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STD.API/PETRO 2-ENGL 1 9 7 b = 0732290 0562097
API OSAPR P r o j e c t No. 2
American Petroleum I n s t i t u t e
DETECTION AND PREVENTION OF SAND EROSION b
OF PRODUCTION EQUIPMENT
by
Dr. P. D. Weiner
D r . G. C. T o l l e
Texas A&M Research Foundation
College S t a t i o n , Texas
LOT
.March, 1976
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ii
TABLE OF CONTENTS
Page
1
2
5
6 I V . INDUSTRY QUESTIOJQTAIRE AND PERSONAL INTERVIEWS . . 8 V. T E S T APPARATUS AND PROCEDURE
V I . T E S T RESULTS 24
V I I . CONCLUSIONS . . . . . . . . . . . . . . . . . . . . 5 5
V I I I . RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 57
58
APPENDIX I REFERENCES ON SAND EROSION . . . . . . . . . 6 1
APPENDIX II PERSONAL INTERVIEW LIST
. . . . . . . . . . . . . . . . . . . . . . I. SUMKARY
11. INTRODUCTION . . . . . . . . . . . . . . . . . . . III. LITERATURE SEARCH . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I X . ACKNOWLEDGEMENTS . . . . . . . . . . . . . . . . .
AND INDUSTRY QUESTIONNAIRE . . . . . . . . . 64
APPENDIX III TEST RUNS AND DATA . . . . . . . . . . . . . 133
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STD.API/PETRO 2-ENGL 177b 0732290 0 5 8 2 0 7 7 T 8 2 W
I. SUMMARY
This r e p o r t d e s c r i b e s r e sea rch performed a t Texas AbM
Unive r s i ty f o r t h e American Petroleum I n s t i t u t e ( M I ) t o i n v e s t i g a t e
sand e ros ion i n o i l and gas product ion equipment.
t h e r e s u l t s of a l i t e r a t u r e survey, a n i n d u s t r y ques t ionna i r e ,
pe r sona l i n t e rv i ews wi th o i l company r e p r e s e n t a t i v e s concerning
sand e ros ion problems, and l a b o r a t o r y tests t o s imula t e sand
e r o s i o n i n t h e f i e l d f o r t y p i c a l f i t t i n g s .
tests are compared f o r various f i t t i n g s , sand concen t r a t ions , and
flow v e l o c i t i e s .
Included are
Data from t h e l a b o r a t o r y
1
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STD.API/PETRO 2-ENGL 1976 0732290 0582300 524
2
II. INTRODUCTION
Sand e r o s i o n of product ion equipment on o f f shore platforms
i s caus ing s u b s t a n t i a l monetary l o s s t o t h e Petroleum Indus t ry .
One major company estimates a l o s s i n excess of one m i l l i o n d o l l a r s
annual ly due t o sand e ros ion problems [l-21 . *
I n o rde r t o a l l e v i a t e sand e ros ion problems which cause
product ion defer red a t a t i m e when an adequate energy supply i s
e s s e n t i a l f o r t h e we l fa re of our n a t i o n , a p r o j e c t w a s i n i t i a t e d
a t Texas A&M Unive r s i ty by t h e American Petroleum I n s t i t u t e under
t h e d i r e c t i o n of t h e API Offshore Safe ty and Ant i -Pol lu t ion Research
Committee (OSAPR), cha i red by D r . R. S. Crog, Union O i l Company of
C a l i f o r n i a , t o s tudy sand e ros ion problems i n o i l and gas product ion
equipment. The p r o j e c t , OSAE'R P r o j e c t No. 2 , II Detec t ion and
Prevent ion of Sand Erosion of Offshore Product ion Equipment", w a s
funded wi th a budget of $62,000 f o r an 18 month program s t a r t i n g
September 1, 1973.
T e n t a t i v e l y , t h e p r o j e c t had a fou r fo ld ob jec t ive :
1. To determine t h e e f f e c t of sand p a r t i c l e v e l o c i t y on
e r o s i o n rates.
To detennine t h e e f f e c t of t h e geometry of product ion
f i t t i n g s on t h e rate of sand e ros ion .
2.
* Numbers i n b r a c k e t s des igna te References l i s t e d i n Appendix I.
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3 .
4 . To c o r r e l a t e t h e e r o s i o n rates of sand d e t e c t i o n devices
To determine e ros ion rates f o r va r ious f i t t i n g materials.
t o t h e l o s s of material from product ion f i t t i n g s .
The tasks t o b e completed i n t h e conduct of t h e i n v e s t i g a t i o n
inc luded a l i t e r a tu re sea rch t o i d e n t i f y p r a c t i c e s used t o minimize
and monitor sand e ros ion i n product ion equipment as w e l l as a series
of v i s i t s w i t h o i l company r e p r e s e n t a t i v e s t o d i s c u s s cu r ren t
p r a c t i c e s employed f o r w e l l p roduct ion con ta in ing sand.
in format ion w a s t o be consol ida ted i n t o a r e p o r t f o r d i s t r i b u t i o n
t o t h e i n d u s t r y wi th t h e b e s t methods used t o prevent and monitor
sand e ros ion be ing i d e n t i f i e d .
included t o s imula t e e r o s i o n i n t h e f i e l d f o r t y p i c a l f i t t i n g
condi t ions . Erosion rates of sand d e t e c t i o n devices were t o be
compared t o t h e e r o s i o n of f i t t i n g s f o r va r ious flow condi t ions .
The system t o be t e s t e d was t o c o n s i s t of sand p a r t i c l e s i n j e c t e d
i n t o a stream of a i r flowing through test f i t t i n g s jo ined by
p ipe s e c t i o n s .
Avai lab le
Laboratory tests were t o be
On September 1 2 , 1973, a m e e t h g w a s h e l d a t S h e l l Development
Company, Houston, Texas, t o f i n a l i z e t h e course of a c t i o n t o b e
followed dur ing t h e p r o j e c t and t o provide i n i t i a l in format ion t o t h e
r e s e a r c h group. The m e t i n g w a s chaired by M r . Claude A. S e l l a r s ,
S h e l l Development Company.
i n d u s t r y and r e sea rch group members were p resen t .
Representa t ives of t h e petroleum
During t h e course of t h e meeting, t h e p r o j e c t o b j e c t i v e s and
t h e gene ra l course of a c t i o n t o b e taken were confirmed. T o augment
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t he l i t e r a t u r e survey and personal i n t e rv i ews , a d e t a i l e d question-
n a i r e concerning t h e ope ra t ion of product ion equipment s u b j e c t t o
sand e ros ion problems w a s approved t o b e s e n t t o p o s s i b l e information
sources .
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STD.API/PETRO 2-ENGL L77b D 0732290 0582303 233
5
III. LITERATURE SEARCH
The l i t e r a t u r e sea rch i d e n t i f i e d s ixty-one p o s s i b l e sources of
in format ion from t e c h n i c a l and t r a d e jou rna l s .
i n d i c a t e d t h a t seventeen of t h e j o u r n a l s were l i k e l y t o pub l i sh
ar t ic les on s u b j e c t s such as sand eros ion . The a b s t r a c t s of t h e s e
j o u r n a l s i n d i c a t e d a shor t age of meaningful sand e ros ion a r t i c l e s .
The a i d of t h e e d i t o r s of t h e j o u r n a l s w a s s o l i c i t e d and fou r t een
papers were rece ived of which n i n e were d i r e c t l y a p p l i c a b l e t o
t h e program. The n i n e papers [3-111 are i d e n t i f i e d i n Appendix I
of t h i s r e p o r t . Enough c r o s s r e fe rences are now a v a i l a b l e t o
provide e s s e n t i a l background information.
F u r t h e r i n v e s t i g a t i o n
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I V . INDUSTRY QUESTIONNAIRE AND PERSONAL INTERVIEWS
Two important sou rces of sand e ros ion informat ion have been
pe r sona l i n t e rv i ews wi th many ope ra to r s and producers and, also, an
i n d u s t r y ques t ionna i r e which has been widely d i s t r i b u t e d .
response t o both in te rv iews and t h e ques t i o n n a i r e w a s e x c e l l e n t
and members of t h e i n d u s t r y are t o b e commended f o r t h e i r pa t i ence
and cooperat ion. The ques t ionna i r e contained a list of t h i r t y
ques t ions and included a survey of cri t ical flow rates, c r i t i ca l
sand concen t r a t ions , types of sand t h a t cause t h e g r e a t e s t e r o s i o n
rate, f i t t i n g s most s u s c e p t i b l e t o e ros ion , materials used t o
prevent e ros ion , sand product ion monitor ing devices i n use , w e l l
depths and p res su res t h a t accelerate e ros ion , r e p o r t i n g proceduzcs,
and remedies used when a sand e r o s i o n f a i l u r e has occurred.
E s s e n t i a l l y , t h e same ques t ions were asked dur ing t h e pe r sona l
in te rv iews . Appendix II con ta ins a l is t of t h e personnel in te rv iewed
and a. reproduct ion of t h e ques t ionna i r e .
The
The r e s u l t s of t h e in t e rv i ews and ques t ionna i r e served as a
guide t o t h e Advisory Committee and Research Team i n i d e n t i f y i n g
s p e c i f i c areas i n which sand e r o s i o n problems were most p reva len t
and a c t i o n most u rgen t ly needed. Of g r e a t i n t e r e s t w a s t h e sonet imes
vary ing exper iences r ega rd ing sand e ros ion problems. However, t h e
gene ra l consensus agreed t h a t sand e ros ion problems are c o s t l y ,
d i f f i c u l t t o prevent , and g r e a t l y reduce o v e r a l l p roduc t iv i ty .
Information ga thered from the interviews and q u e s t i o n n a i r e h a s
been assembled and i s inc luded i n Appendix II. Cr i t ica l flow
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STD.API/PETRO 2-ENGL 197b = 0 7 3 2 2 4 0 0582305 OOb m
7
v e l o c i t i e s , c h a r a c t e r i s t i c s of t h e sand p a r t i c l e s , f i t t i n g s and
f l a w l i n e geometry, methods of c o n t r o l l i n g sand product ion downhole,
sand product ion d e t e c t i o n devices , and f i t t i n g materials were
t o p i c s t h a t received t h e most a t t e n t i o n and generated t h e most
d i scuss ion .
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V. TEST APPARATUS AND PROCEDURE
Information gathered from t h e l i t e r a t u r e survey, personal
i n t e r v i e w s , and i n d u s t r y ques t ionna i r e w a s used t o des ign and
c o n s t r u c t a t e s t apparatus a t t h e Texas A&M Unive r s i ty Research
Annex.
i n j e c t i o n device , ins t rumenta t ion , and flowpath inc lud ing test
f i t t i n g s . A l l p ip ing and f i t t i n g s are of nominal 2" I .D . A s t h e
tests proceeded, several improvements were inco rpora t ed i n t o t h e
air supply system and t h e sand i n j e c t i o n device b u t t h e b a s i c
appara tus remained unchanged throughout a l l test runs. Various test
systems used are depic ted schemat ica l ly i n F igures 1 through 4.
photograph of t h e test f a c i l i t y is shown i n F igure 5 .
Elements of t h e appara tus c o n s i s t of a n a i r supply, sand
A
During t h e ope ra t ion of t h e test appara tus , t h e compressor
suppl ied a i r up t o a maximum of 315 CFM a t 100 p s i g t o a nozz le
a t t h e base of t h e sand i n j e c t i o n device.
w a s metered i n t o t h e airstream through an o r i f i c e which allowed
t h e mass f lowra te of sand through t h e test appa ra tus t o be c o n t r o l l e d
and changed as requi red . The sand acce le ra t ed down t h e i n i t i a l
s e c t i o n of t h e appara tus u n t i l t h e sand and a i r v e l o c i t i e s were
be l i eved t o b e approximately equal .
proceeded through t h e test assembly .exhaust ing a t atmospheric
p r e s s u r e t o a sand c o l l e c t i o n area.
Sand from a supply hopper
Then t h e s a n d / a i r mixture
Ins t rumenta t ion of t h e test appara tus inc luded a p i t o t tlibe
Because connected t o a gauge c a l i b r a t e d t o read i n fee t / second.
2,. . . I . . .
. .
. .
. .
. .
. ..
. .
!
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STD.API/PETRO 2-ENGL L77b 0732270 0 5 8 2 1 0 7 989
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STD-APIIPETRO 2-ENGL L77b = 0732290 0582LLL 30T =
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. .
SAND EROSION TEST FACILITY
F i g u r e 5
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STD-API/PETRO 2-ENGL L77b 0732270 0582LL2 24b =
1 4
t h e d e n s i t y of t h e a i r i n t h e f lawstream w a s temperature-dependenty
it was necessary t o a l low t h e compressor a i r t o "warm up".
p i t o t tube w a s removed be fo re t h e i n j e c t i o n of sand i n t o t h e
flowstream.
The
V i e w s of t h e flowmeter are shown i n F igures 6 and 7.
Sand Probes
Sand probes [12] developed by Exxon Company, USA, were included
i n the test appara tus f o r t h e purpose of c o r r e l a t i n g sand probe
f a i l u r e s t o f i t t i n g f a i l u r e s . As shown i n F igures 8 and 9 , t h e
sand probes were assembled w i t h a p res su re gauge and means f o r
i n t roduc ing and main ta in ing a i r p re s su re w i t h i n t h e probe u n t i l a
h o l e w a s eroded through t h e tube w a l l . Loss of p r e s s u r e i n t h e
probe i n d i c a t e d f a i l u r e . Later i n t h i s r e p o r t , t h e r e s u l t s of
sand probe f a i l u r e s t o test f i t t i n g f a i l u r e s are d iscussed .
Sand Detec tor
The sand d e t e c t o r is an e l e c t r o n i c device shown i n Figure 10
capable of d e t e c t i n g extremely small concen t r a t ions of sand par t ic les
i n a flowstream under a v a r i e t y of ope ra t ing condi t ions . This device
w a s developed by t h e Mobil Research and Development Corporat ion and
i s a v a i l a b l e cormerc ia l ly .
T e s t Procedure
A f t e r a series of pre l iminary tests, it w a s decided t h a t a
sand i n j e c t i o n rate of 3 lb/min w a s s u f f i c i e n t because adequate
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STD.API/PETRO 2-ENGL L77b 0732270 0582LL3 1 8 2
15
FLOWMETER I N OPERATION I N D I C A T I N G A
VELOCITY OF 70 FT/SEC
Figure 6
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VELOCITY PROBES INSIDE FLOWMETER SECTION
Figure 7
16
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17
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w m o œ e n 2 a v)
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STD.API/PETRO I?-ENGL 1 7 7 b 0732270 0582118 7b4
20
e ros ion rates were being r e a l i z e d without undue consumption of sand
and t i m e .
t h e test apparatus ad jus t ed t o o b t a i n t h e d e s i r e d flowstream
v e l o c i t y and t h e sand i n j e c t i o n rate of 3 lb/min.
of t h e tes t , 200 l b of sand w e r e passed through t h e apparatus
be fo re readings w e r e taken.
test f i t t i n g s disassembled, weighed, i n spec ted , and reassembled.
The procedure w a s repea ted u n t i l a test f i t t i n g f a i l e d .
sand probes w e r e eva lua ted , they w e r e rep laced upon f a i l u r e and
t h e weight of sand recorded.
P r i o r t o a test run, t h e test f i t t i n g s w e r e weighed and
A f t e r t h e s t a r t
The sand flow w a s stopped and t h e
When
Dynamic Visua l Flow Stream Analyzer
To observe t h e e f f e c t of t h e geometry of an o i l f i e l d
product ion f i t t i n g on t h e ra te of sand e r o s i o n , a 2-inch I D
g l a s s p i p e flowpath w a s cons t ruc ted . The flowpath, shown i n
F igure 11, permi t ted v i s u a l s t u d i e s t o be made of t h e flow
stream wi th va r ious f i t t i n g s and d e f l e c t o r s . The system w a s ,
i n gene ra l , s i m i l a r t o t h e steel p ipe e r o s i o n appara tus . Sol id ,
nonabrasive p a r t i c l e s of t h e proper d e n s i t y w e r e i n j e c t e d i n t o
t h e flowstream t o s imula t e f lowing sand. A c losed -c i r cu i t
t e l e v i s i o n system and h igh speed photographs w e r e used t o record
t h e passage of t h e p a r t i c l e s through t h e test f i t t i n g s . Some
of t h e r e s u l t i n g f l o w p a t t e r n s are shown i n F igure 12. This
system permi t ted a v i s u a l , nondes t ruc t ive t r ia l and e r r o r
method of ana lyz ing t h e e f f e c t of phys i ca l changes i n
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21 . . . .
DYNAMIC VISUAL FLOW STREAM ANALYZER
Figure 11
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22
Short Ell With Choke Long Ell With Choke
Tee With Choke Tee With Choke
EXAMPLES OF FLOW THROUGH
VISUAL STREAM ANALYZER
Figure 12
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23
shapes and sizes of f i t t i n g s .
f l o w p a t t e r n were then t e s t e d i n the s a n d e ros ion f a c i l i t y .
Those shapes which gave a favorable
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STD.API/PETRO 2-ENGL 1 9 7 b = 0732290 0582122 1 9 5
24
V I . TEST RESULTS
The tes t r e s u l t s f o r t h i s program were o r i en ted toward
answering t h e ques t ion "What can be done f o r d e t e c t i o n and
prevent ion of sand e ros ion i n o i l and gas product ion equipment?".
As summarized i n Table I, a series of tests were completed tak ing
i n t o account t h e e f f e c t s of flowstream v e l o c i t y , sand p a r t i c l e
s i z e , sand p a r t i c l e flow ra te , and test f i t t i n g geometry and
material.
are l i s t e d according t o t h e parameters which were of primary
in f luence on t h e wear rate of t h e f i t t i n g .
To a i d t h e i n t e r p r e t a t i o n of t h e test d a t a , r e s u l t s
Veloc i ty E f f e c t s
Response t o t h e Indus t ry Ques t ionna i r e expressed i n t e r e s t i n
t h e p o s s i b l e ex i s t ence of a " threshold ve loc i ty" above which t h e
wear rate of a f i t t i n g would be g r e a t l y acce le ra t ed . F igures 13
and 14 compare t h e wear rates of a s t anda rd 90" water e l l f o r
t h r e e flow v e l o c i t i e s and a cons tan t sand flow rate. The l i n e a r
w e a r rates do no t deny nor confirm t h a t a threshold v e l o c i t y f o r
a c c e l e r a t e d wear e x i s t s . More d a t a i s needed a t low flow
v e l o c i t i e s (20 t o 40 f t jsec) and in t e rmed ia t e v e l o c i t i e s
(75 t o 90 f t / s e c ) t o conclus ive ly v e r i f y t h e e x i s t e n c e of a
th re sho ld ve loc i ty .
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STD.API/PETRO 2-ENGL L77b 0732270 0582323 O 2 1
Flows tream Veloc i ty ,
f t / s e c
50
70
70
70
70
100
10 o
10 o
100
100
100
100
100
100
10 o
10 o 100
100
100
100
100
100
Sand P a r t i c l e
S i z e
40 /60
16 / 20
40/60
40 / 60
40/60
40/60
40 /60
40 / 60
40/60
40/60
40 / 60
40/60
40 / 6 0
40 /60
40/60
40 /60
40 / 60
40 /60
40/60
40/60
40 / 60
40/60
S ancl F l o w Rate,
l b /min
3.09
1.86
2.44
2.87
3.10
2.58
2.99
2.99
3.00
3.00
3.01
3.03
3.03
3.04
3.04
3.07
3.08
3.08
3.09
3.11
3.11
3.13
Kun 'l 'rst Number Fitting
1-50
4-70
5- 70
2-7 O
3-70
6-100
15-100-A
15-100-B
8-100-A
8-100-B
10-100
ll-100-A
11- 100-B
7-100-A
7-100-B
13-100
16-100-A
16-100-B
12-100
14- 100-A
14- 10 O-B
9-100
90" e l l
90" e i l
90" e l l
90" e i l
90" e l l
90" e l l
90" e l l w i t h 45" p l a t e
90" e l l w i t h 45" p l a t e
Bul lp lugged tee
Bullplugged tee
90" e l l w i t h Veloc i ty Reduction
Chamber
90" e l l w i t h 30" p l a t e
90" e l l w i t h 60" p l a t e
90" e l l
90" e l l w i t h 45" p l a t e
90" e l l
90" e l l w i t h 45" p l a t e
90" e l l w i t h 45" p l a t e
90" e l l
90" e l l
90" e l l w i t h 45" p l a t e
90" e l l w i t h Ve loc i ty Reduction
Chamber
25
water p ipe
water p ipe
water p ipe
water p ipe
water p ipe
water p i p e
Inc one 1
Tef lon coated
f i e l d p i p e
water p i p e
water p ipe
s teel alloy
steel alloy
f i e l d p ipe
s teel a l l o y
sp ray coa t ing "B"
tungs ten c a r b i d e
polyurethane
sp ray c o a t i n g "A"
water p i p e
p olypheny l e n e s u l f i d e
water p i p e
Summary Of T e s t Parameters
Table I
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..
vi t-4 4
STD.API/PETRO 2-ENGL L77b W 0732270 0582324 Tb8 W
O
t4 c
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a" rl E-i =! a Ca a m rl W
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.
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27
O O O Cd
O O ca d
O O \o rl
O O U 4
O O N 4
o O O +
O o m
O O \o
O O U
O o c\I
8 d r.4
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5
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M cl
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U VI a
3 w . a . u
8 d , " Fi zr w u m
cr: < 3 ... - a c
,
-i : -
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28
Veloc i ty Reducing Chamber (VR)
The dependency of f i t t i n g wear rate on flow v e l o c i t y l e d t o
t h e cons t ruc t ion of t he v e l o c i t y reducing chamber (VR) i n F igures 15,
16, and 1 7 .
w i t h b e l l reducers on each end.
c ros s - sec t iona l area, t h e flow v e l o c i t y i n s i d e t h e VR w a s l / 4 t h e
v e l o c i t y i n s i d e t h e 2" pipe . In Run 9-100, t h e VR w a s pos i t ioned
20" upstream of a w a t e r e l l and i n Run 10-100, a s h o r t n i p p l e w a s
used t o p o s i t i o n the VR immediately upstream from a water e l l .
F igures 18 and 19 d i s p l a y t h e e f f e c t of t he pos i t i on ing of t h e VR on
wear rate.
sand p a r t i c l e s have enough t i m e t o accelerate back up t o t h e flow-
stream ve loc i ty i n s i d e t h e 2" p ipe and t h e e f f e c t of t h e VR i s
can ce 1 l e d.
The VR cons i s t ed of a 6' s e c t i o n of 4" I .D. p ipe f i t t e d
Because of the change i n flow
If the VR i s no t pos i t i oned c l o s e t o t h e f i t t i n g , t h e
Regular F i t t i n g s
The f i t t i n g s i n F igures 20 and 2 1 w e r e c l a s s i f i e d as " r egu la r
f i t t i n g s " because they are commercially a v a i l a b l e and were t e s t e d
wi thout any modi f ica t ions . Typica l f a i l u r e s of r e g u l a r f i t t i n g s are
depic ted i n Figures 20 through 23.
Figures 24 and 25 show t h a t f i e l d p ipe resists wear only s l i g h t l y
b e t t e r than common w a t e r p ipe .
w a t e r tee has a w e a r ra te one-half t h a t of a f i e l d e l l o r water e l l .
When poss ib l e , f i e l d el ls should b e rep laced by bul lplugged f i e l d
tees t o inc rease t h e service l i f e of t h e f i t t i n g by a f a c t o r of 7.
The w e a r rate comparisons i n
However, a bul lplugged f i e l d tee o r
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STD-APIIPETRO 2-ENGL 1 9 7 b W 0732290 0582327 777
c
29
n F9
4 U
5 d
i
.
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STD.API/PETRO 2-ENGL L97b 0732290 0582328 b03
4
P
L.i .al
I .
