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  3. Laboratory study of gas abrasion phenomenon containing sand and liquid droplets in pipelines

Laboratory study of gas abrasion phenomenon containing sand and liquid droplets in pipelines

Number of pages: 103 File Format: word File Code: 31798
Year: 2016 University Degree: Master's degree Category: Chemical - Petrochemical Engineering
Tags/Keywords: Abrasion of sand grains - Coupon - difficulty - Gas containing sand - gas wear - pipelines - Sand concentration - Wear rate
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  • Summary of Laboratory study of gas abrasion phenomenon containing sand and liquid droplets in pipelines

    Master's Thesis in Chemical Engineering

    Abstract

    A laboratory study of the wear phenomenon of gas containing sand and liquid droplets in pipelines

    In this work, to investigate the wear phenomenon caused by the movement Two-phase and three-phase fluids are discussed in pipelines. For this purpose, a pipeline test device including: vertical and horizontal pipelines and various connections has been made. The studied fluid consists of three phases: gas, liquid and solid. The gas phase is air, the liquid phase is water, and sand particles form the solid phase. In this research, the parameters affecting the wear rate, including: gas fluid speed, liquid fluid speed, sand particle size and hardness and density of the target metal have been studied. In order to obtain the amount of wear, disk coupons made of aluminum and steel have been used in five different places of the flow (according to the operational conditions of exploitation and transportation of petroleum materials). First, the wear rate of air and sand particles (two phases) is measured in the five mentioned places, and in the next step, the study of air wear containing sand and water particles (three phases) is investigated. At each stage, the results obtained are compared with the values ??determined by the existing standards and solutions are provided.

    The results show that at constant apparent air speed, by adding a small amount of water to the air flow, the amount of wear drops drastically. In addition, wear in vertical flow is more than horizontal flow. Also, the amount of wear in an elbow has increased from a straight pipe.

    Key words: wear of sand grains, coupon, hardness, sand concentration, wear rate

    1- Introduction

    In oil and gas industries, Extraction from the well is inevitably associated with impurities such as sand, solid particles and hydrocarbon liquids and water, which cause many problems in exploitation systems. One of the important problems of these materials is wear. Abrasion has long been recognized as a source of problems in hydrocarbon production and exploitation systems. Many dangerous failures related to elbows, pipes, chokes and measurement and control tools in exploitation platforms, drilling units and other subsea facilities in previous decades have been as a result of wear. These problems and breakdowns include the cost of replacing worn out parts as well as environmental problems and safety issues. All the pipe line inside the well is exposed to corrosion and wear, but some places that deviate from the main path or change the cross section, such as chokes, elbows, tees and subsurface safety valves, are at great risk. And finally, if the wear during the production process is not regularly monitored, predicted and controlled, it can lead to disruption or even complete closing of the well for a long period or irreparable loss of life and money.

    Necessary knowledge and awareness about the amount of wear in the components of the pipes and control tools will lead to the selection of wear-resistant materials and the design of a suitable configuration to protect the pipes and equipment against this potential threat. In the design of a pipeline or exploitation system, the amount of wear should be investigated and predicted first, so that measures such as choosing materials suitable for the intended wear, increasing the size of pipes, preventing the formation and directing of sand and liquid, etc.

    In some cases, when oil and gas are produced from reservoirs with relatively low resistance of the formation (less than 2000 psia), by reducing the pressure of the reservoir, sand particles can be separated from the reservoir rock and a number of particles can be produced together with fluids. These sand particles can cause the wear of pipelines and equipment and as a result lead to the stop of production, and therefore significant economic losses are caused to oil and gas producers.

    In cases where we need to increase production in an exploitation system due to the increase in fluid speed, it will be necessary to predict wear at higher speeds. This project is currently being implemented in Kangan, Aghar and Shanol wells.

    For the mentioned reasons, we need to control and predict the wear phenomenon. Predicting the wear of gas carrying sand and liquid in multiphase flow is a complex phenomenon, and in this condition, several factors affect the wear, which can be mentioned the impact speed, impact angle, particle size, properties of particles and liquid, percentage of sand and liquid, shape of particles and properties of the target metal. Also, there are several methods to prevent the production of sand and their entry into the production pipes, which will be explained in the following. Considering the need to predict the wear rate in this research, by designing and building a complete laboratory system to predict the wear rate, and in this way, to provide a suitable relationship in the wear phenomenon of gas with sand and gas with liquid droplets, we will eliminate the aforementioned deficiency as much as possible.

