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Abstract
Ve = C/Yj)
where
Ve = the maximum allowable erosional velocity in ftlsec
p = the density of fluid in Ib/cu ft at flowing conditions of
temperature and pressure
C = a constant generally known as the C factor, is in the
range of 100 to 125
Ve
C/Yj)
(1)
where
Ve
p
C
known as the C
factor
For a sand-free, two-phase flow situation, the C factor
is limited to 100 for continuous flow and 125 for intermittent
flow. The API RP14E recommends the use of a lower
unspecified C factor for fluids containing sand.
A method for calculating erosion damage as a function of fluid and flow characteristics is proposed. This
approach can be used to calculate a limiting flow velocity for
any specified allowable erosion rate.
Introduction
OTC 4485
Erosion Mechanisms
Erosion is defined as the physical removal of material
from the surface. This is different from corrosion, which
involves material removal by chemical or electrochemical
reaction. The material removal by erosion is caused by one
or more of the following:
B h1 / 6
vp
(3)
= the fluid
(4)
V --~-~
vp
- vp
=~
(2)
where
The total pressure drop along the flow path (ilP) is composed of four components. These are the pressure drops in
the reservoir, across the completion, along the production
tubing, and across any restriction. A typical total pressure
V =
372
VW
(5)
OTC 4485
where
or
=
=
(6)
U = K ~~2
Equation (6) has the same form as the API empirical Equation (1). The value of C based on this criterion is far higher
than that proposed by the API equation. It is clear from the
above discussion, therefore, that the current API erosional
velocity limitation seems to be extremely conservative.
f3
(7)
where
U = the volume of metal eroded
W = the total weight of impinging solid particles
V = the particle velocity
P = the penetration hardness of the target material
~ = a coefficient which depends on the impingement
angle. It equals 1.0 for angles between 10 and 60
degrees and 0.50 for other angles. 12 For the fully
developed turbulent flow system, as in the case of a
producing well system, ~ is appropriately chosen as
0.75.
K
a nondimensional erosive wear coefficient.
Rabinowicz 12 has shown by statistical analysis of
the experimentally determined K values that the
mean value is 0.0103. A reasonable value for K in
the case of the producing well system can be based
on mean piUS two standard deviation. This value for
K is 0.071.
g = the graVitational constant (32.2 tvsec 2 )
2
- K (0.65 W) V (~)
h gP ('IT/4 d 2)
"
(8)
945
where
h = erosion rate (mils per year, mpy)
W = sand flow rate (bbl/month; barrel of sand
pounds)
V = fluid flow velocity (ftlsec)
P = hardness (psi)
d = pipe diameter (inches)
g = gravitational constant (32.2 ftlsec2)
A = correction factor for proper units
Conclusions
1. Erosion damage in gas-producing wells occurs primarily
due to solid particle impingement.
. .. .. .. ... (10)
108
1.36
5 WV
1.86 X 10 P d2
OTC 4485
Acknowledgements
Comparison between the predicted erosion rate using Equation (10) and experimental data developed as part
of API -OSAPR- project 2 on sand erosion by Texas A&M
University Research Center 14 is shown in Table 2. The
results illustrate the validity of Equation (10) in predicting
sand erosion rates. On the average, Equation (10) overestimates the erosion rates by a factor of 1.44.
WV2
93,000 P d2
References
1API RP14E, "Recommended Practice for Design and
Installation of Offshore Production Platform Piping System," Third Ed., December 1981.
(11)
V=
4d
\liiJ
(12)
12
= \TiiT
4Baker, D. W.; Jolliffe, K. H.; and Pearson, D., "The Resistance of Materials to Impact Erosion Damage," Phil.
Trans. Roy. Soc., London, Vol. 260A, p. 168, (1966).
5Hobbs, J. M., "Factors Affecting Damage Caused by
Liquid Impact, National Engineering Laboratory Report
No. 266, December 1966.
(13)
374
OTC 4485
where
p
V
P
10 psi)
Ec
g
K
AV
(A1-2)
11Rabinowicz, E, "The Wear Equation for Erosion of Metals by Abrasive Particles," Proc. Fifth Int. Conf. on Erosion by liquid and Solid Impact, Cambridge, England, p.
38-1, (1979).
h =
U
A
(A1-3)
V22
g~ E2c)
.......
(A1-4)
14Weiner, P. D., and Tolle, G. C., "Detection and Prevention of Sand Erosion of Production Equipment," API
OSAPR Project No.2, Research Report, Texas A&M
University, College Station, Texas, 1976.
_ h 1l6
.
V 1 167
- \IP.yp
........
(A1-5)
APPENDIX 1
V =
200 h 1/ 6
\IP
(A1-6)
375
(A1-7)
TABLE 2
TABLE 1
Target
Material
Ti-6 AI-4V
Nickel
Stainless steel
Hard alloy cast iron
Stainless steel
Steel
Aluminum
Martensitic steel
Cast steel
Threshold
Velocity,
ftlsec
135
100
125
320
390
110
80
195
85
Reference
2
2
2
3
4
5
5
6
6
Velocity
(ftlsec)
Sand Flow
Rate
(bbl/month)
Metal
Weight Loss
(Ib)
Erosion
Test Duration
(hrs)
Experimental
Erosion Rate'
(in/year)
Predicted
Erosion Rate"
(in/year)
50
70
70
70
70
70
70
70
70
70
100
100
100
100
143.90
133.66
144.37
144.37
86.62
86.62
86.62
113.63
113.63
113.63
120.15
120.15
120.15
141.57
0.0705
0.1471
0.1599
0.1568
0.1581
0.1337
0.1000
0.2015
0.2451
0.2246
0.1982
0.2015
0.2323
0.2466
9.773
7.501
7.641
7.641
15.216
15.216
15.216
25.729
30.655
24.239
7.722
7.722
7.722
4.378
71.13
193.41
206.27
202.37
102.43
86.64
64.81
77.20
78.84
91.35
253.04
257.24
296.63
555.43
107.93
196.48
212.22
212.22
127.33
127.33
127.33
167.04
167.04
167.04
360.45
360.45
360.45
424.71
Ratio of
Predicted and
Experimental
Erosion Rates
1.52
1.02
1.03
1.05
1.24
1.45
1.96
2.16
2.12
1.83
1.42
1.40
1.22
0.77
Average =1.44
'Experimental erosion rates are extrapolated and calculated as inches per year. (Metal loss is assumed to be over an
area on the elbow equals to the projected cross-sectional area of the pipe.)
"Predicted erosion rates are calculated using Equation (10) with d = 2 inches and P = 1.55 X 105 psi.
TABLE 3
EROSIONAL VELOCITY AS A FUNCTION OF SAND PRODUCTION
Sand Production
(bblslmonth)
10
5
2
1
1/2
1/4
Erosional Velocity'
(ftlsec)
3.81
5.41
8.51
12
17
24