30
c
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31
4 L
20" 72" c -
Bel l reducer 4 inch I. D. B e l l
h
~~
reducer
I Flow Run 9-100
1 Flow Run 10-100
VELOCITY REDUCING CHAMBER (VR) SCHEMATIC
F igure 1 7
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STD.API/PETRO 2-ENGL 3 9 7 b W O732290 0582330 2 b 3
O
.. al
iw -4 74
P) U
*I+ ? k al VI
#4 c O v) Cu
U
4: O O rl
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I O O 4
I O 4
32
I O ri
3 a 4 I m
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cn h a m u a r l 4 4 M
5 2 rp L bo
œ
n h LI a
W
L) O rl
a 9 d 3
O o 4
x LI
-4
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O O O c-4
33
O O cg rl
O O l4 I
2
O O \o rl
o u o * a h
d .. a C
C
O O N 4
al Ca
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LI a, P 3 2 F -4 U 3 a aJ k
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5 .rl 3 v1 rl rl a,
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U (d k
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a C m O O rl I m
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O m O e O
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STD-API/PETRO 2-ENGL 177b 0732290 0582132 034 =
F l o w
Failure 34
FAILU2E LOCATIOPiS FOR WATER ELL AND FIELD ELL
Figure 20
Water Ell
f
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STD.API/PETRO 2-ENGL L77b 0732290 O582333 T 7 0 m
Flow
Fai lure
I I
.- . f . Flow
35
Bullplunned Water Tee
FA1LUR.E LOCATIONS FOR BULLPLUGGED WATER TEE AND BULLPLUGGED FIELD TEE
F i g u r e 21
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S O cn O
m-
36
FI FI 9) & 3 M rl
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37
m Pl N
al
o O
W
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STD.API/PETRO 2-ENGL L77b 0732290 058213b 78T
a i 4: O O 4 I Co P
v1
u b n U
n ru
O B O r l b
M
U h r a aJ u k al U (d 3 P CI M M 3 rl a rl rl 3 m
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5
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u-i N N
O ur 4
Y, h
O
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U STD-API/PETRO O 4 I m
U al v) \ U ‘H
O O 7 4
h u .i( , , U O
9
P ri
.) o ri w4 V C (d cn . 3 i! k M
v) v) O rl U Øz M rl
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v)
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t, pi cn
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40
Modified F i t t i n g s
"Modified f i t t i n g s " were r e g u l a r f i t t i n g s wi th changes i n
geometry, material, o r both. F igures 26 and 27 show awa te r e l l
f i t t e d wi th an a l l o y steel p l a t e .
4 5 " , o r 60" wi th r e spec t t o t h e incoming flow.
of F igures 28 and 29 show t h a t a t tempts t o i n c r e a s e t h e wear
The p l a t e was o r i en ted a t 30°,
Legends A through i
r e s i s t a n c e of t h e p l a t e by means of a coa t ing material are gene ra l ly
of modest success .
has a wear ra te one-third t h a t of a tungs ten ca rb ide coated p l a t e .
Th i s f ind ing l ead t o t h e d i s p l a y of t h e wear rates of t h e coa t ing
materials only as shown i n Legends J , K, L , and N.
a wear ra te only one-tenth t h a t of tungs ten carb ide . However, t h e
amounts of material l o s t from t h e polyurethane and tungs ten carb ide
s u r f a c e s were almost t h e same. Therefore , a f i t t i n g wi th e i t h e r
a polyurethane o r tungs ten ca rb ide wear s u r f a c e should have a
low wear ra te and an improved s e r v i c e l i f e .
Legend M shows t h a t a polyurethane coated p l a t e
Polyurethane has
Sand Flow Rates ---
Runs 2 , 3, and 5 were made wi th d i f f e r e n t sand flow rates t o
a l low a wear rate comparison t o be made.
t h e wear rates of Runs 2 and 3 i n F igures 30 and 31 is due t o t h e
computat ional method f o r t h e a n a l y t i c a l curve f i t and t h e almost
i d e n t i c a l l i n e s lopes .
f low rates is necessary t o formula te a r e l a t i o n between sand f l v d
rate and e r o s i o n rate.
The apparent i nve r s ion i n
More d a t a covering a wide range of sand
.
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Failure
Flow
Failure t
F l o w
I F l o w . Failure
41
thick
30' plate
Plate Material U . S. Steel
HR Alloy Plate Type T-1,
Quenched and Tempered (321
minimum Brinel l hardness)
-
thick
45" plate
60" plate
Failure Locations O f A
Water Ell Fitted Kith 30°, 45", and 60" Plates
Figure 26
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STD.API/PETRO 2-ENGL 397b m 0732290 0 5 8 2 3 4 0 L O O m
42
E 3 O
CZI Q) S
a 0
W n
9, I n LL L
W
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,
43
U * 2
U U U
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44
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1 8 b o I h
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STD.API/PETRO 2-ENGL L77b 0 7 3 2 2 9 0 0582LLiq ô5b =
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,
Sand P a r t i c l e -
47
S i z e s
Table I on page 25 lists a 40 /60 f r a c sand as used i n a l l
runs except 4-70 i n which a 16/20 frac sand w a s used.
of run 4-70 w a s t o provide d a t a t o make a wear rate comparison f o r
d i f f e r e n t sand p a r t i c l e s i z e s a t var ious sand flowrates. The
r e s u l t s of R u n s 3 and 4 shown i n F igures 32 and 33 i n d i c a t e t h a t
a l a r g e number of sand p a r t i c l e s i z e s would have t o be run a t many
sand f lowra te s t o provide t h e necessary d a t a t o formulate a
r e l a t i o n between wear rate, sand p a r t i c l e s i z e , and sand f lowrate .
In t h e i n t e r e s t of conserving t i m e and f inances , f u r t h e r tests
involv ing d i f f e r e n t sand p a r t i c l e s i z e s were suspended.
The i n t e n t
Summary of Resu l t s For A Veloc i ty Of 100 f t / s e c --
Run 1 a t a v e l o c i t y of 50 f t /sec, Runs 2 through 5 a t a v e l o c i t y
of 70 f t / s e c , and Run 6 a t a v e l o c i t y of 100 f t / s e c provided a d a t a
base t o f i x the parameters f o r t h e remaining tests. D i f f e r e n t sand
flow rates and sand p a r t i c l e s i z e s had a l s o been used i n Runs 1
through 6 .
100 f t / s e c , a 40/60 dry f r a c sand and a sand flow rate of 3 lb/min
w e r e s e l e c t e d as ope ra t ing parameters f o r a l l subsequent runs t o
a s s u r e t h e n a x i m u m amount of test d a t a f o r t h e minimum expendi ture
of funds and t i m e .
from Runs 7 through 16.
i n d i c a t e t h a t a hybr id f i t t i n g composed of a v e l o c i t y reducing
chamber immediately upstream f r o m a bul lp lugged f i e l d tee wi th an
i n n e r l i n i n g of polyurethane would be extremely r e s i s t a n t t o sand
From t h e r e s u l t s of t h e s e runs, a f low v e l o c i t y of
F igu res 34 and 35 are a composite of t h e r e s u l t s
The r e s u l t s l i s t e d i n Legends P , Q, and R
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52
eros ion .
s o f t o r hard , genera l ly are n o t much b e t t e r a t r e s i s t i n g sand e ros ion
than r egu la r f i t t i n g s and t h a t a bul lplugged f i e l d tee is more wear
r e s i s t a n t than most modified f i t t i n g s .
The r e s u l t s i n Legends A through P show t h a t coa t ings ,
Sand Probes -
The sand probe d a t a i n Appendix III f o r Runs 7 , 8, 11, 12,
and 13 i n d i c a t e s a l a r g e s tandard dev ia t ion which would apparent ly
make t h e impending f a i l u r e of a f i t t i n g d i f f i c u l t t o p r e d i c t .
However, a c o r r e l a t i o n exists f o r t h e r eg ions of f a i l u r e f o r a sand
probe as shown i n Figure 36. When superimposed, t h e sand probe d a t a
from Runs 1 2 and 13 (and t h e o t h e r runs i n which sand probes were
used) shows f a i l u r e reg ions which always over lap and which f o r many
probes are almost i d e n t i c a l . Using t h i s t r e n d , f a i l u r e p r e d i c t i o n s
can be made with a reasonable degree of confidence. A s an example,
sand probe #IA of Figure 36 f o r Run 1 2 had a f a i l u r e at a minimum
sand flow of 102 l b , s ay 100 l b f o r c a l c u l a t i o n s . S i n c e one f i t t i n g
i n Run 1 2 had a s e r v i c e l i f e of 798 l b of sand under the s p e c i f i c
ope ra t ing condi t ions , t h e f i t t i n g should be ready t o f a i l a f t e r 8
sand p r o l e s have f a i l e d , Replacement of the f i t t i n g a f t e r 7 sand
probe f a i l u r e s would be reasonable. A t t h e d i s c r e t i o n of t h e
ope ra to r , t h e probe l i f e can be a l t e r e d by s e l e c t i n g probes wi th
d i f f e r e n t w a l l th icknesses .
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STD*API/PETRO 2-ENGL 177b D 0732270 0582353 T9b W
. Sand Probe #2B
f I
I .
' '
1
R u n 13 Sand Probe # 3 A Run 12
I
53
Sand P r o b e #4k ' ' Run 1 2 i I
Sand Probe #iA
1 4
Run 13
Run 12
Sand P r o b e 8 4 B Run 13
'Run 12 I
100 200 300 400 500
Sand Probe #LB Run 13 Run 1 2
I 100 200 300 400 500
Run 13 Run 12
Sand Probe 6 2 A
I 100 200 300 400 500
Run 13
Sand Probe 8 3 B xu11 i3
"Run 12 I
100 200 300 40C 500
Run 13 Sand P r o b e #5A Riin 1 2
1 100 200 300 400 500
Run 13 Sand Probe 65B Run 12
8 100 200 300 400 500
Sand Flow Past ?robe, lb
COMPARISON OF SI\PID PROBE FAILURE DATA FROM RUNS 12 and 13 Figure 36
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Sand Detector -
The sand d e t e c t o r was used i n s e v e r a l runs t o c a l i b r a t e t h e
output of t h e device wi th t h e a c t u a l sand flow known t o be passing
through the flowpath. Once c a l i b r a t e d , t he d e t e c t o r proved
r epea tab le a t the v e l o c i t i e s and concent ra t ions used i n t h i s test.
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55
V I I . CONCLUSIONS
The tes t d a t a reveals that only two methods now e x i s t f o r t h e
c o n t r o l of sand e ros ion i n product ion equipment: (1) Reduce flow-
stream v e l o c i t y , and, (2) Use f i t t i n g s of s p e c i a l design. The f i r s t
method of a reduct ion i n flowstream v e l o c i t y may o r may no t be
reasonable depending on t h e ope ra t ing condi t ions of a p a r t i c u l a r
w e l l .
would be easy t o implement and f i n a n c i a l l y acceptab le .
of t h i s tes t program l e a d t o t he fol lowing conclusions:
The second method may o f f e r a way t o reduce sand e ros ion t h a t
The r e s u l t s
1.
2.
3.
4 .
5.
The wear rate of a f i t t i n g is g r e a t l y increased by an
i n c r e a s e i n ve loc i ty . Therefore , a s u b s t a n t i a l r educ t ion
i n w e a r is p o s s i b l e f o r a moderate decrease i n flowstream
ve lo c i t y .
I f f lowstream v e l o c i t y must be maintained, t he use of a
Veloc i ty Reducing Chamber immediately upstream of a f i t t i n g
w i l l g r e a t l y i n c r e a s e t h e service l i f e of t h a t f i t t i n g .
The s e r v i c e l i f e of a f i t t i n g s u b j e c t t o sand e r o s i o n is
g r e a t l y inc reased by an i n s i d e coa t ing of polyurethane o r
tungs ten carb ide .
A modified f i t t i n g c o n s i s t i n g of a p l a t e i n c l i n e d t o t h e
flowstream has a b e t t e r resistance t o w e a r than a s t anda rd
f i e l d ell.
Whenever p o s s i b l e , a bul lp lugged f i e l d tee should be used
t o r ep lace an ell which h a s f a i l e d because of sand eros ion .
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56
6. A hybrid f i t t i n g c o n s i s t i n g O E ;i Velocity Reducing C1i;iiiil)c.r
immediately upstream of a bullplugged f i e l d tee w i l l have
an excep t iona l r e s i s t a n c e t o wear.
resistance is p o s s i b l e i f the i n s i d e of t h e hybr id f i t t i n g
is coated w i t h tungs ten ca rb ide o r polyurethane.
An even g r e a t e r wear
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STD.API/PETRO 2-ENGL L77b 0732270 0 5 8 2 3 5 5 b3L 9
5 7
V I I I . RECOMMENDATIONS
The r e s u l t s of t h i s program i n d i c a t e t h a t t h e fol lowing
a d d i t i o n a l i n v e s t i g a t i o n s are warranted and should b e performed:
1. More d a t a should b e obtained on t h e Veloc i ty Reducing
Chamber.
be t e s t e d t o determine t h e smallest chamber t h a t w i l l
provide good sand e r o s i o n p ro tec t ion .
A v a r i e t y of l eng ths and i n s i d e diameters should
2. A s tandard performance test should be developed f o r
eva lua t ing f i t t i n g s and r e l a t e d equipment for r e s i s t a n c e
t o sand eros ion .
3 . Optimum des igns should be i d e n t i f i e d f o r f i t t i n g s and
r e l a t e d product ion f a c i l i t i e s t o provide m a x i m u m r e s i s t a n c e
t o sand eros ion . Phys ica l shapes and materials should be
included.
4 . Various design modi f ica t ions i n f i t t i n g s should b e eva lua ted
by l abora to ry tests t o v e r i f y t h e i r increased resistance t o
sand eros ion .
Optimum design should b e used t o p repa re an Indus t ry
s tandard on sand e ros ion i n f i t t i n g s and r e l a t e d equipment.
5 .
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STD.API/PETRO 2-ENGL L97b 0 7 3 2 2 9 0 058215b 578
58
I X . ACKNOWLEDGEMENTS
The TAMU Research Team wishes t o acknowledge t h e suppor t of
t h e American Petroleum I n s t i t u t e and, i n p a r t i c u l a r , t h e guidance
and e f f o r t s of t h e Task Group Advisory Committee. The members of
t h e Advisory Committee m e t on a monthly b a s i s t o extend t h e i r
. e x p e r t i s e toward t h e s u c c e s s f u l completion of t h i s program.
members of t h e Advisory Committee and t h e Research Team for t h e
sand e ros ion p r o j e c t are l i s t e d immediately fo l lowing this sec t ion .
Apprec ia t ion is extended t o M r . Mart in E. True, Exxon Company,
The
USA, f o r permission t o use t h e photographs and ske tches i n
F igures 5 , 6 , 7, 8, 10, 11, 12 , 22, 23, and 27.
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59
API Sand Erosion Task Group Advisory Committee --
C . A. Sel lars , Chairman, Shell Development Company
M. E. True, Vice-Chairman, Exxon Company, USA
W. F. Baldwin, Member, Mobil Research and Development Corporation
E. R. Jennings, Member, Amoco Production Company
B. McGlothlin, Member, Gulf Research and Development Company
L. D. Mullins, Member, Mobil Research and Development Corporation
P . Teymourian, Member, Gulf O i l Company
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60
TAMü Research Team - P. D. Weiner, P r i n c i p a l I n v e s t i g a t o r , Texas A&M Univers i ty
G . C. T o l l e , I n v e s t i g a t o r , Texas A&M Univers i ty
K. M. Weber, Senior Technician, Texas A&M Univers i ty
D. R. Greenwood, Technician, Texas A&M Univers i ty
D. A. Weber, Technician, Texas A&M Univers i ty
T. D. Weiner, Technician, Texas A&M Univers i ty
C. D. Wren, Technician, Texas A&M Univers i ty
C. L. Hulsman, Sec re t a ry , Texas A&M Univers i ty
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APPENDIX I
REFERENCES ON SAND EROSION
,
r.
!
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62
REFEREWES ON~SAND EROSION*
1. Weiner, P. D., "Sand Erosion: An Indus t ry Survey", Spring
Committee Conference Papers , Division of Product ion, American
Petrkleum I n s t i t u t e , 1974. Presented a t t h e Spring Committee
Conference, New Orleans, La . , March 24-27, 1974.
True, M. E. and P. D. Weiner, "Sand Erosion I n C r i t i c a l Equipment
-- A Progress Report On API Research", 1975 Annual Meeting,
Div is ion of Product ion, American Petroleum I n s t i t u t e , 1975.
Presented a t t h e 1975 Annual Meeting, Div is ion of Product ion,
American Petroleum I n s t i t u t e , Dallas, Tex., A p r i l 7-9, 1975.
2.
3. Bauer, H. and E. Kr i ege l , "Experiments On The E f f e c t Of Erosion
O n P l a s t i c s And Metals", Report from t h e Research I n s t i t u t e of
Mannesmann, Inc., Duisburg-Huckingen Germany.
4. Finnie , I . , "Erosion O f Sur faces By So l id Particles", Wear,
Vol. 3 , pp. 87-103, 1960.
McKee, M. L., "Minimize Tubing F a i l u r e s Caused By Sand Abrasion",
World O i l , Vol. 148, June 1959.
O l ive r , L. R., "Modified Producing Hookup Cuts Gas Well
Maintenance", World O i l (Tenneco O i l Company, L a f a y e t t e La.)
5.
6.
* Note: In some instances, t h e r e fe rence material was t r ansmi t t ed
d i r e c t l y t o t h e Sand Erosion Resea ch Group without i d e n t i f i c a t i o n
of the j o u r n a l of pub l i ca t ion . Accordingly, t h e au tho r ( s )
i n d u s t r i a l a f f i l i a t i o n has been l i s t e d i n pa ren thes i s .
%
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7. Rough, R. L. and G. E. Rennick, "Glass P ipes Used To Study
Vertical Flow O f A;r O i l Mixtures" (Morgantown Petroleum
Research Laboratory, Bureau of Mines, Department of t h e
I n t e r i o r , Morgantown W. Va.)
8. S t a u f f e r , W. A., "Wear Of Metals By Sand Erosion", Metal
P rogres s , Jan 1956.
T a r d i f , H. P. and H. Marquis, "Abrasion O f Materials By
Suspended Matter", Canadian Mining and M e t a l l u r g i c a l Jou rna l ,
T ransac t ions , Vol. LXV, pp. 381-390, 1962.
Tek, M. R., "Multiphase Flow Of Water, O i l And Na tu ra l Gas
Through V e r t i c a l Flow St r ings" , p resented a t J o i n t SPE-AIChE
Symposium, Tu l sa Oklahoma, Sept 25-28, 1960.
9 .
10.
11. T i l l y , G. P., "Sand Erosion O f Metals And P l a s t i c s : A Br ie f
Review", presented a t Materials Science Club meeting on
"Abrasive w e a r of materials", Nat iona l Col lege of A g r i c u l t u r a l
Engineer ing, S i l c o e , Bedfordshire , üK, J u l y 16-17, 1969.
12. Swan, R. D. and C . M. R e i m e r , "Three Years Of F i e l d Experience
With Sand Erosion Probes", Spring Committee Conference Papers ,
D iv i s ion of Product ion, American Petroleum I n s t i t u t e , 1974.
E '1
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r
APPENDIX II
' PERSONAL INTERVIEW LIST
AND
INDUSTRY QUEST IONNAIRE
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65
PERSONAL INTERVIEW LIST
Numerous personal interviews on an in formal b a s i s provided
information e s s e n t i a l t o the success of t h i s p r o j e c t .
below are t h e names of many of t h e indus t ry r e p r e s e n t a t i v e s who
took t h e t i m e and made the e f f o r t t o supply background material
and information upon which t h e format f o r t h i s program w a s
e s t a b l i s h e d . Regretably, t h e names of some c o n t r i b u t o r s may
have been omit ted; t h e i r sugges t ions and comments have, however,
been included i n t h i s r epor t .
L i s t e d
Amoco Product ion Company: J a c k i e Dendy, Dave Fleming,
E. R. Jennings, P a t r i c k Ket t ing , J. David Lawson,
Torn Pool , Frank Syfam
A t l a n t i c R ich f i e ld Company: W. R. Gregoire , C h a r l i e Latchem,
B i l l Roark
Con t inen ta l O i l Company: Burton Casad, Bob Matthews,
Fred Radd, D a n R i l ey
Exxon Company, USA: Martin E. True, R
Pennzoi l O i l Company: Dave Davis, Ed Horace Goodrich , I *
1 9 Bob P e t i t
Super ior O i l Company: A. F. Barry, R. L. Davis, B. W. Knighton,
H. J. V i c e
Tenneco O i l Company: K e n Calvert, P o w e l l Campbell, Bus ter Kel ly
U n i o n Texas Petroleum: Hayward Richard
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66
e QUESTIONNAIRE RESPONSE
A response t o t h e i n d u s t r y ques t ionna i r e was rece ived from
t h e fol lowing company r e p r e s e n t a t i v e s :
Pau l M. Berry, Mobil Research and Development Corporat ion
Michael E. Flynn, Exxon Company
A. B. H o r a i s t , Union O i l Company of C a l i f o r n i a
E. R. Jennings , Amoco Product ion Company
David J. Ledet , Amoco Product ion Company
J. A. Pramann, Shell O i l Company
R. D. Riley, Cont inenta l O i l Company
W. H. Si l cox , Chevron O i l F i e l d Research Company
Richard D. S w a n and Char les M. R e i m e r , Exxon Company
F. E. Syfan, Amoco Product ion Company
W. E. Westall, Con t inen ta l O i l Company
J. W. Wolfe, Con t inen ta l Oil Company
i
1
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67 (+estionnaire -- On Product ion P r o b l e m Due To Sand Erosion
The fo l la l i ing ques t ions concerning product ion problems due t o
sand e ros ion a r e an outgrowth of a meeting between r e p r e s e n t a t i v e s
of t h e petroleum i n d u s t r y and members of t he sand erosion research
group. Your b e s t answer t o each of the ques t ions is vital t o the
success of t h i s p r o j e c t . I f a d d i t i o n a l space is needed t o a n s w e r
a ques t ion , p l e a s e add supplementary pages as needed. If a
p a r t i c u l a r q u e s t i o n does not p e r t a i n to your opera t ions , please
a n s w e r "Not Applicable".
any ques t ion w i l l b e welcomed.
Any a d d i t i o n a l comments you make on
1. Flaw v e l o c i t y seems t o b e t h e cr i t ical parameter i n
Have you ever experienced a p o s s i b l e sand e ros ion problems.
' ' threshold" v e l o c i t y a t which t h e e r o s i o n rate appears t o suddenly inc rease? What w a s the numerical va lue? What flaw
phase does t h i s va lue i n d i c a t e ( o i l only o r a two o r three phase
s t ream)? What minimum f l w v e l o c i t y do you f e e l is necessary t o
keep from sanding up? Again, what flow phase does t h i s va lue
i n d i c a t e ?
2. Empir ica l equat ions have been developed t o c a l c u l a t e
t h e c r i t i c a l v e l o c i t y a t which excess ive e ros ion w i l l occur.
One example is Vcritical
d e n s i t y and N i n s l u g s / f t 3 i s a numerical cqnstant (100, 120, 160,
e t c . , depending on company procedure).
a s i m i l a r equa t ion? (If so, p l e a s e w r i t e i t down). Does t h e
equat ion seem r e l i a b l e ?
= N W f t / s e c i n which p is the flow
D o you employ o r know of
P l e a s e inc lude t h e units of p .
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3. H a v e you no t i ced . any r e l a t i o n between the Reynolds
If so, p l e a s e Number for a flow and sand e r o s i o n problems?
state your obse rva t ions .
4. The major f a c t o r s which c o n t r i b u t e t o the rate of sand
e r o s i o n i n p roduc t ion equipment seem t o be p a r t i c l e v e l o c i t y ,
p a r t i c l e ha rdness , p a r t i c l e shape , and t h e a n g l e a t which the
p a r t i c l e impacts w i t h the f i t t i n g .
o t h e r f a c t o r s which you cons ide r impor tan t?
C a n you add and d i s c u s s any
5 . A I O X sand concen t r a t ion by weight is consiZered by
some o p e r a t o r s t o cause t h e maximum e r o s i o n rate. Can you
supply any ev idence t o s u b s t a n t i a t e or coun te r t h i s c l a i m ?