    Abstract

                                

    Experimental Study Of Liquid & Sand Erosion In Pipe Lines

     

    By

    Abdolrazagh Mahmoudi

    In this work the created erosion by the movement of two & three-phase fluids in pipelines has been investigated. The studied fluid consists of gas, liquid and solid phase. The gas phase is air, the liquid phase is water and the solid phase is sand particles. In this work, the influential parameters on erosion rate such as: superficial gas velocity, superficial liquid velocity, sand particle size, hardness and density of metal have been studied. To find out the erosion rate, ring coupons of two kinds of carbon steel and aluminum in five different locations in pipe line were used.

    First, the erosion rate for flow of air containing sand particles (two phase flow) and then the erosion rate for three phase flow of air, sand particle and water were measured in five different locations in the pipeline system constructed for this purpose.

    Finally the data from experiments indicates that for a fixed gas velocity, the erosion decreases substantially if a small amount of liquid is injected into the gas stream. Additionally, the erosion in the vertical flow is greater than the horizontal flow and the erosion rate in the elbow is higher than straight pipe.

  • Contents & References of Laboratory study of gas abrasion phenomenon containing sand and liquid droplets in pipelines

    List:

    1-Introduction:. 2- Theoretical foundations of research 5- 2-1- Definition of wear. 5- 2-1-1- Type of target metal and impact angle 7- 2-1-2- Effect of hardness of target metal. 9

    2-2- Definition of corrosion. 10

    2-2-1- Uniform attack. 10

    2-2-2- galvanic corrosion. 11

    2-2-3- Crevice corrosion. 11

    2-2-4- Preferential washing. 11

    2-2-5- Intragranular corrosion. 12

    2-2-6- pitting corrosion. 12

    2-2-7- erosive corrosion. 12

    2-2-8- Stress corrosion. 13

    2-3- Wear mechanisms...................13

    2-3-1- Drop wear: 13

    2-3-2- Wear caused by sand grains. 14

    2-3-3- cavitation phenomenon. 21

    2-3-4- wear corrosion. 22

    2-4- Abrasion caused by air flow, sand and water..............24

    2-5- Methods used to measure and report the rate of wear... 26

    2-5-1-Measurement method by coupons 26

    2-5-2- Ultrasonic measuring devices. 29

    2-5-3- Electrical resistance probes. 30

    2-5-4- Electrochemical probes. 31

    2-6- Solutions to reduce wear. 31

    2-6-1- Reducing production flow. 32

    2-6-2- Piping system design. 32

    2-6-3- Special wear-resistant materials. 32

    2-6-4- Increasing the thickness of the pipe wall. 33

    2-6-5- Preventing the production of sand and its separation. 33

    3-Review of past research. 36

    3-1- An overview of the standard formula ...............API38

    3-2- Suitable equation for sand..................39

    3-3- Equations of the University of Tulsa Corrosion and Wear Research Center........42

    3-4- Simulation with software.................44

    4- Research method.................................49

    4-1- Device Test................... 49

    4-2- Preparation of sand.....................58

    4-3- Procedures for conducting experiments:..................59

    4-4-Analysis............................60

    5-Results..........................64

    5-1- Effect of sand size on wear in two-phase flow............65

    5-2- Effect of injection water amount in three-phase flow 66

    5-3- Effect of particle size in three-phase flow...............68

    5-4- Comparison of wear in elbow and vertical pipe..............69

    5-5- Comparison of horizontal and vertical elbow..................70

    5-6- Comparison of coupon types..................71

    5-7- Appearance analysis.................................72

    5-7-1-electron microscope. 73

    5-7-2-Coupons analysis with electron microscope. 74

    6-Conclusion and suggestions 83

    6-1- Conclusion......................83

    6-2- Suggestions......................84

    7-Resources........................86

    Source:

    1-            

    [1] Ken Jordan (1998). "EROSION IN MULTIPHASE PRODUCTION OF OIL & GAS." Corrosion98., paper No.58.

    [2] Mysara E. Mohyaldinn, Noaman Elkhatib, Mokhtar C. Ismail (2010). "A Computational tool for erosion / corrosion prediction in Oil / Gas production plant." ICSSST20103rd International Conference on Solid State Science & Technology. [3] N.A. Barton (2003). "Erosion in elbows in hydrocarbon production systems: Review document." Health and Safety Executive.

    [4] S. J. Svedeman (1993). "Experimental study of the erosion / corrosion velocity criterion for sizing multiphase flow lines." NACE., paper no. 02669.

    [5] Y Zhang, B Mclaury, S.A. Shirazi (2009). "Improvements of Particle Near-Wall Velocity and Erosion Predictions Using a commercial CFD Code Department of Mechanical Engineering." Journal of Fluids Engineering., vol 131.

    [6] S.A. Shirazi (1994). "Threshold Velocities How fast can you flow and still avoid sand erosion problem?" E/CRC.

    [7] A. Keating (2000). "Numerical Prediction of erosion corrosion in bends." Department of Mechanical Engineering, The University of Queensland.

