5 6 February 2014 5-6 February 2014
AOG Conference, Perth, Australia , ,
19-20February 2014
6
th
E S d M t F 6
th
European Sand Management Forum,
Aberdeen
26 27 M h 2014 26-27 March 2014
Contact me at email: jpeters@tuvnel com Contact me at email: jpeters@tuvnel.com
NEL Contact Tel: + 44 (0) 1355 220222
NEL Contacts
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 Erosion John Peters jpeters@tuvnel.com
Flow Consortium Phil Mark pmark@tuvnel.com
Heavy Oil Chris Mills cmills@tuvnel.com
M t C lt
Calum Hardie
C i M h ll
chardie@tuvnel.com
h ll@t l 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 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 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 y g @
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