P f you have in fo rma t ion on a "by volume" b a s i s , i t would also
b e apprec ia t ed .
r
- t
i
* I I l f t i
6. Have you had any ev idence t h a t t h e u s e of a polymer
might tend t o mask or h i d e an e r o s i o n rate:
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. 7. What is t h e in f luence of fluw v i s c o s i t y ? Could a high
v i s c o s i t y flow tend t o s h i e l d the p ipe and f i t t i n g s from the sand?
8. Some o p e r a t o r s have not iced t h ô t f i n e sand seems t o cause
a higher erosion rate than course sand.
along t h i s l i n e ?
Have you made any observa t ions
9. Although a l l p i p e and f i t t i n g s exper ience erosion, subsur face
s a f e t y va lves seem e s p e c i a l l y s u s c e p t i b l e according t o some opera to r s . .
Have you n o t i c e d any o t h e r f i t t i n g s (chokes, check v a l v e s , etc.)
t h a t seem t o e rode ou t a t an abnormally h igh rate?
.F
10. The obvious condi t ions which cause sand e r o s i o n inc lude
h igh v e l o c i t y flows and reg ions i n which t h e flow changes d i r e c t i o n .
Have you encountered any other p o i n t s a t which a h i g h e r than usua l
e r o s i o n rate is e v i d e n t ?
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11. What has been your experience wi th g r a v e l packing as a means
t o c o n t r o l sand product ion and thereby c o n t r o l sand e ros ion?
P l e a s e i n c l u d e reasons f o r successes and f a i l u r e s as w e l l as your
a p p r a i s a l of t h e merits of this sand c o n t r o l technique i n your ope ra t ions .
12. What has been your e x p e r i e n c a w i t h sand conso l ida t ion as
a means t o c o n t r o l sand product ion and sand e ros ion? P l e a s e inc lude
reasons f o r successes and f a i l u r e s as w e l l as your a p p r a i s a l of
t h e merits of t h i s s a n d c o n t r o l technique i n your ope ra t ions .
13. Any e r o s i o n tendency seems accelerated by the presence of
c o r r o s i v e agents .
and cor ros ion?
Have you n o t i c e d any c o r r e l a t i o n between e r o s i o n
14. "Bullplugs" s e e m t o provide a cushioning e f f e c t and
reduced e r o s i o n i n many cases i n which a d i r e c t i o n change i s
necessary f o r t h e flow. bu l lp lugs? Do you employ them as a matter of rou t ine? Do you
What has been your exper ience w i t h
t h i n k they are economical ly worthwhile?
OUTFLOW -L
li INFLOW
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15. Various types of f lowl ine sand d e t e c t o r s are available
and are be ing developed.
Is i t a r e l i a b l e i n d i c a t o r of e ros ion?
t h e expense?
DO you use any such device? What kind?
D o you feel i t i s worth
16. Have you t r i e d any sand erosion preven t ion schemes t h a t
w e r e unsuccessful o r d i d n o t work out n e a r l y as w e l l as a n t i c i p a t e d ?
P l e a s e d i scuss t h e scheme, what f a i l u r e occurred, and your a n a l y s i s
of the f a i l u r e .
17. Are you t r y i n g any w e a r resistant coa t ings such as ceramic
on your f i t t i n g s ? Please d i s c u s s any r e s u l t s , good o r bad.
Have you tried any other e r o s i o n r e s i s t a n t materials i n p l a c e of
normal carbon s tee l i n your f lowl ines? I f so, what material d i d
you use? How d i d t h e replacement m a t e r i a l perform? I f several
materials were t r i e d , p l e a s e l ist them i n o r d e r of e r o s i o n r e s i s t a n c e .
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18. Have you n o t i c e d any p a r t i c u l a r p re s su res o r downhole
. dep ths or o t h e r condi t ions a t which e r o s i o n seems acce le ra t ed?
19. Does your sand product ion emerge as i n t e r m i t t e n t s l u g s of
sand or as a continuous stream? Or is t h e r e no p a t t e r n at all?
20. How do you determine when a f i t t i n g i s about t o f a i l due
t o sand eros ion?
21, What measures have you t aken t o reduce sand e r o s i o n and
monitor 'sand product ion?
22. A t l o c a t i o n s which exper ience r eoccur r ing e r o s i o n f a i l u r e s ,
have you no t i ced any p a r t i c u l a r geometry which seems e s p e c i a l l y
s u s c e p t i b l e t o e r o s i o n problems?
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23. Do you employ a s t a n d a r d r e p o r t i n g procedure f o r a l l e ros ion
f a i l u r e s ? Do any f a i l u r e s undergo a l abora to ry ana lys i s? What
l abora to ry tests are used?
24. How f r equen t ly do you i n s p e c t f o r e ros ion? Do you f e e l
t h a t a r e g u l a r schedule or more f requent i n s p e c t i o n s would be
d e s i r a b l e ? Who conducts your in spec t ions? What follow-up
procedures do you i n i t i a t e when an i n s p e c t i o n i n d i c a t e s a p o s s i b l e
t r o u b l e spo t?
25. What a c t i o n do you t ake when a sand e r o s i o n problem i s discovered (reduce flow v e l o c i t y , s h u t down, e t c . ) ?
26. What is a t y p i c a l flow rate you have observed o r ca l cu la t ed
at a sand e ros ion f a i l u r e l o c a t i o n ?
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27. Have you o r your company conducted any sand e r o s i o n tes ts?
A r e any underway now o r a n t i c i p a t e d in t h e f u t u r e ? Without
r e v e a l i n g any p r o p r i e t o r y informat ion , any f i n d i n g s you could
d i s c u s s would be welcomed.
28. What do you cons ide r t o be your most c r i t i ca l sand e r o s i o n
problem?
29. A c o l l e c t i o n of f i t t i n g s t h a t have f a i l e d because of sand
erosion is be ing gathered. Any c o n t r i b u t i o n you could m a k e would
b e welcomed.
30. P l e a s e i n d i c a t e any a d d i t i o n a l q u e s t i o n s , comments, and
informat ion t h a t you f e e l is of importance.
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Your response t o t h i s ques t ionna i r e w i l l be formally
acknowledged i n a r e p o r t t o the API which w i l l b e made a v a i l a b l e
t o t h e p e t r o l e m i n d u s t r y . To give you and your company full c r e d i t , p l e a s e provide t h e fol lowing information:
YOUR NAME
COMPANY
MAILING ADDRESS S t r e e t o r Box
c i t y S t a t e Zip
TELEPHONE NUMBER AC Numb er Ex tension
Your t i m e , t r o u b l e , and e f f o r t s i n completing this q u e s t i o n n a i r e
I f I may provide any f u r t h e r a s s i s t a n c e are g r a t e f u l l y acknowledged.
o r in format ion , p l e a s e c a l l at 713/845-1251.
P l ease r e t u r n t h i s ques t ionna i r e and any a d d i t i o n a l comments t o
D r . P e t e r D. Weiner
Department of Mech ani cal Engineer ing
Texas A&M Unive r s i ty
Col lege S t a t i o n , Texas 77843
' Peter D. Weiner, P.E., Ph.D. Profes so r of Mechanical Engineer ing
COPYRIGHT 2003; American Petroleum Institute
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76 ANSWERS
Quest ionnaire On Product ion Problems Due To Sand Erosion
1. Flaw v e l o c i t y seems t o be t h e c r i t i c a l parameter i n Have you ever experienczd u p o s s i b l e sand e ros ion problems.
'I threshold" v e l o c i t y a t which t h e e ros ion rate appears t o suddenly inc rease? necessary t o keep from sanding up?
What minimum flow v e l o c i t y do you feel is
CONOCO - 1. a. Never experienced. 1.b. Never monitored. Probably
2-3 fps .
CONTINENTAL OIL CO. - 1. N o , b u t it probably e x i s t s . 2. No
g e n e r a l i z a t i o n is v a l i d . Depends on bottomhole pressure , whether
o i l o r gas w e l l , whether w e l l makes water, etc.
r a t e of flow i s normally determined by t r i a l and e r r o r .
The optimum
AMOC0 - We have n o t experienced a threshold v e l o c i t y which causes
inc reased erosion.
t o c r i t i c a l v e l o c i t y . The minimum flaw v e l o c i t y t o prevent t he
formation of sand plugs i s unknown. I n general , w e do n o t have
accura te measurements of sand q u a n t i t y and flow v e l o c i t y during
the per iod i n which a w e l l is sanding up. The minimum v e l o c i t y
would be expected t o be a func t ion of sand quan t i ty , sand shape,
f l u i d v i s c o s i t y , and mechanical arrangement of t he w e l l .
We usua l ly express v e l o c i t i e s with r e spec t
SHELL OIL - This is an experience f a c t o r which v a r i e s from w e l l
t o w e l l . Bu t , w e measure sand product ion i n shakeout tubes and
our rough experience r u l e of thumb i s t h a t above 0.1% by volume,
t h e sand product ion i s l i k e l y t o become a s e r i o u s problem.
AMOC0 - W e d id n o t i n v e s t i g a t e t h i s .
EXXON - We suspec t t h a t there is a th reshold v e l o c i t y , b u t have no
d a t a t o prove it a t present . W e have n o t ca l cu la t ed a minimal flow
v e l o c i t y r equ i r ed t o prevent sandup.
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Question No. 1. Continued 77
CONOCO - What minimum flcw v e l o c i t y do you feel is necessary t o keep
from sanding up? - Erosion is n o t n e c e s s a r i l y d i r e c t l y r e l a t e d t o
v e l o c i t y ; i t is d i r e c t l y r e l a t e d t o loss of energy t h r u f r i c t i o n .
Hence, there is no " threshold ve loc i ty ' ' b u t a " threshold f r i c t i o n
loss" which v a r i e s according t o Reynolds no. i.e., e r o s i o n rate varies
wi th flow r a t e and condui t geometry, and f l u i d p r o p e r t i e s .
w ( B / sec) R e = pieD
AMOCO - Although w e have n o t made a formal s tudy of th re sho ld
e ros ion v e l o c i t y , our e r o s i o n problems normally occur above +30 f t / s e c . -
EXXON - NA
AMOCO - (a) No. (b) A minimum flow v e l o c i t y has n o t been determined
due t o t h e l a r g e number of v a r i a b l e s involved.
MOBIL - A t a 90" impingement angle , e ros ion of b a r e steel is minimal
at sand v e l o c i t i e s of less than 20 f t /sec.
f o r t y p i c a l steels i s roughly 50 f t /sec. s l eeves may have a threshold v e l o c i t y of 200 f t / s e c .
flow v e l o c i t y necessary t o keep from sanding up depends on many
f a c t o r s .
A t h re sho ld v e l o c i t y
Blast j o i n t p r o t e c t i v e
The minimum
A r u l e of thumb is a mínimum v e l o c i t y of 0.4 f t / s e c .
CHEVRON - Flow v e l o c i t y should b e l i m i t e d t o 75 FI'S t o prevent
i n c r e a s i n g e ros ion rate.
should be: 5 FPS.
To prevent sanding up flow v e l o c i t y
UNION - We don' t have an experienced th re sho ld ve loc i ty .
publ ished d a t a w e use and accept 20 f p s as t h e m a x i m u m sand p a r t i c l e
v e l o c i t y acceptab le through a p e r f o r a t i o n and d i r e c t e d a t a tubing
b l a s t j o i n t .
From
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78
2. Empir ica l equat ions have been developed t o c a l c u l a t c t h e c r i t i ca l v e l o c i t y a t which excess ive e r o s i o n w i l l occur. One example is V = N / p f t /sec i n which P is t h e flow d e n s i t y and N is a numerical constant (100, 120, 160, etc. , depending on company procedure). Do you employ or know of a similar equat ion? ( I f s o , p l e a s e w r i t e i t 'down). Does the equat ion seem r e l i a b l e ?
c r i t i ca l
CONOCO - 2.a. No. 2.b. Not appl icable .
CONTINENTAL OIL CO. - Have no experience w i t h above.
AMOCO - W e use t h e equat ion V = lOO/.\cp . This equat ion c r i t seems r e l i a b l e from the s tandpoin t t h a t v e l o c i t i e s lower than
'crit sand product ion is present .
success i n r e l a t i n g e r o s i o n rates t o a r a t i o of Velocity/V cri t ' Erosion rates are a func t ion of f l o w pa th geometry, sand product ion,
f l u i d c o r r o s i v i t y , and t h e i n t e g r i t y of t he steel as in f luenced
by welding p r a c t i c e s .
w i l l n o t u sua l ly cause e ros ion un le s s s i g n i f i c a n t water o r
However, w e have had very l i t t l e
SHELL O I L - W e have n o t done any work i n t h i s area.
AMOCO - N O .
EXON - We do n o t u s e such an equat ion.
CONOCO - Standard procedure i s t o use C = 100 where
c = AQ v
. ::. , L . -
I
R e l i a b i l i t y of t h i s a r b i t r a r y f i g u r e is p r e s e n t l y unproven where:
A = c r o s s s e c t i o n a l area, ( i n ) inc ludes c o r r e c t i o n f a c t o r s f o r d i f f e r e n t 2
Q = flow rate, (MMCFPS) d i f f e r e n t s i z e tub ing (1.90 x c.f.)
A T = flowing temp., (OR)
P = f lowing tbg. press . , (ps ia ) 2 3/8" Tbg. 1.0 48.04 c.f. - -
2 7/8" Tbg. ,885 28.36 3 1/2" Tbg. .i75 16.53 4 1/2" Tbg. .645 8.39
!
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STD*API/PETRO 2-ENGL 177b 0732290 0582177 2T2
79 Question No. 2 Continued
AMOCO - Yes, w e use t h e formula Vc = lOO/w ( f t / s e c ) . I n every
area where sand e ros ion is a problem, the v e l o c i t y exceeds V . However, V
w e do n o t conclude t h a t 100 is n e c e s s a r i l y the most accu ra t e cons tan t
f o r t h i s equat ion .
C is usua l ly s i g n i f i c a n t l y less than V a c t u a l Theref o re
C
EXXON - NA
AMOCO - (a )
(b) appear t o be a r e l i a b l e equat ion f o r f l u i d s wi th sand.
loo/% i s used as t h e m a x i m u m , non-erosive ve loc i ty .
The equat ion is f o r f l u i d s wi thout sand. There does no t
MOBIL - The problem of sand e ros ion i s extremely complex.
equat ion given may be app l i cab le t o some s i t u a t i o n s . W e do n o t
employ t h i s o r ny s imilar equat ion.
The
CHEVRON - Design procedure i s t o use N =
2-phase flow and N = 120 f o r gas. Limit ing v e l o c i t y for some
new designs is 50 fps .
100 f o r l i q u i d o r
UNION - No background.
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80
3. Have you no t i ced any r e l a t i o n between the Reynolds I f so , p l e a s e Number for a flow and sand e r o s i o n problems?
state your observa t ions .
CONOCO - Never observed.
CONTINENTAL OIL CO. - Rela t ionship has n o t been s tud ied .
AMOC0 - We have n o t examined t h i s approach t o e ros ion .
SHELL OIL - None.
M O C O - We never made t h i s type of ana lys i s .
EEXXON - Have not invec t i g a t e d .
CONOCO - No observa t ions . Refer t o #i.
AMOCO - No, t h i s r e l a t i o n h a s n o t been eva lua ted .
EXXON - NA
AMOCO - NO.
MOBIL - For a given f l o w dens i ty , e ros ion rate is roughly p r o p o r t i o n a l
t o t h e cube of t h e flow rate.
CHEVRON - N / C
UNION - No observa t ions .
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81
4 . The major f a c t o r s which c o n t r i b u t e t o t h e rate of sand e r o s i o n i n product ion equipment seem t o b e p a r t i c l e v e l o c i t y , p a r t i c l e hardness , p a r t i c l e shape, and t h e angle a t which t h e p a r t i c l e impacts wi th t h e f i t t i n g . o t h e r f a c t o r s which you cons ider important?
Can you add and d i scuss any
CONOCO - The medium i n which t h e sand p a r t i c l e i s t r anspor t ed
has a bea r ing on sand e ros ion ; i.e., gas , be ing less dense &
viscous than l i q u i d , w i l l p rovide an environment more conducive
t o e r o s i o n than l i q u i d .
CONTINENTAL OIL CO. - Agree w i t h t h e above major f a c t o r s .
i n d i r e c t f a c t o r is t h e l eng th of pe r fo ra t ed i n t e r v a l i n t h e w e l l
which determines the p re s su re drawdown pe r u n i t area, thus t h e
volume of sand carries i n t o t h e w e l l bore.
An
AMOC0 - P a r t i c l e s i z e seems t o b e very important , i .e., f i n e
sand causes more seve re e ros ion than coarse sand. Th i s may
be due t o h i g h e r p a r t i c l e v e l o c i t y of s m a l l p a r t i c l e s .
may also have some e f f e c t as when a p a r t i c l e con tac t s t h e e roding
s u r f ace the re should b e some d i f f e r e n t i a l p ressure .
P res su re
SHELL OIL - NO.
moco -
EXXON - Viscos i ty of t h e ca r ry ing f l u i d . Densi ty of t he ca r ry ing f l u i d .
CONOCO - 1.
impart t h e a c t u a l s t r i k i n g force . 2. P a r t i c l e hardness and material
Combination of p a r t i c l e v e l o c i t y and Larticle dens i ty
hardness . 3. Frequency of p a r t i c l e impingement & angle , bo th of
which are increased i n areas of t u r b u l e n t flow. 4. P a r t i c l e
concent ra t ion .
AMOCO - A l l of our f lowl ine e r o s i o n problems occur i n h igh temperature
f law (+200°F). - W e b e l i e v e th i s to' be another s i g n i f i c a n t variable.
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Quest ion No. 4 Continued 82
EXXON - The medium i n which t h e sand i s c a r r i e d . Wetted sand i n
condensate seems t o e rode more r a p i d l y than sand i n oil.
AMOCO - N O .
MOBIL - In add i t ion , t h e mass of sand moving p e r unit t i m e m u s t b e
considered.
sand eros ion . Within p r a c t i c a l limits, t h e grade of t h e s tee l
does n o t need t o be considered.
The ca r ry ing medium a l s o seems t o a f f e c t t h e rate of
CHEVRON - The amount of abrasive p a r t i c l e s and amount water product ion
also con t r ibu te t o t h e rate of sand e r o s i o n i n product ion equipment.
Erosion depends on p a r t i c l e momentum.
UNION - N O
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83
5 . A 10% s a n d concent ra t ion by weight is considered by some opera tors t o cause t h e maximum e ros ion rate. C a n you supply any evidence to s u b s t a n t i a t e o r counter t h i s claim?
CONOCO - NO.
CONTINENTAL OIL CO. - NO.
AMOC0 - We do n o t have any w e l l s which c o n s i s t e n t l y produce t h i s
l a r g e a q u a n t i t y of sand.
q u a n t i t i e s as small as .i% can cause severe e r o s i o n and t h a t
v e l o c i t y and p a r t i c l e s i ze are more important f a c t o r s than
concent ra t ion i f t h e r e is a s i g n i f i c a n t ( a trace o r more)
con cen t ra t i on.
However, i t is our opinion t h a t
SHELL OIL - NO.
AMOCO - 98% of t h e equipment which eroded w a s w i th sand concent ra t ions
of less than O. 1%.
EXXON - We have no e m p i r i c a l evidence of t h i s .
CONOCO - NO.
AMOC0 - N o , we have no high v e l o c i t y completions which produce t h i s
much s a n d . Those w e l l s which have e ros ion problems only produce
s m a l l q u a n t i t i e s of sand.
EXXON - I n s u f f i c i e n t da ta .
AMOCO - NO.
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Question No. 5 Continued 84
MOBIL - NO.
CHEVRON - When sand concent ra t ion exceeds 10% no a d d i t i o n a l e ros ion
w a s noted.
been reduced by reducing stream sand concent ra t ion by merging a
sand f r e e stream wi th one car ry ing sand.
Many w e l l s sand up p r i o r t o 10%. Erosion rates have
UNION - The volume of sand produced has never been measured
i n our opera t ions . The t o o l s (for measurement) are not r e a d i l y
ava i l ab le .
excess ive sand eros ion and 2) f i l l i n g up product ion equipment wi th
sand or mud, etc.
The only m e a n s of measuring sand product ion has been i)
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85
6. Have you had any evidence t h a t t he use of a polymer might tend t o mask o r h i d e an e ros ion rate.
CONOCO - Never observed.
CONTINENTAL OIL CO. - NO.
AMOCO - W e do n o t understand t h e i n t e n t of th is ques t ion .
SHELL OIL - NO.
AMOC0 - NO.
EXXON - Yes, tests conducted at our P i e r c e Junc t ion l abora to ry i n
1971 and 19 72 i n d i c a t e d t h a t polymer probably decreased e r o s i o n rate.
CONOCO - NO.
AMOCO - NO.
EXXON - N O .
AMOCO - NO.
MOBIL - Use of some polymers can i n c r e a s e t h e th re sho ld v e l o c i t y
above 50 f t / s e c .
no substances t h a t o f f e r good p r a c t i c a l p ro t ec t ion .
Above sand v e l o c i t i e s of 200 f t / s e c , we know of
CHEVRON - N / C
U N I O N -No Experience
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86
7. What is the i n f l u e n c e of flow v i s c o s i t y ? Could a high v i s c o s i t y flaw tend t o s h i e l d t h e p i p e and f i t t i n g s from t h e sand?
CONOCO - 7.a. See 4. 7.b. A h igh v i s c o s i t y would tend t o s h i e l d
t h e p ipe and f i t t i n g s .
CONTINENTAL O I L CO. - It is poss ib l e .
AMOC0 - Our experience i n d i c a t e s that v i s c o s i t y is an important
f a c t o r i n e r o s i o n processes .
f a i l u r e frequency i n o i l p ip ing than i n gas piping.
5% of our corrosion-erosion r e l a t e d f a i l u r e s occur i n o i l s e rv i ce .
Our Research Department has v e r i f i e d t h a t e r o s i o n rates a c t u a l l y
decrease a t very h igh v e l o c i t i e s .
This is v e r i f i e d by a much lower
Only about
SHELL OIL -
AMOCO - W e d id n o t i n v e s t i g a t e .
EXXON - We have some evidence from f i e l d usage of sand probes which
tends t o i n d i c a t e t h a t h igh v i s c o s i t y crudes may have a r e t a r d i n g
e f f e c t on e ros ion rates.
CONOCO - Highly v iscous f l u i d s tend t o r e t a r d the frequency of
p a r t i c l e c o l l i s i o n s on t h e condui t w a l l . The i n f l u e n c e of v i s c o s i t y
is again seen i n determining whether flow is laminar o r t u r b u l e n t
i .e . , Reynolds' no.
AMOC0 - Viscos i ty may b e a f a c t o r i n h igh temperature flow, b u t
w e do n o t know t h i s t o b e t r u e . Low v i s c o s i t y may l u b r i c a t e t h e
sand and p ipe w a l l s less than a h i g h e r v i s c o s i t y .
EXXON - It could a i d i n sh i e ld ing . See Question 4.
AMOCO - (a) Unknown. (b) Unknown.
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87 (&estion No. 7 Continued
MOBIL - Do not have quantitative information to supply.
CHEVRON - N/C
UNION - It appears that dry gas streams are more subject to sand
erosion than streams that contain some liquids; i.e., water, condensate.
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88
8. Some ope ra to r s have n o t i c e d t h a t f i n e sand seems t o cause a h i g h e r e r o s i o n rate than course sand. a long this l i n e ?
Have you made any observa t ions
CONOCO - NO.
CONTINENTAL OIL CO. - NO.
AMOC0 - Fine sand does cause h i g h e r e r o s i o n rates than coarse
sand as i n d i c a t e d by our f i e l d experience. I n t e s t i n g e ros ion
of a s a f e t y va lve , our Research Department has v e r i f i e d t h a t f i n e
sand causes more e ros ion than coarse sand.
SHELL OIL - N o , I would suspec t t h e opposi te .
AMOCO - A l l t he sand produced i n Tr in idad is extremely f i n e
approx. 30% less than 325 US Standard Sieve.
EXXON - We have had one case where t h i s w a s t r u e , however, it i s
imposs ib le f o r us t o i s o l a t e t h e g r a i n s i z e e f f e c t from the e f f e c t s
produced by o t h e r v a r i a b l e s .