    [8] Q. H. Mazumder, S. A. Shirazi and B. S. McLaury (2004). "A MECHANISTIC MODEL TO PREDICT SAND EROSION IN MULTIPHASE FLOW INA MECHANISTIC MODEL TO PREDICT SAND EROSION IN MULTIPHASE FLOW IN ELBOWS DOWNSTREAM OF VERTICAL PIPES. NACE., paper no. 04662.

    [9] A. Gnanavelu, N. Kapur, A. Neville, J.F. Flores, N. Ghorbani (2011). "A numerical investigation of a geometry independent integrated method to predict erosion rates in slurry erosion."  Wear 271., 712– 719.

    [10] Y Zhang, B Mclaury, S.A. Shirazi (2010). "A TWO-DIMENSIONAL MECHANISTIC MODEL FOR SAND EROSION PREDICTION INCLUDING PARTICLE IMPACT CHARACTERISTICS." Erosion/Corrosion Research Center Department of Mechanical Engineering The University of Tulsa NACE., paper no. 10378.

    [11] Xianghui Chen, Brenton S. McLaury, Siamack A. Shirazi (2004). "Application and experimental validation of a computational fluid dynamics (CFD)-based erosion prediction model in elbows and plugged tees." Computers & Fluids 33 ., 1251–1272.

    [12] S. N Shah, S Jain, Y, Zhu (2005). "Coilded Tubing erosion during hydraulic slurry flow." SPE 89479.

    [13] J. Andrews (2005). "Production enhancement from sand management philosophy, A Case Study from Statfjord and Gullfaks." SPE94511.

    [14] M. Bailey, I.L. Blanco and R.S Rosine (2001). "Comparison of computational CFD of erosion in coiled tubing on reel-to-injector flow area." SPE 121171.

    [15] M. Bailey, I.L. Blanco and R.S Rosine (1998). "Comparison of computational CFD of erosion in coiled tubing to field and test data."  SPE 113619.

    [16] K. Jordan, Erosion in multiphase production of Oil and Gas, Corrosion 98., paper No 58.

    [17] M. MOHYALDIN1, N. ELKHATIB, M. CHE ISMAIL (2007). "Evaluation of Different Modeling Methods Used for Erosion Prediction."  NACE Shanghai. , paper no. 11005.

    [18] B.S. McLaury, and S.A. Shirazi (1998). "Generalization of API RP 14E for Erosive service in Multiphase Production." SPE 5681.

    [19] O. Njobuenwu, M (2012). "Fair weather modeling of pipe bend erosion by dilute particle suspensions." Computers and Chemical Engineering.

    [20] D. TENG, G. NETTLESHIP, S. HICKING, K. HINDMARSH (1998). "HIGH RATE GAS WELL DESIGN: ISSUES AND SOLUTIONS GOODWYN GAS CONDENSATE." SPE 50081.

    [21] Chenliang Fan, Brenton S. McLaury, Siamack A. Shirazi and Edmund F. Rybicki (2012). "Experimental Research of Sand Erosion in Gas Dominant Flows." NACE., C2012-0001422.

    [22] Mamdouh M. Salama (1998). "An Alternative to API 14E Erosional Velocity Limits for Sand Laden Fluids." SPE., OTC 8898. [23] E.S. Vankatesh (1986). "Erosion damage in oil and gas wells." SPE 15183.

    [24] M.M. Salama and E.S. Venkatesh (1983). "Evaluation of API RP 14E Erosional Velocity Limitations for Offshore Gas Wells." SPE., OTC 4485.

    [25] Ri Zhang, Haixiao Liu, Chuntian Zhao (2013). "A probability model for solid particle erosion in a straight pipe." Wear., Wear308(2013)1–9.

    [26] B.S. McLaury, J. Wang, S.A. Shirazi, J.R. Shadley, E.F. Rybicki (1997). "Solid particle erosion in long radius elbows and straight pipes". in: Proceedings of SPE Annual Technical Conference and Exhibition, San Antonio., TX, SPE 38842.

    [27]Ronald E. Vieira, Netaji R. Kesana, Siamack A. Shirazi, Brenton S. McLaury (2014). "Experiments for Sand Erosion Model Improvement for Elbows in Gas Production, Low-Liquid Loading and Annular Flow Conditions." CORROSION2014., Paper No. 4325.

    [28] N.A. Barton (2003). "Erosion in Elbows in Hydrocarbon Production Systems: Review Document." Research Report 115, HSE, ISBN 0 7176 2743 8.

    [29] J. R. Shadley, S. A. Shirazi, E. Dayalan, and E. F. Rybicki (1998). "Prediction of ErosionCorrosion Penetration Rate in a CO2 Environment with Sand," CORROSION/98., paper no. 59.

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Laboratory study of gas abrasion phenomenon containing sand and liquid droplets in pipelines
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