Case Study

CFD Erosion Analysis

Oil & Gas Operator

Project
Summary

An oil and gas operator wished to

determine the levels of erosion in
their subsea well production system.
This was achieved through NELs CFD
modelling capability. Erosive flow was
simulated in the system under various
operating conditions, to determine the
highest levels of erosion. These results
allowed the client to take preventative
measures to extend the life of their
components in the field.

The Issue
As hydrocarbon recovery becomes more challenging
worldwide, there is an increasing risk of sand being
produced alongside oil and gas. Sand and other
particles impinge on internal wall surfaces and erode
away material from the production system, reducing
the life of components. As a result it is important to be
able to predict the lifetime of production systems and
components to ensure that unexpected failure and loss of
containment due to erosion does not occur.

The Approach
The client wished to determine if the erosion in their
subsea production system was likely to exceed a
specified maximum limit per annum. Drawing on NELs
experience of 20 years independent erosion analysis and
consultancy, NEL worked closely with the client to

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determine a series of complex piping configurations for

analysis, which represented the field configuration.
Using CFD, the configuration would be simulated over a
range of erosive flow conditions, together with different
construction materials, to determine wear rates and
locations.

The Solution
NELs fluid dynamics engineers created a 3D model of
the production system, which included a choke valve,
T-bends and a Venturi tube. CFD erosive flows were
simulated for the various conditions, giving predicted
erosion levels and wear paths throughout. The location
and severity of the erosion levels were analysed and the
wear paths compared and ranked for each case. It was
found that maximum predicted erosion levels in many
cases exceeded the upper limit for the system.

Benefits to Client
NEL provided valuable erosion wear data to the client. It
allowed them to determine erosion hotspots within their
system, and predict the operating life of their equipment.
These predictions enabled the client to take preventative
measures to extend the life of components and revise the
choke design/ material specifications. Erosion data can
also be used to review operating conditions with regards
to limiting erosive wear in the field. The data also helped
the client to develop more robust risk failure analysis and
erosion inspection management programmes.

TUV

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Client