CONOCO - Under same flow condi t ions and t h e same number of sand
p a r t i c l e s , i t is f e l t t h a t t he l a r g e r , more dense p a r t i c l e s are
more ab ras ive . Usual ly f i n e sand e x i s t s i n g r e a t e r q u a n t i t y and
the frequency of c o l l i s i o n s wi th t h e condui t is much g r e a t e r and
t h e r e f o r e more damaging.
AMOC0 - Y e s , i n our most r e c u r r e n t f l owl ine e r o s i o n problem, sand
product ion w a s n o t observed un t i l a f l u i d sample w a s cent r i fuged .
A f i n e powdery sand w a s recovered. V A s 75 f t / s e c
V ss 25 f t f s e c C
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89
Quest ion No. 8 Continued
EXXON - Ours i s normally a f i n e grade of sand.
due t o t h e f a c t t h a t t h e f i n e sand releases from t h e formation
easier and s t a y s i n a s l u r r y wi th the o i l .
This is poss ib ly
AMOCO - N O .
MOBIL - P a r t i c l e s i z e and impingement angle are r e l a t e d as regards
e ros ion .
and very l i t t l e a t 90".
most s e r i o u s a t 90" impingement. The h a r d e r the material, t h e
more important t h e r e l a t i o n s h i p becomes.
S m a l l p a r t i c l e s i z e could cause damage a t 180" impingement
Large p a r t i c l e s i z e e r o s i o n is apparent ly
CHEVRON - Produced sand appears t o cause g r e a t e r sand e r o s i o n
problems than coarse sand.
UNION - Don't have any p a r t i c u l a r observa t ion t o base my opinion
on as t h e l a r g e s t pe rcen t of our sand makers produce f i n e sand.
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90
9. Although a l l p ipe and f i t t i n g s exper ience erosion, subsur face s a f e t y va lves seem e s p e c i a l l y s u s c e p t i b l e according t o some opera tors . Have you no t i ced any o t h e r f i t t i n g s (chokes, check va lves , e t c . ) t h a t seem t o erode out a t an abnormally h igh r a t e ?
CONOCO - Any r e s t r i c t i o n i n the flow path o r po in t of change i n
the flow pa th w i l l erode f a s t e r than o the r p a r t s .
CONTINENTAL OIL CO. - B a l l v a l v e s , i f l e f t only p a r t i a l l y opened
o r shu t .
AMOC0 - The e ros ion of subsur face s a f e t y va lves is h igh ly dependent
on the i n t e r n a l geometry of t h e valve.
valves i n both o i l and gas s e r v i c e have experienced t h e wors t e ros ion
are chokes, choke bodies , dump valves , and tees. Check va lves ,
e l l s , and o t h e r f i t t i n g s where flow d i r e c t i o n o r v e l o c i t y change
a l s o erode.
For example, many O t i s "F"
SHELL O I L -
- Otis both showed h igh rates of e ros ion Gray choke boxes
A l l types sand sc reens have shown high r a t e s of e ros ion .
EXXON - Chokes, Dump Valves on Separa tors , and f lowl ine elbows.
CONOCO - Flowlines d i r e c t l y downstream of t h e choke t o the product ion
manifold.
on header b a r r e l s oppos i te f lowl ine t i e - in .
Standard p r a c t i c e i n C a l i f o r n i a is t o weld "cushion pads"
AEIOCO - Downhole e r o s i o n is n o t a severe problem i n our h igh v e l o c i t y
opera t ions as t h e s e w e l l s are n o t equipped u/ wel lbore r e s t r i c t i o n s .
E X O N - The r o t a t i n g d i s k choke design (a t tached) is e s p e c i a l l y
s u s c e p t i b l e t o c u t t i n g out dawnstream due t o t h e angle which i s
imparted t o the sand p a r t i c l e s causing them t o s t r i k e t h e choke body.
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91
Quest ion No. 9 Continued
AMOC0 - Yes, chokes are e s p e c i a l l y s u s c e p t i b l e .
MOBIL - Any i n - l i n e f i t t i n g s t h a t involve an i n t e r n a l change of
d i r e c t ion.
CHEVRON - Abnormally high rates of e ros ion occur i n areas of
turbulence (above c t o m chokes, etc).
90" ells, b l a s t j o i n t s o r s e c t i o n s of t u b u l a r oppos i t e producing
p e r f o r a t i o n s , tees, dump va lves , c e n t r i f u g a l pump bodies and
impe l l e r s and items immediately downstream which are sub jec t ed
t o increased flow ve loc i ty .
Other f i t t i n g s are chokes,
UNION - The f i r s t s u r f a c t choke a t t h e Xmas tree and t h e f i r s t e l l
downstream of t h i s choke s u f f e r t h e l a r g e s t amount of sand e ros ion
problems.
s a d e ros ion q u i t e f requent ly . The water dump va lves are a f f e c t e d
more by sand e ros ion than condensate dump valves because as a r u l e
t h e p re s su re drops through t h e water valves are g r e a t e r .
Water dump valves on s e p a r a t o r s a l s o are damaged by
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9 2
10. The obvious condi t ions which cause sand e ros ion inc lude h igh v e l o c i t y f l m s and regions i n w h i c h t he flow changes d i r e c t i o n . Have you encountered any o t h e r p o i n t s at which a h ighe r than u s u a l e ros ion rate is evident?
CONOCO - Erosion is also gene ra l ly high at t u r b u l e n t p o i n t s downstream
of rest r i c t ions .
CONTINENTAL OIL CO. - NO.
AMOCO - Turbulent regions d m s t r e a m of r e s t r i c t i o n s o f t en erode.
Severe changes i n flow d i r e c t i o n i n a f i t t i n g usua l ly r e s u l t i n
s eve re erosion.
SHELL OIL - NO.
AMOCO - I n t h e Gray choke box t h e r e are s i x turns .
cu t out a t very high rates compared t o the Thornhill Craver
equipment used.
These chokes
EXXON - Any poin t of p re s su re drop.
CONOCO - Adjustable Wil l i s - type chokes u t i l i z i n g two ceramic d i s c s
are highly suscep t ib l e . Gates & seats on wing valves .
AMOC0 - Erosion appears t o b e s i g n i f i c a n t l y acce le ra t ed i n the
- + 6 ' downstream of the wellhead choke.
turbulence.
This is probably due t o
E X O N - Any l o c a t i o n where a l a r g e p re s su re drop i s experienced
tends t o create turbulence and cause e ros ion .
drop i m p l i e s r e s t r i c t i o n and t h e r e f o r e a l o c a t i o n where sand
impinging on m e t a l w i l l cause erosion.
O f course t h e p r e s s u r e
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9 3
Question No. 10 Continued
AMOC0 - High erosion has been noted downstream of chokes.
MOBIL - NO.
CHEVRON - Higher erosion rates occur on parts operating under high
pressure differentials , on perforations, and particularly the
tubing run through a producing zone i n duals, e t c .
q ues t i onn a i re) (Drawing on
UNION - NO.
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STD-APIIPETRO 2-ENGL rn 0732290 0582392 509 m
9 4
11. Some opera tors have managed to reduce sand e r o s i o n by g r a v e l packing. Have you t r i e d t h i s method? Any luck?
CONOCO - 1l.a. Y e s . 1 l .b . Yes.
CONTINENTAL OIL CO. - This Div is ion has done one g r a v e l pack job
b u t w e l l f a i l e d t o produce, pre-packed liners were run i n a few
w e l l s s e v e r a l yea r s ago b u t only one w e l l i s s t i l l producing.
Plugging of t h e gravel-pack occurred i n t h e o t h e r wells.
M O C O - As prev ious ly d iscussed , most of our e r o s i o n i s in gas
l i n e s .
b u t t h e o r e t i c a l l y a good g r a v e l pack should reduce sand product ion
and eros ion .
to reduce sand product ion, however, w e do no t u sua l ly exper ience
e r o s i o n i n o i l systems.
We have had very poor success g r a v e l packing gas w e l l s ,
We have been s u c c e s s f u l i n g r a v e l packing o i l wells
SHELL OIL - Yes, w e have had cons iderable experience.
s e r i o u s sand c o n t r o l problems g r a v e l packing i s t h e most e f f e c t i v e
method c u r r e n t l y ava i l ab le .
For
AMOCO - Y e s , g r a v e l packing and t h e t r i p l e wrap sc reen have been
used. Trace amounts of sand are s t i l l made. I t is t he t r a c e
amounts which do the most damage.
EXXON - Y e s . Y e s . Open h o l e gravel-packed w e l l s produce less sand.
CONOCO - Have g r a v e l packed i n t e r v a l s t o 600' i n th i ckness i n
unconsol idated sand and have been very success fu l .
s t a r t i n g t o g r a v e l pack by t h e S l u r r y Pack process t o g e t h ighe r
product ion rates and longer pe r fo ra t ed i n t e r v a l s .
We are now
AMOC0 - NO.
E X O N - NA
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STD.API/PETRO 2-ENGL L77b D 0 7 3 2 2 9 0 0582393 4 4 5 D
95
Quest ion No. 11 Continued
AMOC0 - (a) Yes. (b) Some.
MûBIL - Yes. I f t h e g r a v e l i s properly s i z e d wi th r e spec t t o
formation sand size, grave l packs can prevent t h e movement of
sand i n t o t h e wel lbore.
CHEVRON - Have had good success wi th g rave l packing.
UNION - We have not had a g r e a t d e a l of experience wi th g r a v e l
packing gas w e l l s .
b u t our experience is l imi ted .
Those t h a t have been g r a v e l packed seem s u c c e s s f u l
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96
12. Sand conso l ida t ion would appear as a reasonable method Have you had any exper ience wi th t h i s
Were your e f f o r t s success fu l , of no consequence, o r t o c o n t r o l sand eros ion . technique? poss ib ly even de t r imen ta l f o r sand e ros ion con t ro l ?
CONOCO - 12.a. Y e s . 12.b. Yes, although i t has never been
de t r imen ta l t o sand e r o s i o n c o n t r o l , i t has at times been de t r imen ta l
t o f l u i d product ion.
CONTINENTAL O I L CO. - Sand conso l ida t ion has been t h e method used
i n a l l w e l l s i n t h i s Div is ion where sand product ion is an t i c ipa t ed .
P l a s t i c i z i n g on completion has gene ra l ly been s u c c e s s f u l (80-90%).
AMOC0 - Were your e f f o r t s success fu l , of no consequence, o r
poss ib ly even de t r imen ta l f o r sand e ros ion con t ro l ?
some gas w e l l s which have been p l a s t i c consol idated.
when proper ly used, does restrict sand product ion, which i n t u r n
should reduce e ros ion .
r e q u i r e s a s h o r t p e r f o r a t e d i n t e r v a l and a l s o restricts permeabi l i ty .
Therefore , most w e l l s t h a t are p l a s t i c consol idated do no t produce
a t high enough rates t o cause e ros ion .
We do have
The p l a s t i c ,
However, s u c c e s s f u l conso l ida t ion usua l ly
SHELL OIL - We have had cons iderable experience wi th sand consol ida t ion .
This technique has a p p l i c a t i o n s b u t is n o t as e f f e c t i v e as grave l
packing.
AMOCO - Sand conso l ida t ion w a s n o t used i n Trinidad.
EXXON - Some success.
CONOCO - Sand conso l ida t ion done under i d e a l cond i t ions has a very
good chance of success , a l s o works b e s t i n new w e l l s . W e have
consol ida ted t h e sand i n several w e l l s s u c c e s s f u l l y by p l a s t i c
t r e a t i n g . Th i s w a s used more t o prevent sanding-up than sand eros ion .
P l a s t i c t r e a t i n g w i l l p revent sand incu r s ion i f t h e fol lowing precaut ions
are taken. (Continued)
i
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STD.API/PETRO 2-ENGL 1 9 7 b D 0732290 0582375 218
97 Question No. 12 Continued
CONOCO - (Continued)
a)
b) c) Prevent completion f l u i d , water , etc. from mixing i n t o
Flow clean p e r f s b e f o r e p l a s t i c i z i n g
Keep a l l i n j e c t i o n f l u i d s clean & f r e e of any s o l i d s
t re atmen t
d) D o not f r a c formation
e ) Leave w e l l shut- in s u f f i c i e n t l y t o allow p l a s t i c t o cure.
AMOCO - Not to c o n t r o l sand erosion.
have p l a s t i c i z e d w e r e no t causing e ros ion problems.
The completions which we
E X O N - NA
AMOC0 - (a ) Y e s . (b) P a r t i a l l y successfu l . - MOBU., - No q u a n t i t a t i v e d a t a t o o f f e r .
CEEVRON - Sand consol ida t ion w a s no t always 100% e f f e c t i v e but no
evidence found t o be de t r imenta l . Gravel packing is more e f f e c t i v e .
UNION - Success rate seems poor. The permeabi l i ty damage seems
t o cause more r a t e reduct ion on the w e l l s than would normally b e
required t o con t ro l sand by rate reduct ion alone.
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98
13. Any e ros ion tendency seems acce le ra t ed by the presence of Have you no t i ced any c o r r e l a t i o n between e ros ion co r ros ive agents .
and cor ros ion?
CONOCO - Yes.
CONTINENTAL OIL CO. - A c o r r e l a t i o n has been no t i ced i n certain areas.
AMOCO - The combined e f f e c t s of co r ros ion and e r o s i o n have been
very seve re i n some of o u r piping. The cor ros ion i s p r i m a r i l y
condensate corrosion" due t o o rgan ic ac ids (our gas has about
Corrosion-erosion has been found
I I
1% CO2 and very l i t t l e H2S.)
t o be p a r t i c u l a r l y s e v e r e i n h e a t e f f e c t e d areas adjacent t o
welds and i n t h e weld metal i t s e l f . We cons ider combined
corrosion-erosion t o b e a major problem.
SHELL OIL -
moco - No.
EXXON - We have no e m p i r i c a l evidence t o i n d i c a t e this, though i t
seems t h e o r e t i c a l l y p l a u s i b l e .
CONOCO - Yes.
AMOCO - Yes, t h e presence of CO h igh temp, and sand has caused 2'
very s e v e r e e r o s i o n which is uniform along t h e f lowl ines . -
EXXON - Any corroc ion w i l l speed up t h e f a i l u r e as w e l l as weaken
t h e m e t a l and provide a coarse s u r f a c e f o r t h e sand t o s t r ike.
AMOC0 - Y e s .
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STD.API/PETRO 2-ENGL L97b 0732290 0582397 090
99 Ques t ion No. 1 3 Continued
MOBU, - Yes. even minimal e ros ion can i n c r e a s e t h e rate of m e t a l l o s s t o corros ion .
I n any environment where cor ros ion is encountered,
CHEVRON - Y e s , one aggrava tes t h e o t h e r .
UNZON - Very d e f i n i t e l y .
g ives a rough s u r f a c e for sand t o attack.
seems t r u e - corros ion rate inc reased by eros ion .
Once co r ros ion has s t a r t e d , i t very o f t e n
Actua l ly t h e r eve r se
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100
14. "Bullplugs" seem t o provide a cushioning e f f e c t and reduced e r o s i o n i n many cases i n which a d i r e c t i o n change i s necessary f o r t h e flow. bu l lp lugs? th ink they are economically worthwhile?
What has been your exper ience wi th Do you employ them as a matter of rou t ine? Do you
CONOCO - 14.a. We have used them t o prevent e r o s i o n a t tu rns i n
p ip ing . 14.b. Only when t h e r e is p o s s i b i l i t y t h a t w e l l w i l l
produce sand. 14.c. Yes, s i n c e they can save shut-down t i m e
and l a b o r t o r e p a i r a l i n e .
CONTINENTAL O I L CO. - Bullplugs are used as a matter of rou t ine
b u t e r o s i o n m i t i g a t i o n is probably a secondary cons idera t ion .
No s tudy of t h i s p r a c t i c e has been made.
AMOC0 - W e use "bul lplugs" r a t h e r than "ells" i n l o c a t i o n s where
an e x t r a long r ad ius e l l cannot be used and severe e r o s i o n due
t o sand is expected.
f o r a long t i m e , i t seems t o b e an improvement over e l ls , b u t
t he "bullplug" and t h e "tee" s t i l l experience e r o s i o n i n some
cases. I n add i t ion , the e x t r a weld requi red is s u b j e c t t o
corrosion-erosion f a i l u r e s and i n c r e a s e s t h e p r o b a b i l i t y of
t h a t mode of f a i l u r e .
Although w e have n o t been us ing t h i s method
SHELL OIL - We do employ b u l l p l u g s as a matter of r o u t i n e and
f e e l they are economically worthwhile.
AMOCO - Bullplugs perform b e t t e r than ells.
employs them as a m a t t e r of rou t ine .
worthwhile e s p e c i a l l y i n an of f shore opera t ion .
Amoco Tr in idad now
I b e l i e v e they are economically
i
EXXON - We have found t h a t b u l l p l u g s tend t o bo th s h i f t t h e a rea
of m a x i m u m dwnst ream and t o reduce the t o t a l amount of erosion.
We ins ta l l them in l i e u of elbows on a l l new and replacement
f lowl ines where sand might poss ib ly be a problem.
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._ , _ -
l o 1 Question N o . 1 4 Continued
CONOCO - Yes t o a l l ques t ions ; however, v e l o c i t y c o n t r o l is still
necessary.
AMOCO - No.
gas w e l l s which r e q u i r e welded connections.
e r o s i o n occurs i n subsur face pumps.
Our w e l l s which have e ros ion problems are h igh p res su re
The only o t h e r p reva len t
E X O N - I pe r sona l ly t r y t o employ them whenever t h e d o l l a r c o s t
is no t p r o h i b i t i v e . They are worthwhile i n reducing e r o s i o n i n
sha rp angles .
AMOC0 - (a) Experience has been good. (b) Y e s , on t h e f i r s t
bend downstream of chokes. (c ) Yes.
MOBIL - Bullplugs do reduce e r o s i o n damage. The p lug improves t h e
angle of impingement as w e l l as reduces t h e s p i r a l motion of t h e
f l u i d downstream of the tum. Th i s improved flow p a t t e r n reduces
v e l o c i t y of eroding p a r t i c l e s .
CHEVRON - Bullplugs have been used s u c c e s s f u l l y on headers and on
90" turns downstream of flcw r e s t r i c t i o n s .
and are considered economical.
They are used rou t ine ly
U N I O N - Our experience has been t h a t b u l l p l u g s or t a r g e t s , do i n
f a c t work.
l i n e d o r long r ad ius hook-ups.
W e use t h e s e when i t is n o t p o s s i b l e t o i n s t a l l ctrearn-
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15. Various types of f lowl ine sand d e t e c t o r s are a v a i l a b l e and are be ing developed. Is it a r e l i a b l e i n d i c a t o r of e ros ion? t h e expense?
Do you use any such device? What k ind? Do you f e e l i t is worth
CONOCO - 15.a. No. lS.b. N o appl icable . 15.c. Not app l i cab le .
15.d. Not app l i cab le .
CONTINENTAL OIL CO. - No d e t e c t o r s have been i n s t a l l e d b u t a sand
probe i s be ing obta ined i n the n e a r fu tu re . L i t e r a t u r e i n d i c a t e s
t h a t i t w i l l b e worth the expense.
AMOC0 - We use an e r o s i o n d e t e c t o r that senses e r o s i o n of t h e p ip ing
i t s e l f t o shu t i n t h e well when e ros ion becomes ex tens ive . This and
o t h e r e r o s i o n monitors (such as t h e one developed by Exxon) should
d e t e c t e r o s i o n , however, none of ours have been a c t i v a t e d by
e r o s i o n y e t . The expense and complication of e r o s i o n monitors
r e s t r i c t s t h e i r use t o p i p i n g t h a t has previous ly experienced
e ros ion .
SHELL O I L - We do n o t use any of t hese devices b u t have t e s t e d some.
AMOCO - None were used i n Tr in idad .
EXXON - (i) by t h e EXXON Offshore D i s t r i c t .
s e r v i c e were b u i l t by Camco, though w e have some by O t i s , some by
CSE (La faye t t e , La.) and some b u i l t i n our P i e r c e J u n c t i o n Laboratory.
(3) I n two yea r s , w e have never experienced a s i n g l e case of
f lowline/equipment cu tou t on a w e l l p ro t ec t ed by a p rope r ly i n s t a l l e d ,
p rope r ly s i z e d sand probe. ( 4 ) T o t a l expenses.
W e use "sand probes", which were invented and developed
(2) Most of t h e probes w e have i n
CONOCO - A s o n i c d e t e c t o r is be ing used f o r w e l l completion t e s t i n g .
Twenty-two expendable sand probes have r e c e n t l y been i n s t a l l e d .
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10 3 Question No. 15 Continued
M O C O - No, b u t t he "Macco Sand Probe" i s t o b e f i e l d t e s t e d s h o r t l y .
EXXON - We use a smal l probe which is b a s i c a l l y a pres su re gage
alarm. When t h e probe erodes through, t h e change i n p r e s s u r e s i g n a l s
an alarm. It i s worth t h e expense i n that i t i s one of t h e b e t t e r
a v a i l a b l e methods of d e t e c t i n g e ros ion .
AMOCO - NO.
MOBIL - Yes.
by Mobil Research and Development. We also use u l t r a s o n i c th i ckness
measurements, and O t i s sand dec to r s . These devices provide
u s e f u l information r e l a t e d t o e ros ion .
p r e d i c t a f a i l u r e be fo re i t occurs is worthwhile.
must be considered along w i t h t h e expense of t h e consequences of
a f a i l u r e . Some i n s t a l l a t i o n s , very c r i t i ca l ones, can j u s t i f y
a l a r g e expense.
W e use t h e Surface Sand Detec t ion system developed
Any procedure t h a t w i l l
The expense
CHEVRON - 3 Vanguard Sand Probes are i n se rv i ce . One c u t ou t wi th
no apparent e r o s i o n & f lowl ine .
s e r v i c e f o r 4 months w i t h no cu t o u t s t o da te .
needed b e f o r e r e l i a b i l i t y and j u s t i f i c a t i o n can be determined.
3 C a c o probes have been i n
More t e s t i n g i s
UNION - No sand d e t e c t o r s have been used t o date .
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104
16. Have you t r i e d any sand e r o s i o n prevent ion schemes that were unseccessfu l o r did n o t work o u t nea r ly as w e l l as a n t i c i p a t e d ? P l e a s e d i scuss t h e scheme, what f a i l u r e occurred, and your a n a l y s i s of t h e f a i l u r e .
CONOCO - 16.a.
pockets a t po in t s of flow change o r provid ing a d d i t i o n a l p ipe &
f i t t i n g w a l l th ickness .
b u t tend t o provide a means of l i v i n g wi th e ros ion .
None o t h e r than provid ing bu l lp lugs o r f l ange
These are n o t e ros ion prevent ion schemes,
CONTINENTAL OIL CO. - R e s i l i e n t b l a s t j o i n t s were t r i e d oppos i t e
p e r f o r a t i o n s bu t d id n o t prove s a t i s f a c t o r y as evidenced by
r ap id e ros ion .
p e r f o r a t i o n s and below s a f e t y valves . However e ros ion s t i l l
occurs .
a smooth s u r f a c e f o r pack-Offs.
Hardened s tee l b l a s t j o i n t s are now used oppos i te
Flow couplings are used below b l a s t j o i n t s t o provide
AMOC0 - We have not t r i e d anything unusual.
i n t h e fu tu re .
We do p lan some tests
SHELL OIL -
AMOCO - NO.
EXXON - N O .
CONOCO - I n s t a l l e d sand t r a p s , i.e. h o r i z o n t a l v e s s e l w /ba f fe l s t o
d i v e r t f luid-sand drawoffs l oca t ed on bottom v e s s e l . Thinking w a s
t h a t v e l o c i t y would be reduced and sand would se t t le and b e drawn o f f .
Worked t o a reasonable degree w / o i l w e l l s , b u t v i s c o s i t y of f l u i d
& r e t e n t i o n t i m e would n o t permit good segrega t ion .
AMOCO - Y e s , w e have t r i e d t o treat w i t h f i l m forming i n h i b i t o r s ,
b u t r e s u l t s were poor. Lowering v e l o c i t y w/ l a rge r I.D. f l owl ines
has been o u r only s u c c e s s f u l approach t o date .
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10 5 Ques t ion No. 1 6 Continued
. <
E X O N - With t h e choke problem, a downstream p o s i t i v e choke w a s
employed t o prevent t h e sand from inpinging on t h e w a l l s and t o t r y
t o d i r e c t sand flow t o t h e center of t h e pipe.
e f f e c t i ve .
It w a s moderately
AMOCO - Sand t r a p s have been used i n one remote loca t ion . It w a s
d i f f i c u l t t o ope ra t e and maintain.
MOBIL - No experience.
CHEVRON - Unsuccessful sand e r o s i o n prevent ion schemes:
a) I n c r e a s i n g w a l l th ickness of s teel i n 90" r ad ius b inds - cont inued t o cut-out u n t i l a tee and cushion c a v i t y i n s t a l l e d .
b ) I n s t a l l e d sand sc reen on f lowl ine immediately downstream of
tree. IL quickly c u t out. c) B l a s t j o i n t s oppos i te p e r f o r a t i o n s
sometimes c u t ou t prematurely.
UNION - The only th ing t h a t has been t r i e d w a s a s a f e t y s h u t i n
device t o s h u t i n a w e l l a f t e r t h e sand e r o s i o n has c u t at choke
body o r f lowl ine .
tub ing around t h e c r i t i c a l area. This tub ing w a s t h e pneumatic
l i n e c o n t r o l l i n g the s u r f a c e s a f e t y valve.
has never worked. This compares t o locking the barn after t h e
ho r se i s s t o l e n .
This approach w a s t o t i g h t l y wrap 1/4" p l a s t i c
To my knowledge t h i s
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10 6
1 7 . Are you t r y i n g any wear r e s i s t a n t coa t ings such as ceramic on your f i t t i n g s ? P lease d i scuss any r e s u l t s , good o r bad. Have you t r i e d any o t h e r e ros ion r e s i s t a n t m a t e r i a l s i n p l a c e of normal carbon steel i n your f l awl ines? I f so , what material d i d you use? How d i d t h e replacement material perform? w e r e t r i e d , p l e a s e l i s t them i n o r d e r of e r o s i o n resistance.
I f s e v e r a l materials
CONOCO - 17.a.
pump p a r t s when sand product ion is expected. 17.b. Better than
steel . 17.c. Not i n f lowl ines , b u t ha rd metals such as tungsten
have been used f o r surfac;ng p a r t s i n r e s t r i c t e d flows. 17.d.
S t a i n l e s s steels have been used i n f lowl ines , b u t t h e s e were
in tended f o r cor ros ion prevent ion and no t e ros ion . 17.e. Not
app l i cab le . 17 . f . Not appl icable .
Ceramic is normally used i n wel lhead chokes and
CONTINENTAL O I L CO. - No d e t a i l e d informat ion available on the
n a t u r e of t h e r e s i u e n t material used. See above.
M O C O - We have n o t used any s p e c i a l coa t ings o r materials except
i n va lve and choke t r i m . Ceramic o r tungs ten ca rb ide i s used.
f o r t hese services.
SHELL OIL - W e normally use s teel b l a s t j o i n t s f o r e r o s i o n
product ion i n t h e upper zones of d u a l completions.
AMOCO - Only i n t h e chokes where e i t h e r ceramic o r t ungs t en carb ide
are used. Both ceramic and tungs ten ca rb ide perform, much b e t t e r
than s t a i n l e s s s t ee l o r S t e l l i t e .
Erosion r e s i s t a n c e - tungs ten carb ide , ceramic, Stel l i te , mild steel
s t a i n l e s s steel.
EXXON - W e have used tungs ten ca rb ide t r i m i n choke beams and gas
flow c o n t r o l valves wi th some success . However, w i t h enough sand
and enough v e l o c i t y tungs t e n ca rb ide does erode.
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STD.API/PETRO 2-ENGL 197b 0 7 3 2 2 7 0 0582205 T î 7 m
10 7 (luescion No. 1 7 Continued
CONOCO - Ceramic chokes have been used s u c c e s s f u l l y .
AMOCO - We are p resen t ly f i e l d t e s t i n g a f luwl ine s e c t i o n which is
i n t e r n a l l y coated u/ "E lec t ro l e s s Nickel".
r ecen t ly i n s t a l l e d and i t s performance has n o t y e t been determined.
This p i p e w a s only
EXXON - S t a i n l e s s appears s l i g h t l y b e t t e r than C.S.
w e a r resistant is t he cemented tungs ten carbide.
t r i m b u t is n o t f e a s i b l e for t u b u l a r goods.
The most
This makes good
AMOC0 - (a) Y e s , no s tudy ava i l ab le . (b) No.
MOBIL - Ceramic f i t t i n g s are no t e f f e c t i v e a t 90" impingement
angles . We have a l s o eva lua ted o t h e r materials. Polypropylenes
can be e f f e c t i v e at sand v e l o c i t i e s up t o 200 f t / s e c and temperatures
up t o 185'F.
CHEVRON - Ceramic g a t e valves and chokes have s u c c e s s f u l l y been
used. Rubber l i n e d valves and pumps i n l o w p r e s s u r e service were
used success fu l ly . Tungsten, used on t a r g e t s , has given b e t t e r
results than ceramics.
UNION - We have t r i e d ceramic and Tungsten Carbide trimmed chokes.
Tungs ten Carbide seems to provide b e t t e r service under more extreme
condi t ions .
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10 8
18. Have you n o t i c e d any p a r t i c u l a r pressures o r downhole depths a t which e ros ion seems acce le ra t ed?
CONOCO - Never observed.
CONTINENTAL OIL CO. - No, except t h a t a gas sand pe r fo ra t ed oppos i te
a tub ing s t r i n g c o n s t i t u t e s t h e wors t downhole condi t ion f o r e ros ion .
AMOC0 - No, b u t t h e e f f e c t s of temperature and p res su re on f r e e
water in t h e p ip ing can i n c r e a s e corrosion-erosion by i nc reas ing
t h e presence of a c i d i c f r e e w a t e r .
SHELL OIL - NO.
AMOC0 - NO.
EXXON - NO.
CONOCO - NO.
AMOC0 - NO.
EXON - When a w e l l is completed i n a r e l a t i v e l y loose packed sand
formation and has the characteristics t o l i f t t h e sand (high flow rate)
t o the s u r f a c e erosion i s acce le ra t ed .
AMOC0 - Most e ros ions seem t o be r e s t r i c t e d t o top 3,000' of tubing.
MOBIL - No experience.
CHEVRON - NO.
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109 Question No. 18 Continued
UNION - The biggest sand erosion problem d d o l e i s at the blast
joint in a dual completion.
because of sand erosion.
Interzone communication problems occur
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110
19. Does your sand product ion emerge as i n t e r m i t t e n t s l u g s of sand o r as a continuous stream? O r is t h e r e no p a t t e r n a t a l l ?
CONOCO - 19.a. Both. 19.b. Low w e l l v e l o c i t i e s produce sand i n
s l u g s and genera l ly r e s u l t i n sanded-up tubing. High w e l l v e l o c i t i e s
produce sand i n a continuous stream.
CONTINENTAL O I L CO. - Believed t o b e i n s l u g s i n most cases b u t
some w e l l s produce a s teady stream of sand, e s p e c i a l l y gas w e l l s .
AMOCO - We do n o t have any r e l i a b l e d a t a on t h i s top ic .
SHELL OIL - No, the re does n o t seem t o b e a p a t t e r n .
AMOCO - Trace amounts are made cont inuously wi th i n t e r m i t t e n t
s lugg ing from some w e l l s .
EXXON - It depends e n t i r e l y on t h e r e s e r v o i r . Some produce s m a l l
amounts of sand at a s teady rate. Others produce no sand a t a l l
u n t i l they suddenly "cave in" dawnhole, produce s l u g s of sand, and
f i n a l l y sand up.
CONOCO - No p a t t e r n except when a w e l l starts producing water sand
product ion i s acce le ra t ed .
- AMOCO- The only patterns w e have observed is i nc reased sand product ion
w/ i nc reased producing ïa te .
EXXON - More of a sand-oi l s l u r r y a t high f l o w rates.
AMOCO - (a ) Both. (b) No P a t t e r n .
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111 Question No. 19 Continued
MOBIL - Any of these sand production types can and do occur.
CHEVRON - There is no sand production pattern.
streams have been experienced.
Slugs and continuous
UNION - W e s e e m t o have a l l three.
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1 1 2
20. How do you determine when a f i t t i n g is about t o f a i l due t o sand eros ion?
CONOCO - By u l t r a s o n i c i n s p e c t i o n and previous e r o s i o n h i s t o r y .
CONTINENTAL OIL CO. - Penetron surveys are run on r e g u l a r schedules
on a l l p la t forms .
f i t t i n g s e t c . is determined and replacements made where needed.
A check on t h e th i ckness of t h e m e t a l i n f lowl ines ,
AMOCO - W e d e t e c t e r o s i o n and p r e d i c t when f a i l u r e s w i l l occur
p r imar i ly on t h e b a s i s of u l t r a s o n i c w a l l t h i ckness in spec t ions .
Erosion i n welds and some f i t t i n g s i s d e t e c t e d by rad iographic
techniques, i f f a i l u r e frequency warrants t h e expense of a radio-
graph i c i n s p e c t ion .
SHELL OIL -
AMOCO - When i t f a i l e d .
f i t t i n g s . U l t r a son ic t e s t i n g was done on a l l flow l i n e s t o
check f o r e ros ion .
There w a s no p r e d i c t i v e method used on
EYXON - By v i s u a l , u l t r a s o n i c , o r rad iographic i n s p e c t i o n subsequent
t o sand probe cu touts .
CONOCO - Routine audiogage of f i t t i n g s & f lowl ines .
AMOCO - Quar te r ly u l t r a s o n i c in spec t ion .
E X O N - Sand probes p rev ious ly mentioned p l u s v i s i b l e i n s p e c t i o n by
opera tors .
AMOCO - By a "cor ros ion - e r o s i o n survey" us ing an u l t r a s o n i c device.
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11 3 Question No. 20 Continued
MOBIL - Ultrasonic thickness measurements have been used.
appropriate inspection and replacement procedures are more widely used.
However,
CHEVRON - Biannual thickness surveys ultrasonic and X-ray instruments
are useful.
and warning of erosion i n system.
Choke inspection gives evidence of sand production
UNION - 1) Annual X-ray. 2) Visual inspection for loss of metal.
I - . .. - .. . . _ .
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114
21. What measures have you taken t o reduce sand e r o s i o n and monitor sand product ion?
CONOCO - Reduction i n stream v e l o c i t i e s and g r a v e l packing w e l l s
which produce sand.
samples of w e l l product ion f l u i d s .
Sand product ion i s monitored by tak ing p e r i o d i c
CONTINENTAL OIL CO. - Only as p rev ious ly mentioned:
on optimum rate, running b l a s t j o i n t s , etc. W e are cons ider ing
use of more sand probes i n l i n e s .
p u t t i n g w e l l
AMOCO - Sand e r o s i o n has been decreased by us ing "bullplugged"
tees, e x t r a long r ad ius "ells", and l a r g e r I . D . p iping.
product ion is monitored p r imar i ly by a shake-out of produced
l i q u i d s when w e l l tests are taken.
Sand
SHELL OIL - We attempt t o monitor sand product ion wi th wel lhead
shakeouts .
AMOCO - Change t o ha rde r materials t o reduce e ros ion . Sand shake
out used t o monitor sand product ion.
EXXON - On new f lowl ines and on w e l l s where t h e f lowl ine is rep laced
due t o sand eros ion , w e i n s t a l l a l a r g e r l i n e (3" vs. 2") and use
bullplugged tees i n s t e a d of elbows.
CONOCO - While t e s t i n g a w e l l , a sand pot is used & cons tan t ly
monitored as a s a f e t y precaut ion . On producing w e l l s , t h e sample
po t i s checked a t l eas t weekly. (See 815)
AMOCO - N e w e r f lowl ines are designed t o keep f l u i d v e l o c i t i e s below
Vc. based on AOF ca lcu la t ions .
For d r i l l i n g x development w e l l s , new f lowl ines are designed
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115 Question No. 21 Continued
EXXON - Tungsten carb ides when p o s s i b l e , s t r a i g h t e n i n g devices , sand
probes, xxh p ipe t o inc rease l i f e i n v i t a l areas.
AMûCO - El imina te as many bends as p o s s i b l e , use long r ad ius bends.
MOBIL - Inc rease t h e number of open p e r f o r a t i o n s , i n c r e a s e p ipe
s i z e t o decrease flow v e l o c i t i e s .
i n tees. We a l s o decrease product ion rates. We use grave l packs
where appropr ia te . We a l s o monitor sand product ion us ing our
Surface Sand Detec tor system.
U s e wide ang le t u r n s and b u l l p l u g s
CHEVRON - To reduce sand e r o s i o n flcw v e l o c i t y is sometimes monitored
and l i m i t e d t o 75 f t / s e c . and f l u i d cushions are p laced a t d i r e c t i o n
changes. Sand probes are be ing t e s t e d .
UNION - Long rad ius e l ls and l a r g e diameter f lowl ines i n conjunct ion
wi th b l a s t j o i n t s downstream of Xmas tree p o s i t i v e chokes have been
i n s t a l l e d .
monitor sand production.
Sample b o t t l e s i n s t a l l e d on f lowl ines are used t o
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116
22. A t l oca t ions which experience reoccurr ing e r o s i o n f a i l u r e s , have you no t i ced any p a r t i c u l a r geometry which seems e s p e c i a l l y s u s cep t i b l e t o e ros ion prob l e m s ?
CONOCO - Those w i l l provide numerous flow changes and r e s t r i c t i o n s .
CONTINENTAL OIL CO. - NO.
AMOC0 - The most troublesome geometry is t h a t which r e q u i r e s impingement
i n a d i r e c t i o n perpendicular t o t h e m e t a l s u r f a c e as on t h e backs ide
of "tees" and t h e bottom of dump o r c o n t r o l valves.
bodies are a l s o troublesome.
Ells and choke
SHELL OIL - NO.
AMOCO - The Gray choke box is t h e only i t e m which we used i n which
geometry probably aided eros ion .
EXXON - Long s t r a i g h t runs of p ipe followed by elbows are most
s u s c e p t i b l e . Also f lowl ine r e s t r i c t i o n s such as chokes o r reduced
opening va lves followed by elbows and headers .
CONOCO - Already discussed.
AMOC0 - Normally, we use 2' r ad ius 45' bends i n ou r f lowl ines .
(Drawing on ques t ionna i r e )
EXXON - Any obs tac l e s t o f low o r areas of turbulence (elbows, tees, e t c ) .
AMOC0 - NO.
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Question No. 22 Continued 117
MOBIL - Yes. Sharp bends o r changes i n p ipe size.
CHEVRON - Flaw r e s t r i c t i o n s , v e l o c i t y and d i r e c t i o n changing devices ,
e.g. 90" reducing elbow, are most s u s c e p t i b l e t o e ros ion .
UNION - No, o t h e r than 90" angle turns.
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118
23. Do you employ a s t anda rd r epor t ing procedure f o r a l l e ros ion f a i l u r e s ? Do any f a i l u r e s undergo a l abora to ry ana lys i s?
CONOCO - 23.a. Yes, through our equipment f a i l u r e repor t . 23.b. Yes,
i f they are unusual o r r e s u l t from equipment malfunction.
CONTINENTAL OIL CO. - No s t anda rd procedures except i f no t i ced by
Penetron crew p r i o r t o f a i l u r e . A l ab a n a l y s i s is run only when
f a i l u r e i s of an unusual na ture .
AMOC0 - A l l equipment f a i l u r e s , e s p e c i a l l y those involv ing leaks
as do cor ros ion and e ros ion f a i l u r e s , are repor ted on a s tandard
form. Unusual f a i l u r e s are sometimes s e n t t o our Research Department
f o r i n spec t ion and a n a l y s i s of any cor ros ion products .
SHELL OIL -
AMOC0 - 1. No. 2. Yes, l a b s tudy c u r r e n t l y underway t o determine
why sand c o n t r o l s c reens are eroding.
EXXON - Yes.
per iod ending i n 1973.
ceased because of sand probe i n s t a l l a t i o n s on a l l w e l l s .
n o t analyzed any f a i l u r e s i n t h e l abora to ry .
fi e r o s i o n f a i l u r e s were r epor t ed f o r a two year
Since then , e r o s i o n f a i l u r e s have v i r t u a l l y
We have
CONOCO - No, o t h e r than on subsur face s a f e t y va lves on e ros ion
f a i l u r e is repor ted t o t h e U.S.G.S.
AMOC0 - Yes, each f a i l u r e i s repor ted t o t h e area o f f i c e through
use of a p r i n t e d Ques t ionna i r e .
t o ou r Company Research Dept. f o r e v a l u a t i o n of cause of f a i l u r e .
Most eroded specimens are t r ansmi t t ed
EXXON - Visual i n s p e c t i o n i s made and r e p o r t s are w r i t t e n on cause
and p o s s i b l e c o r r e c t i v e measures.
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119
Question No. 23 Continued
AMOCO - (a) Yes. (b) Y e s .
MOBIL - Not applicable t o us, although we do laboratory analyses
i n special situations.
CHEVRON - Standard reporting procedures follow a l l surface erosion
failures. However, no routine lab analyses i s made.
UNION - No to a l l questions.
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120
24. H o w f r equen t ly do you i n s p e c t f o r e ros ion? Do you f e e l t h a t a r e g u l a r schedule o r more f requent i n spec t ions would be d e s i r a b l e ? Who conducts your in spec t ions? What follow-up procedures do you i n i t i a t e when an inspec t ion i n d i c a t e s a p o s s i b l e t r o u b l e s p o t ?
CONOCO - 24.a. Various, depends on e ros ion h i s t o r y . 24.b. Our
schedule appears appropr ia te . 24. c. F i e l d personnel and u l t r a s o n i c
i n s p e c t o r s from our mainteiiance engineer ing s t a f f . 24.d. Repair ,
r ep lace and/or redes ign and revise opera t ions .
CONTINENTAL OIL CO. - Annually i n most cases.
in spec t ions can be arranged i f needed. Conducted by maintenance
engineer ing s e c t i o n of Con t inen ta l O i l .
c o n s i s t of replacement of aping, valves o r equipment.
More f requent
Follow up procedures
AMOCO - All our gas p ip ing and p ip ing which might be s u b j e c t t o
e r o s i o n is inspec ted a t least annual ly by an Amoco employee us ing
an U l t r a s o n i c w a l l th ickness meter.
a computer program t o p r e d i c t a f a i l u r e da te . The f a i l u r e da t e
inco rpora t e s a s a f e t y f a c t o r and a l l p ip ing is rep laced b e f o r e
t h e f a i l u r e da t e .
The readings are e n t e r e d i n t o
SHELL OIL -
AMOCO - Ultra s o n i c surveys w e r e conducted monthly.
EXXON - W e i n spec t f l owl ines a f t e r every t h i r d sand probe cutout .
We a l s o i n s p e c t f l owl ines annual ly o r less o f t e n based on sand
probe experience and previous i n s p e c t i o n r e s u l t s . In spec t ions
are done by a service company.
as i n d i c a t e d by in spec t ions .
Flowlines o r components are rep laced
CONOCO - Annual audiogage i n s p e c t i o n on each platform.
i n s p e c t i o n s may be needed at c e r t a i n l o c a t i o n s .
performed by Conoco's maintenance engineer ing group.
are remedied.
More f requent
Inspec t ions are
Trouble s p o t s .. .. .. . .
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12 1
Question No. 24 Continued
AMOCO - Quar te r ly .
conduct t h e in spec t ions . I f i t is deemed necessary, t h e f a c i l i t y
i s s h u t i n . Otherwise, it is repa i r ed as soon as poss ib le .
F i e l d personnel and t h e area cor ros ion engineer
EXXON - Inspec t ion are d i f f i c u l t as they imply shutdown t o in spec t .
As f a r as I know w e do n o t x-ray i n s p e c t f o r e r o s i o n unless the
need arises.
AMOCO - (a) Yearly. (b) Y e s . (c) P r o f e s s i o n a l assistants.
(d) Order replacement of damaged material. -
MOBIL - Operat ions personnel , r a t h e r than research personnel perform
t h i s func t ion .
CHEVRON - Erosion in spec t ions are made b i annua l ly on headers , a f t e r 5
yea r s service on s e p a r a t o r s and every 2 years t h e r e a f t e r , and on
hot-spots upon reques t .
Of g r e a t e r importance is l i m i t i n g v e l o c i t y and making proper design
f o r charges i n flow d i r e c t i o n .
cons t ruc t ion engineers and v e l o c i t y monitor ing i s done by product ion
personnel wi th problems r epor t ed t o cons t ruc t ion engineers .
These in spec t ions are made through Associated Inspec t ion & Tes t ing ,
Inc. , Vin Rus Inspec t ion Co . , o r Owensby & Kri t ikos , Inc. Trouble
s p o t s are given immediate a t tent ion-normally r e s u l t i n g i n replacement
wi th a more adequate design.
E x i s t i n g i n s p e c t i o n program seems s a t i s f a c t o r y .
Thickness surveys are handled by
UNION - W e are v i s u a l l y i n s p e c t i n g only sand makers on a monthly
b a s i s . This appears t o b e adequate. W e conduct an annual X-ray
in spec t ion of a l l w e l l s and c e r t a i n s e l e c t e d manifolds and risers.
F i e l d Operators conduct t h e v i s u a l i n spec t ions . When an i n s p e c t i o n
i n d i c a t e s a p o s s i b l e t r o u b l e spo t , several follow-up procedures
are poss ib le :
e l i m i n a t e sand product ion , r ep ip ing t o s t r eaml ine flow, o r r e p a i r
w i t h inc reased frequency of inspec t ion .
reduce w e l l flow rate, remedial work on w e l l t o
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122
25. What a c t i o n do you take when a sand e r o s i o n problein is discovered (reduce flow v e l o c i t y , shu t down, etc.)?
CONOCO - See 24.d. (Repair , r ep lace and/or redes ign and revise
opera t ions .
CONTINENTAL OIL CO. - The usual procedure is t o c u t back on t h e
rate of f l m i f e ros ion is severe .
AMOCO - I f a f a i l u r e is imminent, t he process o r w e l l i s shut- in .
I f design f e a t u r e s are not a t f a u l t , t he equipment is replaced.
I f e ros ion is due t o ar! inadequate des ign then t h e system is
redesigned t o minimize e ros ion .
SHELL OIL -
AMOC0 - Repair equipment and cont inue t o flow.
EXXON - When a sand probe c u t s ou t , t h e w e l l s h u t s i n au tomat ica l ly .
Fur ther a c t i o n (reduced flow rate, sand conso l ida t ion i n workover,
shut - in , e t c . ) depends on a procedure which is a t tached .
CONOCO - Replace damaged p a r t . Product ion i s reduced only when
t h e r e i s a danger of sand-up.
AMOCO - The f a c i l i t y i s s h u t d a m and t h e eroded p a r t replaced.
E X O N - Depends on s e v e r i t y of problem. I f i t is a cu tou t of
t ub ing o r pipe, we s h u t d w n and r e p a i r , t hen v i s u a l l y i n s p e c t .
AMOC0 - Reduce production.
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Question No. 25 Continued 123
MOBIL - Action is based on particular s i tuat ion that has occurred.
CHEVRON - When sand erosion problem is discovered, f l o w ve loc i ty
i s reduced and s p e c i f i c equipment is redisgned or replaced i f
economically feas ib le .
UNION - Reduce flow rate and observe.
trimmed choke.
ve l o c i t y .
Install Tungsten Carbide
Modify piping t o streamline flow or reduce flow
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124
2 6 . What is a t y p i c a l flow rate you have observed o r ca l cu la t ed a t a sand e ros ion f a i l u r e loca t ion?
CONOCO - Not ca l cu la t ed .
CONTINENTAL OIL CO. - On a gas w e l l p la t form e r o s i o n is no t i ced
a t rates i n the o rde r of 5 m c f / d / w e l l .
t o provide t y p i c a l da ta .
O i l rates are t o o v a r i a b l e
AMOCO - Erosion occurs a t flow rates equa l t o o r g r e a t e r than t h e
maximum non-erosive flow rate" f o r a p a r t i c u l a r system. The maximum II
non-erosive flow rate i s t h e flow rate f o r which the v e l o c i t y
equals V
i s usua l ly a s soc ia t ed wi th sand or water product ion.
maximum non-erosive flow rates a t 1200 psig pres su re are 4 MMCm
f o r 2 inch p ip ing and 10 MMCFD for 3 inch p i p i n g when XX-Hvy
p ip ing is used.
excess of twice t h e maximum non-erosive f l m rate.
Erosion occas iona l ly occurs a t lower rates, b u t c r i t * Typica l
Severe e r o s i o n usua l ly occurs a t rates i n
SHELL OIL -
AMOC0 - We never made any c a l c u l a t i o n s .
EXXON - Three t o twenty feet p e r second f o r o i l w e l l f lowl ines .
h i g h e r i n chokes and i n gas w e l l s . Much
CONOCO -
AMOCO - From f 45 f t / s e c t o + 80 f t / s e c . - -
EXXON - 1000 B / D
AMûCO - Variable.
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12 5 Question No. 26 Continued
MOBIL - Insuff ic ient quantitative data t o of fer .
CHEVRDN - Flowrates greater than 75 FPS are typical at sand erosion
fa i lure locations.
flowing in to low pressure (100 - + p s i ) system through 2” NPS
flowlines.
More s p e c i f i c - 1000-2000 BOPD with 800-1500 GOR
UNION - I don’t think you can name a typical f l a w rate.
erosion fa i lures have occurred from 1,500 MCF/D to 15,000 MCF/D.
Sand
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126
27. Have you o r your company conducted any sand e r o s i o n t e s t s ? A r e any underway now o r a n t i c i p a t e d i n t h e f u t u r e ? r evea l ing any propr i e to ry information, any f i n d i n g s you could d i s c u s s would be welcomed.
Without
CONOCO - 27.a. No, n o t i n t h i s d i v i s i o n of t h e Company. 27.b. Not
app l i c a b le.
CONTINENTAL O I L CO. - No knowledge of above.
AMOCO - Some sand e r o s i o n tests have been made on s a f e t y valves.
We p lan t o test s e v e r a l welding techniques t o determine an optimum
method f o r a l l e v i a t i n g t h e corrosion-erosion problems w e have
had w i t h welds, b u t t h i s w i l l be a p r a c t i c a l test r a t h e r t han a
sand test.
SHELL O I L -
AMOCO - Experiments are being conducted t o determine t h e mechanism
of e r o s i o n on a sand c o n t r o l sc reen .
a h o l e i n a s c r e e n in t h e lab a t rates i n excess of t h o s e i n
t h e f i e l d .
As y e t w e have n o t eroded
EXXON - Success fu l tests were conducted a t P i e r c e Junc t ion i n 1971
and 1972 t o determine t h e e f f e c t i v e n e s s of sand probes and of
bu l lp lugged tees vs . elbows. S e e SOE F a l l 1973 P r e p r i n t 114555 a t t ached .
CONOCO - No tests t o da t e .
AMOCO - Not i n o u r ope ra t ions i n Lake Charles .
EXXON - Y e s .
AMOC0 - (a) Y e s . (b) Unknown.
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127 Question No. 27 Continued
MOBIL - Y e s t o both ques t ions .
t o d i scuss these f i n d i n g s , huwever.
prob lems i n ob ta in ing clearance.
W e w i l l have t o o b t a i n c l ea rance
We would n o t a n t i c i p a t e any
CHEVRON - About mid-1974 we w i l l u t i l i z e a n o i s e record ing device
by Schlumberger-Mobil t o determine sand product ion rates from upper
zones of dua l w e l l .
UNION - No formal t e s t i n g t o my knowledge i n t h e f i e l d .
Research Lab has conducted tests t o determine t h e abras ion r e s i s t a n t
p r o p e r t i e s of va r ious b l a s t j o i n t material. For more information,
I suggest you con tac t Union's Research Lab i n Brea, Ca l i fo rn ia .
The
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STD-APIíPETRO 2-ENGL L77b 0 7 3 2 2 7 0 058222b 7 1 1 Ip
128
28. What do you cons ider t o be your most c r i t i c a l sand erosion prob l e m ?
CONOCO - Pr imar i ly our o b j e c t i v e is t o prevent sand product ion
s i n c e t h i s maintains w e l l product ion and prevents e ros ion .
t h i s w e design equipment t o b e s t l i ve wi th t h e problem.
e r o s i o n is t h e most c r i t i ca l problem s i n c e i t i s t h e most expensive
t o r e p a i r .
F a i l i n g
Downhole
CONTINENTAL OIL CO. - G a s w e l l s .
AMOCO - Our most c r i t i ca l sand e ros ion problem occurs i n choke
bodies and i n f i t t i n g s w i t h undes i r ab le geometry. Our o t h e r c r i t i c a l
problem i s t h a t of corrosion-erosion i n h e a t e f f e c t e d zones.
-
SHELL OIL - Those t h a t are a matter of s a f e t y o r could a f f e c t t h e
environment.
AMOC0 - Erosion of t h e d m h o l e sand c o n t r o l equipment, i.e. g r a v e l
pack screens .
EXXON - Headers and check va lves .
CONOCO - Choke beans on subsu r face s a f e t y valves. Surface choke bodies .
AMOCO - High v e l o c i t y e r o s i o n of flowlines i n gas w e l l s . - EXXON - Chokes i n o f f shore service.
u n t i l e ros ion occurs .
Usual ly rates are increased
AMOC0 - Choke bod ies and i n d i r e c t h e a t e r c o i l s .
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. I STD.API/PETRO 2 - E N G L 197b 0 7 3 2 2 7 0 0582227 b 5 8 E
Question No. 2 8 Continued 129
MOBIL - B l a s t damage t o product ion tub ing i n dua l ly completed gas
wells, and s u r f a c e f a c i l i t y damage.
CHEVRON - Cr i t i ca l e ros ion problems exist on subsur face s a f e t y
devices , b l a s t j o i n t s , product ion headers , wellhead chokes, and
downstream of high p res su re (50W p s i ) vessel dump valves . The
most c r i t i c a l o r dangerous s i t u a t i o n would be a cu t ou t bottom
master valve on a Xmas tree.
UNION - Sub-surface s a f e t y valve sand e ros ion is probably the most
seve re problem. The next m o s t s eve re problem is a t t h e t u r b u l e n t
area d i r e c t l y downstream of t h e p o s i t i v e choke a t the Xmas tree.
B l a s t j o i n t s oppos i te the upper zone p e r f o r a t i o n s i n a dua l are
a l s o c r i t i c a l .
-
f
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29. e ros ion i s be ing gathered. b e welcomed.
A c o l l e c t i o n of f i t t i n g s t h a t have f a i l e d because of sand Any con t r ibu t ion you could make wculd
CONOC0 - Any f i t t i n g that restricts o r causes change of f law K i l l
f i t i n t o t h i s category.
CONTINENTAL OIL CO. - This could probably b e arranged.
AMOCO - We would b e happy t o donate equipment t h a t has f a i l e d , X-rays
of e ros ion , and photographs of equipment t h a t has f a i l e d .
SKELL OIL -
AMOC0 -
130
W O N - W i l l s h i p a small c o l l e c t i o n .
CONOCO -
AMOCO - Most of ou r eroded equipment is t r ansmi t t ed t o our Research
Department i n Tu l sa where i t is t e s t e d .
EXXON - NA
AMOCO -
MOBIL - W e have an elbw t h a t is an e x c e l l e n t example of f a i l u r e
due t o v e l o c i t y change.
UNION - Other than dump valve trim, we don't have any at present .
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131
30. P lease i n d i c a t e any a d d i t i o n a l ques t ions , comments, and informat ion t h a t you f e e l is of importance.
CONOCO - Pr imar i ly sand e r o s i o n problems should b e cured r a t h e r
than prevented. Th i s means s topping sand product ion. Even wi thout
sand e r o s i o n t h e product ion of sand creates many o t h e r problems
i n t h e process ing of gas and o i l and r equ i r e s f r equen t c leaning
of process ves se l s .
e r o s i o n resistant materials t h a t i nc reases on-stream time is very
b e n e f i c i a l .
Hawever, any design of p ip ing o r use of
CONTINENTAL O I L CO. -
AMOCO - We are one of t h e groups t h a t recommended t h i s p r o j e c t .
We f e e l t h a t t h e approach should be t o determine what e f f e c t t h e
v a r i a b l e s have on e ros ion rates and t h a t t h e goal should b e a
set of cr i ter ia t o determine what measures should be taken t o
prevent e ros ion when t h e v a r i a b l e s are known.
SHELL O I L -
moco -
EXXON -
CONOCO -
moco -
EXXON - Lines c u t t i n g ou t w h i l e a d r i l l i n g ope ra t ion is going on has
made t h e USGS cons ider no product ion wh i l e d r i l l i n g on t h e same
p la t fo rm of fshore . There i s a need t o f i n d b e t t e r c o r r e c t i v e measures
i n t h e i n d u s t r y from both an economical as w e l l as a s a f e t y s t andpo in t .
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132
Question No. 30 Continued
AMOC0 -
MOBIL - None.
CHEVRON -
l JNION - Please be aware t h a t t h e comments made r e f e r t o t h i s o f f i c e ' s
experiences which are exc lus ive ly connected wi th gas production.
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133
APPENDIX III
TEST RUNS AND DATA
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STD.API/PETRO 2-ENGL L77b D 0732290 0582232 T L 5 D
134
SAND EROSION TEST DATA
Run 1 - 50
Sand: 40/60 f r a c (dry)
T e s t s e c t i o n : 90' e l l
Elapsed t i m e , Sand flow, hours pounds
o. O00 O. 516
1.084
1.653
2.183
2.723
3.317
3.854
4.386
4.92
5.487
6.00
6.535
7.101
7.666
8.229
8.745
9.267
9.773
O
100
200
300
400
500
6 10
71 O
8 10
9 10
10 10
1110
12 10
1310
1410
1510
16 10
1710
18 10 **
Date: 10-22-74
Flow v e l o c i t y : 50 f t f s e c
I n i t i a l weight: 1061.5 grams
Test s e c t i o n Test s e c t i o n weight , grams weight loss, gram
1061.5
1058.8
1056.8
1055. O
1053.5
1051.9
1050. O
1048.2
1047. O
1045.2
1043.2
1041.5 1040. O
1038.5
1036.2
1034.4
1032 8
1031.0
1029.5
0.0
2.7
4.7
6.5
8 .O
9.6
11.5
13.3
14.5
16.3
18.3
20.0
21.5
23.0
25.3
27.1
28.7
30.5
32.0
Average sand flow rate: 185 l b / h r 3.09 lb/mín
**Specimen d i d NOT f a i l . T e s t aborted because of low wear rate. -
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136
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STD.API/PETRO 2-ENGL L97b 0732270 0582235 72q
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,
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S T D - A P I / P E T R O 12-ENGL L97b = 0732290 0582237 57'7
139
SAND EROSION TEST DATA
Run 2 - 70
Sand: 40/60 frac (dry)
Test s e c t i o n : 90' e l l
Elapsed t i m e , hours
o. O00
O. 242
O. 478
0.720
1.172
1.736
2.307
2.868
3 .430
4.000
4.716
5.368
5.898
6.459
6.970
7.501
Sand f low, pounds
O
40
80
120
200
300
40 O
500
60 O
680
780
900
1000
1100
1200
1292"
Date: 10-11-74
Flow v e l o c i t y : 70 ft/sec
I n i t i a l weight: 1065 grams
Test s e c t i o n weight, grams
1065
106 3
1060
1058
1055
1049
1044
1040
1034
1029
1024
10 18
1013
100 8
100 3
998.2
Test s e c t i o n weight l o s s , grams
0
2
5
7
10
16
2 1
25
31
36
4 1
47
5 2
57
62
66.8
Average sand flow rate: 172.24 l b / h r 2.87 lb/min
*FAILURE
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S T D - A P I / P E T R O 2-ENGL 277b D 0732290 0582238 433
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i ' -
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G O 4-
ro O 84 U s
C O 4 . . C 3 E:
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141
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rri h
STD-APIIPETRO 2-ENGL 1976 W 0732270 0582242 764
O \o
rri O rri ri I4
144
O h
I CJ
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~~~~ ~
STD.API/PETRO 2-ENGL L97b 0732290 0582293 A T O 9
a al rl d 4 w C
rl L) al a m *
i!
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\o VI U O m
O O O N
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DISCUSSION OF RESULTS
146
RUTS 1-50 and 2-70
R u n s 1-50 and 2-70 provided t h e f i r s t r e s u l t s d i r e c t l y
comparable f o r two d i f f e r e n t f low v e l o c i t i e s , 50 f t / s e c and 70 f t / s e c .
As i nd ica t ed on t h e comparison p l o t s , t h e sand f low rate was
s l i g h t l y h igher a t 50 f t / s e c than a t 70 f t / s e c and t h e o t h e r
parameters ( temperature , sand g r a i n s i z e , flow loop geometry, etc.)
w e r e t h e same.
flow rate is thought t o be n e g l i g i b l e s i n c e t h e 50 f t l s e c specimen
wi th t h e h igher sand flow rate cont inued t o be s e r v i c e a b l e (it w a s
never t e s t e d t o f a i l u r e ) long a f t e r t he 70 f t / s e c specimen wi th
t h e lower sand f low rate had f a i l e d .
due t o t h e excess sand a t 50 f t / s e c is minimal as evidenced by t h e
wide gap i n the wear ra tes of t h e two 90' ells.
of t h e e l l a t 70 f t / s e c is about t h r e e times t h e wear rate a t
50 f t /sec. I f a sand p a r t i c l e w e r e t o have t h e same speed as t h e
airstream, the 70 f t / s e c p a r t i c l e would have roughly twice t h e
k i n e t i c energy a v a i l a b l e t o e rode t h e e l l as t h e 50 f t / s e c p a r t i c l e .
The comparison of t h e w e a r rates i n d i c a t e s t h a t a p o s s i b l e v e l o c i t y
th re sho ld may exist above which t h e wear rate becomes excessive.
tests are necessary a t h ighe r v e l o c i t i e s t o e s t a b l i s h whether o r
n o t such a c r i t i ca l v e l o c i t y e x i s t s o r could be def ined .
specimen is a v a i l a b l e and w i l l b e t e s t e d t o f a i l u r e t o provide a
b a s e l i n e for t h e wear rate.
The e f f e c t of t h e s l i g h t discrepancy i n t h e sand
Any p o s s i b l e cushioning e f f e c t
The wear rate
More
The 1-50 ft /sec
i
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147
SAND EROSION TEST DATA
RUI 3-70-A
Sand: 40/60 f r a c (dry)
T e s t s e c t i o n : 90° e l l
Elapsed t i m e , hours
o. O00 O. 530 1.067
1.610 2.150
2.700
3,240
3.762 4.298
4.83 5.375
5.912 6.463 6.995 7.543 7.641
Sand flow, pounds
O 100
200 30 O 400
500
600
700
80 O 900
1000
1100
1200 1300 1400 1420*
Date: 12-3-74
Flow velocity: 70 f t / s e c
I n i t i a l weight: 1075.6 grams
T e s t s e c t i on weight , grams
1075.6
1068.0
1063.5 1059.3
1055.5
1051.0
1046.6
1041.2
1038.4 1032.1 1025.7
1019.8
1015.0
1010. o 1004.0 1003. O
Test s e c t i o n weight loss, grams
o .o 7.6 12.1 16.3
20.1
24.6
29.0
34.4 39.2
43.5 49.9
55.8
60.6 65.6 71.6 72.6
Average sand fltm rate: 186 lb /hr 3.10 lb/min
*Fai lure
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STD.API/PETRO 2-ENGL 1976 D 0732270 05822Lib 50T D
i _.
.. .
1 I
i
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a 2\, 4 a
v'
,-
149
b h l = I Q r J
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STD.API/PETRO 2-ENGL L77b O732290 0582248 382 .
C 15 O i C.- C- c i c-
I I I I l l
I I I I I * I I I l l I I
I-
--
I l l I I I I I
l I - 1 I I
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+I-----+.---- - i+--- +,ce.-- + I I I
l I I I I : \ I .. c I I I
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n
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n
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I
c 151 c
r r
c r
u al Q u o U m
c i
C i C
r-
rr
c c
n
U 4 v1
3
I
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~~ ~ ~
~ ~~~~~
STD.API/PETRO 2-ENGL 177b m 0732290 0582250 T30 m
152
SAND EROSION TEST DATA
Run 3-70-B
Sand: 40/60 f r a c (dry) T e s t s e c t i o n : 90' e l l
Elapsed t i m e , Sand flaw, hours pounds
o. O00 O. 530
1.067
1.610
2.150
2.700
3.240
3.762
4.298
4.830
5.375
5.912
6.463
6.995
7.543
7.641
O
100
200
30 O
400
500
600
700
800
900
1000
1100
1200
1300
1400
1420*
Date : 12-3-74
Flow v e l o c i t y : 70 f t / s e c
I n i t i a l weight: 1068.2
T e s t s e c t i o n T e s t s e c t i o n weight, grams weight l o s s , grams
1068.2
1059. O
1054.4
1050. O
1046.0
1041. O
1036.2
1031.0
1027.0
1023.1
1017.0
1011.4
1006.8
1002.4
998.4
997.0
0.0
9.2
13.8
18.2
22.2
27.2
32.0
37.2
41.2
45.1
51.2
56.8
61.4
65.8
69.8
71.2
Average sand flow rate: 186 l b / h r 3.10 lb/min
W e s t n o t continued t o f a i l u r e because t h e upstream e l l (3-70-A) f a i l e d firs t.
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STD.API/PETRO 2-ENGL L77b D O732270 0582253 777
I
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.. .. . . . I . STD-API/PETRO 2-ENGL L77b = 0732290 0582252 803
I
15 4 c 1.
0 t - - - - - * c - - - - t -I- c.- c + e<- c- - .i -I- -- - .L
I I I 1 - 1 I I I i c i I I I I I I
I I I I
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I l
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+ + + - - - I - +--I--,+, r t + c c c - c + c + c e I - + , I l i - I
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r -
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STD.API/PETRO 2-ENGL L77b = 0732270 0582253 7'4T D
+ I - - - * ++,I- -+c +---cc I l I I I I I I I I I I I I I I I I I I l I I 1 J. a- I- Y 1 -- &-'- L -c -c &
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I * . n
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n
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STD.API/PETRO 2-ENGL L77b 9 0732290 0 5 8 2 2 5 5 512
U h
J: O Il U Q
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159
. .835 lb/rnin
Sand Detec tor set on Range 4
A Typical Sand Detec tor Output For Low Sand Flow
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Sand Detector S e t on Range 5
A Typical Sand Detector Output For High Sand Flow
!
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STD-API/PETRO 2-ENGL 177b H 0732270 05822bL 8Lb
i 16 3
DISCUSSION OF RESULTS
Run 3-70 (A and B)
Run 3-70 w a s designed t o a s c e r t a i n whether o r n o t the ab ras ive
a c t i o n of t h e sand p a r t i c l e s tended t o break down t h e sand p a r t i c l e s
themselves i n t o smaller sizes o r perhaps "round of f" t h e a n g u l a r i t i e s
of t h e p a r t i c l e s t o produce a sphere- l ike geometry. I f e i t h e r o r
bo th of t hese a c t i o n s occurred, t h e wear rate of t h e downstream
e l l (e l l B) should be d i f f e r e n t from t h a t of t h e upstream e l l ( e l l A)
upon which t h e p a r t i c l e s f i r s t impinge.
wear rates of t h e e l l s i n d i c a t e almost i d e n t i c a l wear rates f o r
both el ls .
s e r v i c e a b l e , t h e remaining service l i f e of e l l B appeared minimal.
It is noted t h a t e l l A i n i t i a l l y weighed more than e l l B b u t the
small excess weight was w i t h i n manufacturing to l e rances and
con t r ibu ted nothing t o t h e l i f e of t h e e l l .
of t h e sand p a r t i c l e s by means of a h igh power microscope revea led
no apprec iab le change i n t h e s i z e and shape of t h e sand p a r t i c l e s
be fo re and a f t e r pass ing through t h e flawloop. Therefore , t h e
similar wear rates are c o n s i s t e n t w i t h t h e lack of change i n t h e
sand p a r t i c l e geometry.
The two p l o t s of t h e
Although e l l A a c t u a l l y f a i l e d and e l l B remained
Subsequent examination
A comparison has a l s o been made f o r t h e w e a r rates of e l l A
i n 3-70 and t h e ell of 2-70.
l i f e s of t h e ells are almost i d e n t i c a l which i n d i c a t e s no
apprec i ab le e f f e c t of t h e downstream e l l (e l l B) i n run 3-70. "he
Again, t h e wear rates and service
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164
apparent i nve r s ion i n t h e wear rates due t o whether Elapsed T ime
o r Sand Flow i s s e l e c t e d as t h e h o r i z o n t a l axis is due t o t h e
computational method f o r the a n a l y t i c a l curve f i t and a l s o the
almost i d e n t i c a l l i n e s lopes .
t h e inve r s ion would have n o t occurred,
Had t h e wear rates been ve ry d i f f e r e n t ,
Some t y p i c a l sand d e t e c t i o n ou tpu t s have a l s o been included.
The d e t e c t o r w a s c a l i b r a t e d for a p a r t i c u l a r range (corresponding
t o an a n t i c i p a t e d sand flow rate) by plac ing t h e d e t e c t o r i n t h e
flowstream and i n j e c t i n g a known amount of sand i n a given t i m e .
The sand d e t e c t o r ou tput is s t eady which corresponds t o t h e s t eady
rate a t which sand w a s i n j e c t e d i n t o t h e flowstream.
output w a s obtained on an a u x i l i a r y s t r i p c h a r t recorder dr iven a t
3 3 / 4 i nch / sec r a t h e r than on the reco rde r furn ished wi th t h e
d e t e c t o r because t h e d e t e c t o r recorder moves a t 1 inchAr, too
slow f o r t h e des i r ed d a t a t o be recorded f o r t h e s e tests.
The sampile
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16 5
SAND EROSION TEST DATA
RU 4 - 7 0 - A
Sand: 16/20 f r a c (dry)
T e s t s e c t i o n : 90' e l l
Elapsed time, hours
0.000
1.058
2.181
3.214
3.985
4.759
5.516
6.418
7.296
8.334
9.191
10.051
10.897
11.758
12.616
13.483
15.216
Sand flaw, pounds
O
100
200
300
400
500
600
700
800
900
1000
1100
1200
1300
1400
1500
1700*
Date: 12-5-74
Flow velocity: 70 f t / s e c
I n i t i a l w e i g h t : 1093.8 grams
T e s t s e c t i o n weight , grams
1093.8
1083.3
1078.0
1073.2
1068.2
1065.2
1062.2
1057.5
1053.6
1049.3
1046.9
1044. O
1040.6
1037.5
1033.8
1030.3
1022.0
T e s t s e c t i o n weinht loss, grams
0.0
10.5
15.8
20.6
25.6
28.6
31.6
36.3
40.2
44.5
46.9
49.8
53.2
56.3
60.0
63.5
71.8
Average sand flow rate: 111.7 Ib/hr 1.86 lb/min
*FAILURE
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. . STD.API/PETRO 2-ENGL L î 7 b m 0732290 05822b4 5 2 5 DI
Yìcw V e l x í t y ---- 70 f t l s e c .............. .___ I
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16 7
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170
SAND EROSION TEST DATA
RU^ 4 - 7 0 - B
Sand: 16/20 f r a c (dry)
Test s e c t i o n : 90' e l l
Elapsed t i m e , Sand f l a w , hours pounds
o . O00 1.058
2.181
3.214
3.985
4.759
5.516
6.418
7.296
8.334
9.191
10.051
10.897
11.758
12.616
13.483
15 . 216
O
100
200
30 O
400
500
600 700
800
900
1000
1100
1200
1300
1400
1500
1700*
Date: 12-5-74
Flaw velocity: 70 ft/sec
I n i t i a l weight: 1092.7 grams
Test s e c t i o n T e s t s e c t i o n weight , grams weight l o s s , grams
1092.7
1087.0
1084.5
1082.3
1080.0
1075.2
1070.2
1064.4
1060.6
1056.5
1054.2
1051.7
1049.6
*1047.3
1042.9
1039.5
1032.0
0.0 5.7
8.2
10.4 12.7 17.5
22.5
28.3
32.1
36.2
38.5
41.0
43.1
45.4
49.8
53.2
60.7
Average sand f l o w rate: 111.7 l b / h r 1.86 &/min
*Specimen n o t t e s t e d to f a i l u r e . Upstream e l l ( e l l A) f a i l e d f i r s t .
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Comprcueor Prreeurc 61.5 p s i -e-
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STD.API/PETRO 2-ENGL L77b 073ZZY0 0 5 8 2 2 7 3 538
175
...
.. .
RIDI 4 - 7 0 - C
Sand: 16/20 frac (dry)
Test s e c t i o n : 90’ e l l
SAND EROSION TEST DATA . .
Elapsed t i m e , hours
2.69 7**
3.214
3.985
4.759
5.516
6.418
7.296
8.334
9.191
10.051
10.897
11.758
12.616
13.483
15.216
Sand flow, pounds
250**
300
40 O
500
600
700
800.
900.
1000
1100
1200
1300
1400
1500 1700*
Date: 12-5-74
Flow v e l o c i t y : 70 f t / s e c
I n i t i a l weight: 1060.0 grams
T e s t sectian w e i g h t , grams
1060. O
1058.3
1054.9
1052. O
1050. O
1046.0
1042.0
1038.6
1037.0
1034.5
1032.5
1029 . 7
1025.7
1022.5
1014.6
T e s t s e c t i o n weight l o s s , grams
0.0
1.7
5.1 8.0
10.0
14. O
17.5
21.4
23.0
25.5
27.5
30.3
34.3
37.5
45.4
Average sand f l o w rate: 111.7 l b / h r 1.86 lb/min
*Specimen n o t t e s t e d t o f a i l u r e . Upstream e l l (ell A) f a i l e d f i r s t .
**250.0 pounds of sand had been i n j e c t e d and 2.697 hours e l apsed when e l l C w a s a t t a c h e d t o flowloop.
I”
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STD.API/PETRû 2-ENGL L î 7 b 0732290 05822711 O L T
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STD.API/PETRO 2-ENGL L77b 9 0732270 0 5 8 2 2 8 5 2 5 T
18 7
DISCUSSION OF RESULTS
Run 4-70 (A, B, and C)
The comparison of t h e wear rates shows e l l A t o wear f a s t e r than
e l l B and e l l B t o wear f a s t e r than e l l C , as expected, s i n c e t h e
sand p a r t i c l e s had a s l i g h t loss i n v e l o c i t y , and t h e r e f o r e less
k i n e t i c energy, as they proceeded down t h e flowloop.
time, i t was necessary t o use a second o r d e r curve t o f i t t h e
exper imenta l d a t a p o i n t s f o r e l l A. This occurence may have been due
t o a d e f e c t i n e l l A which appeared t o have an abnormal i n i t i a l wear
rate as i n d i c a t e d by the data.
may have also con t r ibu ted t o t h i s a c c e l e r a t e d wear rate. A f t e r t h e
start of t h e test, t h e wear rate of e l l A appeared so much h i g h e r
than expected t h a t e l l A and e l l B w e r e in te rchanged i n t h e flowloop
t o see if a p o s s i b l e p o s i t i o n i n g problem e x i s t e d . The i n d i v i d u a l
wear rates of e l ls A and B cont inued t o be t h e same s o t h e e l ls were
rep laced i n t h e i r o r i g i n a l p o s i t i o n s .
had a f law i n t h e s u r f a c e hardness s i n c e t h e r e s u l t s of Run 3-70
i n d i c a t e d t h a t bo th e l l s A and B should have had about t h e same wear
rates.
flowstream, t h e wear rate of e l l A appeared t o s t a b i l i z e .
exper ience i n d i c a t e s t h a t appa ren t ly i d e n t i c a l hardware from t h e same
manufacturer can have s u b s t a n t i a l l y d i f f e r e n t ope ra t ing c h a r a c t e r i s t i c s .
A s soon as equipment is available, hardness tests will b e run on each
test specimen be fo re be ing a t t ached t o t h e flowloop.
For t h e first
The i n c r e a s e i n sand p a r t i c l e s i z e
It w a s concluded t h a t e l l A
A f t e r about 800 pounds of sand had been i n j e c t e d i n t o t h e
This
A t h i r d e l l
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STD-API/PETRO 2-ENGL 197b 0732270 0 5 8 2 2 8 b 2 9 b
188
1
( e l l C) w a s a t t ached t o t h e end of t h e flowloop a f t e r t h e test w a s
s t a r t e d and 250 pounds of sand had been i n j e c t e d i n t o the flowstream.
This a d d i t i o n a l e l l was added t o provide another test specimen f o r
wear rate comparisons downstream of ell A. The wear rate of e l l C
is comparable t o t h a t of e l l B and may have even more c l o s e l y
approximated the w e a r rate of B had it been i n t h e flawloop a t t h e
start of t h e test.
as i n d i c a t e d i n t h e schematic.
Subsequent flowloops w i l l c o n s i s t of t h r e e ells
A comparison w a 8 made f o r t h e wear rates of t h e upstream ells (A)
i n Runs 2-70, 3-70,, and 4-70. R u n s 2-70 and 3-70 used 40/60 sand
a t a nominal rate of 3 pounds/minute.
a rate of 1.86 pounds/minute.
t h e s i z e h u t at h a l f t h e rate of R u n s 2-70 and 3-70. The r e s u l t s
i n d i c a t e t h a t the e l l i n Run 3-70 l a s t e d about t h e same as t h e e l l
of Run 2-70, as expected, b u t t h a t the e l l of Run 4-70 had almost
twice t h e l i f e of t h e f i r s t two. This r e s u l t is of i n t e r e s t s i n c e
t h e t o t a l amount of energy absorbed by the upstream e l l w a s about
t h e same i n a l l t h r e e cases.
that a l a r g e r sand s i z e may a c t u a l l y reduce the wear rate of t h e tes t
specimen.
g r a i n size can b e made.
a l s o y i e l d p e r t i n e n t in format ion .
Run 4-70 used 16/20 sand a t
Roughly, Run 4-70 used a sand twice
These p re l imina ry r e s u l t s i n d i c a t e
More d a t a i s needed be fo re a d e f i n i t e dependency on sand
A hardness test of t h e tes t specimens may
Another comparison was made f o r the w e a r rates of t h e second
e l ls (B) i n t h e flowloops of Run 3-70 (4û/60 sand a t 3.1 lb/min)
and Run 4-70 (16/20 sand at 1.86 lb/min). Again, t h e test specimen
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STD.API/PETRO 2-ENGL 197b 9 0732290 0582287 022 =
189
wi th the l a r g e r sand g r a i n s i z e l a s t e d almost twice as long as the
test specimen w i t h t h e smaller sand g r a i n , thus enforc ing t h e f ind ings
for t h e upstream e l l comparisons.
For the f i r s t t i m e , a sand probe device was i n s e r t e d i n t o t h e
flowstream i n an at tempt t o ob ta in c o r r e l a t i o n d a t a that could b e
used t o p r e d i c t t h e s e r v i c e l i f e of t h e test specimen.
apparatus schematic f o r t h e l o c a t i o n of the 4 sand probes and the
sand probe sketch.)
a petcock-type va lve , appropr i a t e f i t t i n g s , and a probe s e c t i o n
which was a c t u a l l y i n s e r t e d i n t h e flowstream.
w a s made of 304 welded s t a i n l e s s steel , had a 3/16" OD, and a .035"
t h i c k w a l l .
(See t h e
The sand probe cons i s t ed of a p res su re gauge,
The probe s e c t i o n
The probe w a s charged through the open petcock wi th
z a i r t o a p res su re of 70 l b / i n , t he petcock then c losed , and t h e sand
probe screwed i n t o a threaded s e c t i o n welded on t h e flow p ipe
perpendicular t o t h e flawstream.
on t h e probe, t h e w a l l th ickness w a s reduced.
w a l l , i n d i c a t i n g a s imulated probe f a i l u r e , w a s evidenced by a zero
reading on t h e p re s su re gauge.
Sand Probe #l f a i l e d a f t e r 535 pounds of sand had been i n j e c t e d i n t o
the flawstream, Sand Probe 82 d id n o t ever f a i l , Sand Probe # 3 f a i l e d
a f t e r 545 pounds of sand had been i n j e c t e d i n t o t h e flawstream,
and Sand Probe 8 4 never f a i l e d .
vertical p o s i t i o n on the top of the pipe. Other p o s i t i o n s of the
probe ( s i d e of t h e p ipe , v e r t i c a l l y under the p i p e , e t c . ) w i l l b e
even tua l ly inves t iga t ed .
As t h e sand p a r t i c l e s impinged
A r u p t u r e i n the probe
Refer r ing t o the appara tus schematic,
A l l probes w e r e o r i e n t e d i n the
The almost i d e n t i c a l r e s u l t s from probes 1
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190
and 3 show the potential of the sand probe as a fa i lure prediction
device. The sand probe used i n th i s test was designed and
constructed by Kenneth Weber, the senior technician on th is project . )
(Note:
t I
i t
Î i I i !
l. I
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19 1 SAND EROSION TEST DATA
A
Run 5 - 70 (A, B , and C)
Sand: 40/60 frac (dry)
Test section: Three 90" e l ls Flow velocity: 70 f t / s ec
Date: 1-23-75
I n i t i a l weights: E l l A 1069.5 grams
E l l B 1050.5 grams
E l l C 1088.6 grams
Average flowstream temperature: 117'F
E l l B E l l C - E l l A Elapsed Sand T e s t sect ion T e s t section Test section
t i m e , hours pounds grams grams grams
flow, weight loss, weight: l o s s , weight loss,
0.0
0.635
1.325
2.588
3.741
3.872
4.981
5.120 5.156
6.462
6.440
7.915
10.215
11.338
11.548
12.881
14.119
15.257
17.089
L8.389
L9 . 695
!O. 999
!2.315
!3.599
0.0
100. o 200. o 400 .O
512. O
600.0
680.0
700. O
800. O
885. O
1000. o 1200. o 1400. O
1550. O
1600. O
1800. O
2000. o 2200. o 2400-0
2600 O
2800. O
3000. O
3200. O
3400 . O
0.0
5.7
8.0
11.8
13.3
15.3
17 .7
18.2
20.1
23.0
24.7
30.3
36.9
40.4
42.7
48.2
53.4
59.6
65.5
71. O
73.5
76.9
80.0
84. O
0.0
5.7
8. O
11.5
13.4
14.7
17.8
18.4
19.5
23.6
24.3
30.2
36.7
40.6
42.7
48.3
53.6
59.0
63. O
68.0
70.8
74.3
77.0
81.5
o .o 6.6
9.1
14.4
16.9
19.5
22.4
23.1
25.9
29.2
32.7
39.2
48.7
51.1
55.2
61.4
67.9
74.6
79.6
86.0
88.9
92.9
96.6
101.1
--- Sand Probe Data
Sand Probe Number 1 2 2A 2B 3 4 5
3 I O E
ta B
P I rl
rn 00 Co
I FAIL
3 O O co
FA I L
P 4 o co rD
1 FAIL
t 5Ì N d rn
FAIL
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192 SAND EROSION TEST DATA (Continued)
Run 5 - 70 (A, B , and C)
Ell B E l l C - E l l A Elapsed Sand %est s e c t i o n T e s t s e c t i o n Test s e c t i o n
t i m e , flow, weight loss, weight loss, weight loss, hours pounds grams grams grams
23.723
24.239 25.523 25.729
26.844 28.157 29.480
30.655
3417.0
3500. O 3700.0
3731. O
3900. O 4100. O 4300. O 4476.0
84.1 81.5 101.2*
87.0 84. O 102. o 91.5 89.0
91.5 89.1 **
94. O 99.0 105. O 111.3***
-I__- Sand Probe Data
Sand Probe Number 1 2 2 A 2 B 3 4 5
s z
k
t
i.
Specimen f a i l e d . E l l C l e f t i n p l a c e and test continued.
Specimen f a i l e d . E l l A w a s rep laced s o t h e test could be continued u n t i l E l l B f a i l e d .
Specimen f a i l e d . T e s t concluded.
IOTE: - The sand probes were not rep laced a f t e r f a i l u r e because replacement probes
were n o t ava i l ab le .
,verage sand flow rate: 146 l b / h r 2.44 I b / d n
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19 3
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19 4
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6 a C . .
1
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STD.API/PETRO 2-ENGL L77b 0732270 0582273 32b
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STD.API/PETRO 2-ENGL 177b 0732E'90 0582294 2b2 I
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I
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STD.API/PETRO 2-ENGL L77b m 0732290 058227b 035 m
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STD.API/PETRO 2-ENGL 197b 0732290 0582298 908 &
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*
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201
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STD.API/PETRO 2-ENGL 1 9 7 b 0732290 0582300 39b I
c C c. c ù c n
n
5
I
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s a W
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L b ï S T D . A P I / P E T R O 2 - E N G L 1 7 7 b 0 5 8 2 3 0 2
204 m rl d w n
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STD.API/PETRO 2-ENGL 1 7 7 b H 11732290 0582303 U T 5
205
DISCUSSION OF RESULTS
Run 5-70 (A, B, and C )
E s s e n t i a l l y t h e same appara tus w a s used i n R u n s 4-70 and
5-70. However, i n 5-70 the sand d e t e c t o r w a s r e loca ted as shown
i n t h e Apparatus Schematic and 40 /60 sand w a s used i n s t e a d of
16/20.
of i ts loca t ion .
Performance of t h e sand d e t e c t o r w a s t h e same rega rd le s s
Close examination of t h e test d a t a i n d i c a t e s a s l i g h t v a r i a t i o n
of t h e wear rate of t h e e l l a t p o s i t i o n A from t h e expected l i n e a r
rate. Fur the r examination of t h e f i t t i n g i n d i c a t e d t h a t t h e
hardness w a s nor uniform so t h a t l o c a l i z e d s o f t s p o t s may have
quick ly eroded t o accelerate t h e f a i l u r e of t h e el l . Hardness
tests w i l l be made on t h e f i t t i n g s of fo l lowing runs t o exp lo re
t h i s p o s s i b i l i t y .
The f a i l u r e d a t a from t h e sand probes w a s reasonably uniform
f o r t hose probes i n l o c a t i o n s 1, U, 2B, 3, and 5. The sand probe
i n l o c a t i o n 2 never f a i l e d and t h e probe i n l o c a t i o n 4 took almost
twice as long t o f a i l as t h e o thers .
no t s u f f i c i e n t material available t o permi t t h e immediate replace-
ment of f a i l e d probes s o t h a t a continuous test could n o t be made.
Probe material is now a v a i l a b l e f o r u se i n R u n 6 .
Unfor tuna te ly , t h e r e w a s
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206 SAND EROSION TEST DATA
FA L
FAIL
* m
Run 6-100 (A, B , and C)
Sand: 40/60 f r a c (dry)
Test s e c t i o n : Three 90" e l l s
F l o w v e l o c i t y : 100 ft/sec
FAIL
Date: 4-17-75
Initial weights: E l l A 1119 grams
E l l B 1101.5 grams
E l l C 1078 grams Average flowstream temperature: 119°F
*
FAIL
FAIL I * Co FI nl
E l l C - E l l B - E l l A - ?lapsed Sand Test s e c t i o n T e s t s e c t i o n T e s t s e c t i o n
Sand Probe Data --- t i m e , flow, weight l o s s , weight loss, weight l o s s , Sand Probe Number hours pounds grams grams grams 1 2 2 A 2 B 3 4 5
0.000
1.308
2.174
2.372
2.610
3 .O50
3.187
3.475
3.896
4.233
S.634
i. 747
i. 132
i.895
i.905
1.930
8.051
.118
.216
-433
.940
0.0
200 .o 338. O
368. O
400 .O
472.0
495.0
540.0
600. O
655 .O
720.0
735.0
800. O
915.0
920.0
925.0
940.0
950. O
965.0
1000. o 1075.0
0.0
11.5
19.0
21.1
23.0
28. O
29.6
32.9
37.0
41.1
46.0
47.2
52.0
63.0
63.1
68.0
68.1
68.1
68.2
71.0
77.8
0.0 11. o 18.7
21. o 23.0
28.2
29.4
32.5
36.5
41.2
46.2
47.9
52.5
62.8
63.0
68.1
68.1
68.2
68.2
71.5 79.0
0.0
12.5
22.3
24.9
27.0
32.1
33.4
40.0
41.5
46.4
52.6
53.4
59.5
70.2
70.2
70.3
70.3
70.4
71.0
80.5
89.9
FAIL
* O cv fn
FAIL
v)
FAIL
* O r( U
FAIL
* u) m
FAIL
I =2z m m Crl
I FAIL
FAIL
FAIL
3% O \o FI
I FAIL
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STD.API/PETRO 2-ENGL 1 7 7 b 0732290 0582305 9 7 5 m
20 7 ;AND EROSION TEST DATA (Continued)
tun 6-100 (A, B, and C)
4 E l l B E l l C - E l l A -
: lapsed Sand Test s e c t i o n T e s t section T e s t s e c t i o n t i m e , flow, w e i g h t l o s s , w e i g h t l o s s , weight l o s s , hours pounds p;r ams grams gr am 1
--- Sand Probe Data
Sand Probe Number î A 2B 3
7.391 1143.0 84.4 84.9
7.722 1200.0 90.0 (a) 91.5 (b) 105.5 (cl
a) E l l A f a i l e d .
b)
c) E l l C s t i l l serviceable.
E l l B ready t o f a i l - bump on s u r f a c e .
verage sand flow rate: 155 l b / h r 2.58 lb/min
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208
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209
n V
O ’ O rl I
rg
El 5
al P O w P4
V
m 3
t
o 4-
* E P
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~ ~~ ~~ ~~
S T D . A P I / P E T R O 2-ENGL 197b 0 7 3 2 2 7 0 0582308 b87 W
2 10 O
i: 4 .
C CT n
. 3 U
rl Y( 8
- T
c . . a. < n -
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I I I I I I I I I I I 1 l I I 1 I
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I I +c-~-c+ccecc+-c---+~----+-----+ I I I I I I
I I I I I I
I I I I I
l I I I I I 1
I 1 I I I
1
I
c 3 I c. c -. hLL
CI
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I I I I I I C
---+ci+ . I I I 1 I I . I D
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C c d <\'
. C C i C.
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S T D . A P I / P E T R O 2-ENGL L77b 0 7 3 2 2 9 0 0582309 513 -
.."
:r ,?,
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a, ..
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S T D . A P I / P E T R O 2-ENGL 197b m 0732290 05823LD 235
I
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213 O
I . I ' I
I I I l I
I I I l l l I I + - I L I -
I I I I I
CCiCIC
I I I l
. I I 1 . I
+----m.
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I I 1 I
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u % I I I I I .d - 1 I
+--cr.c +--,--+--U-$ +I- I-,--- +---cl-+
I I I G a i I al 3 ;
I o w l I I
I I I . I I I I I I I l I
I
I I I I I 5
c
C C C c a 4 U ' fi
. C C
c 0 .
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~~
STD.API/PETRO 2-ENGL 377b W 073229û 0 5 8 2 3 3 2 0 0 8
I
l I I I I I I I
I +c-c--.( -u--c+ I I I I ' I I I I I l I I
l l I 1
I t I 1 !
I I I I l I 1 I I I I I 1
c O C C. m .
0
c c c IP J
C
c C O U
C
C
c 5 .
214
.
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~~-~ -~ ~ ~
STD.API/PETRO 2-ENGL 1 9 7 b 0732290 05823113 TLILf
duii 140. 6-100 sand 40/60 frac (dry)
I n i t i n 1 --
Weight 1078 grams
2 15
Campressor Preasure 87 D si
I I I I I
1k-l- I_ I I
i .- F% '.
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2 16 3
I - it
C .P n
c m n
C
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0
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+ I I I I I I l l a I I I I I I
I
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--CL-+
I I
I I
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l I l I l I I I I I I I I I I I
- I I I 1
I I I t I I
I i I I I I
5 u
+-- -Cl-+
I I I I I I I I I I I l I I
---e- .e---- ,++..----+ I I I I I I l I 1 I I I I I
--i---+
I
I l I
I I I I I I +ec--c+-c-c-+c--c-+-----+-----+ I I I I I I I I I I I I 1 I l I I I l I I I I I
. "l
l
I I l I I I
l + -c1 I I I
l +---ce I I I I I I
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I I I I 1 I I I I I
I I
i \
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c r\'
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C c.
-1 c < . I . . '. . -
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c
c
l
i a
21 7
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al o (d ru
a lo Q U
h W * u
* " 5 2 3 p : d E-i a al rn
d w 8
u II
5 3
4 m d d d r l W ' W
.. m u " u4
E 1 U
218
al o " d
rl Pl
I VJ
al
5
3 C " rl b al
VJ
E U " al rn rn \ rl u d w O O
O 2 QI
al al k c E-i Cu O m a u ul p:
U al
5 OI U cr) U4 rl O
o Q
II
i .
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o st lu
I I I
4 m v
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W rl rl w O O Q\
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E u II II O W d & cd
5 3 3
B O V
.. W U d vi
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~ ~~
STD.API/PETRO 2-ENGL 5 2 b 9
s
\D m
N m
ac) N
U cy
O N
\o rl
N ri
Co
U
O
2 20 f i
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4 rl rl w o h I
ir,
5 M
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5 8 O h I
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m
II
3
5
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B & M .L
m m O FI
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m a & u 7 O O c U
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al
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I
a Ei I VI
3 d
c)
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I 4
4
rl l i
al
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O
1 \D N I Q\ h l
U N
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O U
\o m
Cu F)
00 Cu
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221
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8 t.4 O
W
m o t . 4 . . o r n a k ‘ w w r l a
o r l aï 5 a, u ru O
d O m L 5 a
u o 4
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~
~ ~ ~ _ _ _ ~~
STD.API/PETRO 2-ENGL L î 7 b m 0732290 0582320 184
O .j
3
F:
m N
U N
O fl
3
hl 4
m
U
O
VI bl 3 O c a
fda 4 w
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m e n
222
O O
a Ei O h
I vi
& O ru VI al U a pr; h
al
5 4-i O
4
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STD-APIIPETRO
hi I--
~~
2-ENGL 197b 0732290 0582323
U hi
O O O in
O O in .j
O O O U
O O Vl m
O O O <r)
O O w hi
O O O N
O O m d
O D 5
O 0 m
O
U d w
5 V
k al 2 ö U
P rl
m . k
rl B E ; ? !a a E rd m
223
O O rl I
\o
?d
8 cn
II
d
rn 3 O rl kl
71
m 9
i k M
O O m 3
O h
I ul
.. m U
6 3
.rl
4 a rl u d C +I
l-l rl al
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O
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!i c4 E d
? m rl d w Fc O
v.c rn
rd . 3? w . .-(
ö al Cu rl
rl
w O
O O rl
I rn W d
do k
O u 4
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224 SIEVE ANAMSIS
"Old" 40 /60 "New" 40 /60
x Grams x Sieve Size Grams
1.999 1.559 2.311 2.017
24.890 19.418 28.982 25.300
59.942 46.765 52.048 45.436
20.827 16.249 15.744 13.744
14.549 11.351 10.086 8.805
P a 5.970 4.658 5.382 4.698
30
40
50
60
80
128.177 100.000 114.553 100.000 Totals
Test .performed through the courtesy of Mr. E. R. "Dick" Jennings, Amoco Production Co., Tulsa, Oklahoma.
i : I .
j . i
i. ..
1
f i
2 .
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~ ~-
~
~
STD-API/PETRO 2-ENGL 177b 0 7 3 2 2 7 0 0 5 8 2 3 2 3 773
225
HARDNESS DATA
RU 5-70 E l l C
66 55
6 1 32
62 63
59 57
6 1 63
59 59
59 61
62 60
22 58
RUA 5-70 Ell A
62 49
58 33
60 26
6 1 55
58 63
60 60
57 54
56 50
T-30 scale (see s k e t c h f o r l o c a t i o n of test po in t s )
High 66 Lcnr 22 Average 66
Brinell Average Hardness 117
The scale is c a l l e d "T-30" because the i n d e n t a t i o n b a i l is 30 mm in diameter
T-30 scale
High 63 Low 26 Average 57
B r i n e l l Average Hardness 107
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226
Run 2-70 T-30 scale
64 57 High 64 Low 32 Average 57
57 so 41 32
59 58
61 60
60
Brinell Average Hardness 107 57 42 63 62 60
58 60 58
Run 4-70 Ell A
54 60 60
56 60
55 38
59
5 2 High 6 1 Low 12 Average 55 55
61
12
59
43
60
57
57
Brinell Average Hardness 104
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STD-APIIPETRO 2-ENGL 177b = 0732270 0 5 8 2 3 2 5 7bb m
227
C (bottom of I c i r c l
Orientation of Specimen for Hardness Test
6 3
- 60
Flow
R U ~ 5-70 E l l A
Location of T e s t Points
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228
RUI 4-70 Ell A
Locat ion of Test Poin t s
58
RUI 5-70 E l l C
Location of Test Poin t s
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64
Run 2-70
Location of Test Points
229
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STDOAPIIPETRO 2-ENGL Lî7b H 0 7 3 2 2 9 0 0582328 475
230
DISCUSSION OF RESULTS
RUI 6-100 ( A , B, and C)
I n t h e Discussion of R e s u l t s f o r Run 5-70 (A, B, and C ) , e l l A
w a s observed t o have an apparent ly v a r i a b l e wear rate which lead
t o t h e conclusion t h a t a hardness test should be made on each test
specimen t o a s s u r e a reasonably uniform set of test specimens f o r
comparison.
B r i n e l l Hardness numbers f o r a given specimen b u t average B r i n e l l
Hardness numbers f o r each specimen that are almost t h e same. There
e x i s t s t h e p o s s i b i l i t y t h a t t h e c r i t i c a l reg ion f o r wear i n a
p a r t i c u l a r specimen may conta in a l a r g e number of l o c a l i z e d weak
s p o t s , b u t as t h e e ros ion occurs t h e l o c a l i z e d weak spo t s should
average out from specimen t o specimen. Therefore , t h e hardness
v a r i a t i o n has no t in f luenced t h e wear rates of the i n d i v i d u a l
specimens t o any apprec iab le ex ten t .
The Hardness Data i n d i c a t e s a wide range of l o c a l
During t h e course of t h e run, t h e o r i g i n a l supply of 40 /60
sand w a s deple ted and sand from a "new" supply used i n t h e flowstream.
The "new" sand had a markedly d i f f e r e n t co lo r and f e e l s o t h a t a
s i e v e a n a l y s i s w a s performed t o confirm t h e s i m i l a r i t y of t h e
p a r t i c l e s i z e d i s t r i b u t i o n between t h e "old" and "new" ba tches .
The a n a l y s i s i n d i c a t e d t h a t both ba tches had a n almost i d e n t i c a l
p a r t i c l e s i z e d i s t r i b u t i o n .
The comparison of t h e wear rates f o r e l ls A , B , and C i n
Run 6-100 i n d i c a t e s t h a t A and B had i d e n t i c a l w e a r rates b u t
i
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STD.API/PETRO 2-ENGL 1 7 7 b = 0732270 0582327 3 O L
231
t h a t C had a h ighe r wear rate.
s e r v i e c a b l e a f t e r e l l A f a i l e d and e l l B w a s ready t o f a i l .
one observes t h a t t h e i n i t i a l weight of e l l A w a s 1119 grams,
e l l B 1101 g r a m , and e l l C 1078 grams, t h e f a i l u r e s seem i n v e r s e
t o t h e i n i t i a l weights . Actua l ly , t h e i n i t i a l weights are w i t h i n
a few pe rcen t of each o t h e r and the exac t l o c a t i o n of t h e a d d i t i o n a l
metal impossible t o a s c e r t a i n . Therefore , t h e f a i l u r e s and near
f a i l u r e s are comparable and no anomaly exists.
S u r p r i s i n g l y , e l l C was s t i l l
If
The comparison of t h e wear rates f o r e l l A a t flows of
70 f t l s e c and 100 ft /sec, and a l s o e l l B f o r t h e same f lowra te s ,
i n d i c a t e s t h a t t he w e a r rate approximately t r i p l e s as t h e v e l o c i t y
inc reases from 70 f t / s e c t o 100 ft/sec.
1 / 2 mV2, of a p a r t i c l e is computed f o r t h e s e two v e l o c i t e s , it
appears t h a t t h e wear rate t r i p l e s as t h e k i n e t i c energy doubles.
This rule-of-thumb r e l a t i o n s h i p may l e a d t o e s t a b l i s h i n g a p r e d i c t i o n
f o r t h e s e r v i c e l i f e of a specimen. A s an example, the e l l of
Run 2-70 f a i l e d wi th t h e least weight loss, 6 6 . 8 grams, of a l l
runs thus f a r i n 7.5 hours a t a f l o w v e l o c i t y of 70 ft/sec.
t h e e l l had an average wear rate of 8.9 grams/hour.
were inc reased t o 100 f t / s e c , doubl ing t h e k i n e t i c energy, t h e
wear rate would i n c r e a s e t o 26.7 grams/hour s o t h a t t h e service
l i f e of t h e e l l would drop t o only 2.5 hours . A d e c i s i o n would
then have t o b e made as t o whether o r n o t t h e product ion inc rease
were o f f s e t by t h e acce le ra t ed wear.
I f t h e kinetic energy,
Therefore ,
I f t h e v e l o c i t y
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232
Sand probe d a t a w a s taken continuously throughout Run 6-100.
An i n spec t ion of the Sand Probe Data does not i n d i c a t e any de f inab le
c o r r e l a t i o n between sand probe f a i l u r e and e l l f a i l u r e .
cons tan t condi t ions under which the test w a s conducted, a c o r r e l a t i o n
w a s expected t o b e found. The g l a s s flowloop may provide some
c l u e a s t o a p o s s i b l e i r r e g u l a r i t y i n the flow even though t h e
v e l o c i t y , sand flow rate, and other parameters are apparent ly
cons tan t .
t h e sand probe in an e f f o r t t o e s t a b l i s h a c o r r e l a t i o n .
For t h e
Erosion f a i l u r e s w i l l cont inue t o b e monitored wi th
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~
STD.API/PETRO 2-ENGL L97b W 0732270 0582331 T b T =
0.0 (O. o/o .O) 0*0**12;i/
SAND EROSION TEST DATA
I
233
Run: 7-100 (A and B) Date: 7-28-75
Sand: 40/60 frac (dry) In i t i a l weights:
T e s t f i t t i n g s : 90" F i e l d E l l a t A F i e l d E l l 1226 grams* 1129 grams
Flow ve loc i ty : 100 f t / s e c Average flawstream temperature: 116'F
90" Water E l l wi th 45' P l a t e Water e l l and p l a t e a t B
* Inc ludes t h e e l l and p l a t e (wear f i t t i n g s ) b u t n o t t h e clamp assembly (non-wear f i t t i n g ) . I n i t i a l e l l weight: 785 grams In i t i a l p l a t e weight: 344 grams
Sand Probe Data --- Elapsed Sand F i e l d e l l Water e l l and 45" Time, Flow, weight l o s s , p l a t e weight l o s s , Sand Probe Nunher
o. O00 0.683
0.819
1.079
1.083
1.300
1.350
1.717
1.771
1.969
2.128
2.169
2.595
2.633
3.267
3.271
3.275
' 3.546
3.583
3.964
3.990
4.378
0.0
126. O
151. O
199. o 200. o 240.0
249. O
316 . O
326. O
363.0
392.0
400.0
477.0
483.0
598.0
599.0
600.0
649. O
655.0
724.0
729. O
800 . O
20.8
25.0
32.9
33.0
38.4
39.6
48.8
50.1
55.0
59.0
60.0
69.6
70.5
84.8
84.9
85.0
91.6
92.5
101.9
102.5
112.0 *
(O .0/5. O)
(O. O/6.0>
(O. O/8. O
(O .0/8. O)
(1.0/10.8)
(1.2/11.5)
(2.9/16.2)
(3.1/16.9)
(4 O /19.5)
(4.8/21.5)
(5.0/22.0)
( 6.9 / 27.8)
(7.1/28.3)
(9.9/37.0)
(9.9 /37 .O)
(10.0/ 37. O)
(10.7/40.5)
(10 . 8/40 . 9)
(11.8/45.8)
(11.9 /46.1)
(13 . O m . O)
5.0
6.0
8.0
8.0
11.8
12.7
19.1
20.0
23.5
26.3
27.0
34.7
35.4
46.9
46.9
47.0
51.2
51.7
57.6
58.0
64.0
F A 1
I 123#
F a i l
11411
Fail
I
I F a i l
I 12Oil
F a ' l F a i (11511
329%
I F a i l
F a i l
I
199#
1 F a i l
15 1% I
F a i l
I I
165#
I 2 40#
F a i l
I
207#
F a i l
222#
I
F a i l Fail
I 172#
I I I
F a i l 2521,
183#
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~ ~-
STD.API/PETRO 2-ENGL L77b = 0732270 0582332 7Tb - I
821.0 (13.1/52.2) 65.3 1161 F a i l
23 4 (SAND EROSION TEST DATA Continued)
I 832 . O (13.2/52.8) 66 .O
840 .O (13.2/53.2) 66.4 F a i l
4.496
4.557
4.59 7
5.247
5.392
5.467
5.667
5 . 750
5.943
6 . 383
6.583
6.693
6.919
7.024
7.255
7.283
7.675
7.822
7.944
8.122
8.137
8.375
8.600
8.779
257# I
159#
1 1050.0 (15.0/66.1) 81.1
1085.0 (15.7/68.8) 84.5 F a i l
1164. O
1200. o (18.0/78.0) 96.0
1220.0 (18.5/79.5) 98.0 F a i l
1261.0 (19.5/82.7) 102.2 I 1280 . O (20.0/84.1) 104.1 10811
(17.2/75.2) 92.4 1358 I
I
(23.4/96.0) 119.4 F a i l
(23.8/97.9) 121.7 I (23.8/98.1) 121.9 m i )
I (24.2/100.7) 124.9
(24.6D03.0) 127.7 F a i l
(25.0/105.0) 130.0" I
I I I 2755 F a i l .
1323.0
1328. O
1400.0
1426. O
1448. O
1481.0
1483. O
1526.0
1567.0
1600. O
I F a i l 3918
I I (21.0/ 87.3) 108.3
(21.2/87.6) 108.8 F a i l
(23.0/93.0) 116 .O
(23.2/94.7) 117.9
I 15 a t
F a i l 203W I 2651
I I
F a i l
F a i l
* ** FAILURE The water e l l and t h e p l a t e were weighed s e p a r a t e l y t o determine t h e i r
r e s p e c t i v e weight losses. The data is recorded as (weight loss of e l l / w e i g h t loss of p l a t e ) t o t a l weight loss
Average sand flow rate: 182.7 l b / h r 3.04 lb/min
For t h e modified e l l wi th a 45" plate: The t o t a l weight loss w a s %30& grams or 11.5% of t h e o r i g i n a l weight. w h i l e t h e P l a t e l o s t 105.0 grams or 30.5% of i t s o r i g i n a l weight, material was U. S. S t e e l üR Alloy P l a t e Type T-1, Quenched and Tempered (321 minimum B r i n e l l hardness)
The e l l lost.25,O grams o r 3.18% of i ts o r i g i n a l weight The p l a t e
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U
9 a lil
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c
I
I
I
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3
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STD*API/PETRO 2-ENGL L77b 0732270 0582335 b u 5
1 23 7
O o d
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d 4 al
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: 4 : O 0
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23 8
O a I '
I d I l
I - 1 I * I I $ 1
I I I I . .
I I 1 I
I i 1 I
l i 1 I 1 I
I l I
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1 I I I
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l t : I I +H+.C(HU+HC.- e * + I I
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I I I I
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STD-APIIPETRO 2-ENGL L97b m 0732290 0582337 q88 m
.- . . . 239
l I I
I I I O I .
~ r c . 4 r u w + I O o i a i c i I l
I I I I + w c i u u u I
I I I I + "YYY
I I I I I I I l I
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+ u w u y.,. c 4 u U Y r l
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U 4 u rn
t u M
1- I O l e I O I I U
L + W ~ u u Y + C u ~ Y u + ~ u W w u + H u u u u + Y u u u c I + o
I I I * I I I c i
I l l I I I
I I I I 1 I I I I 1 I 1 I l I I I O
I Y I I 1 I l e
rn m u1 O c;l
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2 40
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\
al ci Q rl a
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m h m
~~~~ ~~ ~~~
STD-API/PETRO 2-ENGL L77b 9 0732290
II II II II
3 3 3 3
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O O @l
O m FI
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2 42
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a al U a c4 LI (d al 3 w O
d O rn
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STD*API/PETRO 2-ENGL L97b 0732270 05823LiL 9 0 9
2:
4 3 ma
II n II n
3 3 3 5
a l e
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U rn al B u O Eri a al U a e: k a s"
c O m rl & m
4
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Flow
S T D - A P I / P E T R O 2-ENGL L97b W 0 7 3 2 2 9 0 0 5 8 2 3 4 2 8 4 5
Failure
Flow
244
A Schematic Of The Failure
Locations FOK Run 7-100 (A and B)
I
I
I
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STD.API/PETRO 2-ENGL L97b 0732290 0 5 8 2 3 4 3 7 8 1 m
SAND PROBE DATA 245
For c o r r e l a t i o n of t h e sand probe d a t a , t he fo l lowing equat ions
have been used.
Average n E x
i= 1 i 1 n
x = - A
x i s the average A
x is the i& d a t a p o i n t i
n is t h e number of d a t a p o i n t s
Standard Deviat ion
n 1 = [ A c (Xi-xA)2 ] 2 n i= 1 sD
S is the s t anda rd dev ia t ion D
When only a f e w d a t a p o i n t s are a v a i l a b l e as i s the case i n Run 7-100,
f o r t h e c a l c u l a t i o n of t h e s tandard devia t ion . 1 - is replaced by - n ín- 1) Genera l ly , a s tandard d e v i a t i o n g r e a t e r than 10 i n d i c a t e s s c a t t e r e d
d a t a wi th l i t t l e c o r r e l a t i o n .
Sand Probe #l
Sand Flow P a s t Probe, lb
108, 114, 115, 116, 118, 119, 120, 121, 123, 126, 128, 130, 135
Range 108-135 (27) Average 120.5 Standard Deviat ion 6.85
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STD.API/PETRO 2-ENGL L î 7 b 0732290 0582344 bL8 IO
246
Sand Probe 112
Sand Flow P a s t Probe, l b
326, 329, 380, 391
Range 326-391 (65) Average 356.5 Standard Deviat ion 33.8
Sand Probe f 3
Sand Flow P a s t Probe, l b
193, 199, 203, 207, 222, 229, 230
Range 193-230 (37) Average 211.9 Standard Deviat ion 15.0
Sand Probe # 4
Sand Flow P a s t Probe, l b
151, 158, 159, 161, 164, 165, 168, 172, 183
Range 151-183 (32) Average 164.6 Standard Deviat ion 9.2
1
Sand Probe 115
Sand Flow P a s t Probe, l b
237, 240, 252, 257, 265, 275
Range 237-275 (38) Average 254.3 Standard Devia t ion 14.6
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O O U
O in m
O O m
O in N
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248
SIEVE: ANALYSIS OF 40/60 FRAC SAND
Batch #i Batch #2 Batch #3 Sieve S i z e Grams % G r a m s % G r a m s %
30 1.999 1.559 2.311 2.017 0.179 .896
40 24.890 19.418 28.982 25.300 4.802 24.010
50 59.942 46.765 52.048 45.436 9.552 47.660
60 20.827 16.249 15.744 13.744 2.860 14.300
80 14.549 11.351 10.086 8.805 - - Pan 5.970 4.658 5.382 4.698 2.626 13.130
T o t a l s 128.177 100.000 114.553 100.000 20.019 99.996
Test performed through t h e cour tesy of M r . E. R. "Dick" Jennings , Amoco Product ion Co., Tulsa , Oklahoma.
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249 DISCUSSION OF RESULTS
Run 7-100 (A and B)
Prel iminary tests w i t h t h e g l a s s p ipe flowloop ind ica t ed t h a t
a d e f l e c t o r p l a t e a t t ached t o a 90" e l l might provide a s u r f a c e wi th
a r e l a t i v e l y low w e a r rate.
30°, 4 5 " , and 60" were s e l e c t e d .
wi th an angle of 45" w a s run i n series wi th a s tandard 90" f i e l d
e l l as shown i n t h e Apparatus Schematic.
d a t a , t h e e l l modified w i t h t h e 45" d e f l e c t o r plate had a s e r v i c e
l i f e of twice t h e s t anda rd 90" f i e l d e l l . The p l a t e material was
.218 i nch t h i c k wi th a B r i n e l l hardness of 321 wh i l e t h e f i e l d e l l
had a w a l l th ickness of .250 inch b u t a nominal B r i n e l l h a r d n e s s of
only 130. Therefore , t h e material hardness as w e l l as d i f f e r e n t
geometr ies of t h e test f i t t i n g s l e a d t o t h e increased service l i f e
of the e l l w i th t h e 45" p l a t e .
experienced most of t h e wear s o t h a t a v a r i a t i o n of t h e d e f l e c t i o n
angle as w e l l as a t h i c k e r p l a t e could s u b s t a n t i a l l y inc rease t h e
l i f e of t h e f i t t i n g .
t h e test f i t t i n g s i n d i c a t e t h e s u p e r i o r i t y of t h e bul lp lugged f i t t i n g
t o any o t h e r f i t t i n g s o it appears t h a t a geometry which can
For i n i t i a l tests, i n c i d e n t angles of
In t h i s run, t h e d e f l e c t o r p l a t e
A s i nd ica t ed by the test
As t h e d a t a i n d i c a t e s , t h e p l a t e
The two p l o t s which compare t h e wear rates f o r
e f f e c t i v e l y reduce t h e k i n e t i c energy of t h e sand p a r t i c l e s is
d e s i r a b l e .
cons t ruc t ed f o r t e s t i n g i n t h e f u t u r e .
Run 8-100 a c t u a l l y preceded Run 7-100 s o t h a t r e s u l t s for t h e
f i t t i n g s of Run 8-100 appear on the comparison p l o t s .
To t h i s end, a s t a g n a t i o n chamber dev ice is be ing
I t should be noted t h a t
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250
Run 8-100 provided a d d i t i o n a l sand probe d a t a which ind ica t ed
t h a t f a i l u r e p red ic t ions made from sand probe readings would h e
f a u l t y .
s t i l l shows an incons is tency which would prec lude i t s use f o r f a i l u r e
p red ic t ions . Accordingly, t h e sand probes are be ing redesigned and
w i l l b e a v a i l a b l e f o r t e s t i n g i n f u t u r e runs.
Sand probe d a t a w a s taken i n this run and although b e t t e r ,
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251 SAND EROSION TEST DATA
Run: 8-100 (A and B) Date: 6-27-75
Sand: 40 /60 f r a c (dry) i n i t i a l weights:
Test f i t t i n g s : Bullplugged f i e l d tee a t A Bullplugged f i e l d t e e 3293 grams* Bullplugged water tee a t B Bullplugged water tee 1858 grams
. . Flow ve loc i ty : 100 f t / s e c Average flowstream temperature: 116'F
* I n i t i a l weight of bu l lp lugged f i e l d tee included t h e tee and cap (wear f i t t i n g s ) b u t no t t h e c lamps , b o l t s , and gaske t s (non-wear f i t t i n g s ) .
450. O 31. O 29.7
474.0 32.9 32.0 Fafl
Elapsed T i m e , hours
0.0
.883
1.117
1.289
1.483
1.728
2.200
2.300
2.531
2.608
2.754
3.534
3.817
4.108
4.142
4.515
4.592
4.667
4.917
5.417
5 - 439
5.467
*
3 F a i l
949.0 54.5 64.2 F a i l 2958
953.0 54.6 64.4
958.0 54.7 64.7
5.700 1000.0 56.0 67.0
F a i l I
F a i l I -r
654. O 44.9
708.0 46.8
715.0 47.0
785.0 49.5
800. O 50.0
814. O 50.4
47.2
I F a i l
50.5
50.9
55 .1
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252 (SAND EROSION TEST DATA Continued)
Elapsed Sand Bullplugged f i e l d Bullp lugged water --- Sand l'robe. I);lin
T i m e , Flow, tee weight l o s s , tee weight l o s s , Sand Probe Nuinber hours pounds grams grams
6.133 1080.0 60.8 73.0 6.342 1119.0 63.2 76.0 298f 3805
6.774 1200.0 68.0 82.0
6.988 1239.0 70.3 84.3
7.058 1251.0 7 1 . 1 85.1
7.090 1257.0 71.4 85.4
7.247 1285.0 73.1 87.1
7.500 1331.0 75.9 89.9 F a i l
7.882 1400.0 80.0 94.0
8.056 1432.0 81.8 95.9
8.353 1487.0 84.8 99.2
8.400 1495.0 85.3 99.7
8.708 1552.0 88.4 103.2
8.726 1556.0 88.6 103.4
8.904 1588.0 90.4 105.3
8.964 1600.0 91.0 106.0
9.679 1731.0 96.3 115.2 2551)
9.760 1746.0 96.9 116.3
9.842 1761.0 97.5 117.3
10.050 1800. O 99 .o 120. o 10.113 1811.0 99.9 121.0
10.417 1866.0 104.3 125.6
10.572 1894.0 106.5 128.0
10.825 1940.0 110.2 131.9
11.004 1972.0 112.8 134.7
11.157 2000.0 115. O 137.0
11.308 2027.0 116.5 139.4 1 F a i l
11.367 2038.0 117.1 140.3 F a i l #
1 3 8l 11.903 2137.0 122.6 148.7
11.947 2145.0 123.0 149.4
12.111 2176.0 124.7 152.0 F a i l
F a i l 25 1 B 16 6f
22511 F a i l
F a i l 2 4 4B
F a i l
31411
F a i l 149 #
197# 27911
F a i l
. ..
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~~
STD-API/PETRO 2-ENGL L 7 7 b 0 7 3 2 2 9 0 0 5 8 2 3 5 3 8 5 8 W
253 (SAND EROSION TEST DATA Continued)
Elapsed Sand Bullplugged f i e l d T i m e , Flow, tee weight loss , hours pounds grams
12.188
12.240
12.563
12.829
12.908
13.254
13.325
13.500
13.604
13.700
13.821
14.283
14.296
14.413
14.417
14.950
15.083
15.108
15.319
15.361
15.500
15.822
15.867
16.117
16.233
16.511
16.583
16.606
16.996
17.250
17.267
2190.0
2200.0
2259. O
2308.0
2323.0
2386.0
2400.0
2432.0
2451.0
2468.0
2490. O
2575.0
2577.0
2599.0
2600. O
2698.0
2723.0
2727.0
2766. O
2774.0
2800.0
2859. O
2867.0
2913.0
2935. O
2986.0
3000. O
3004.0
3076.0
3123. O
3126. O
125.5
126. O
130.2
133.6
134.6
139.1
140. O
142.1
143.3
144.5
145.9
151.4
151.6
153.0
153. O
159.9
161.6
161.9
164.7
165.2
167 .O
169.1
169.4
171.0
171.7
173.5
174.0
174.3
179.3
182.6
182.8
Bullplugged water tee weight l o s s ,
grams
153.2
154. O
160.5
165.9
167.5
174.6
176. O
179.4
181.4
183.2
185.5
194.4
194.7
196.9
197.0*
t 147i1
1 F a i l
t
i t I t J t
1418
F a i l
131.11
F a i l
128f
F a i l
i4011
1
t
I
F a i l
119#
F a i l
1
i
15 4B
Sand Probe Unta Sand Probe Number --_I_
ilaFii f 171#
232#
I 23111
1 F a i l
19 111 143#
F a i l
F a i l i
I 306#
i F a i l
t ! !
I I
!
I 323:;
j
.i
i i i
F a i l
30 2 3
1 1
F a i l
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~ ~
S T D - A P I / P E T R O 2-ENGL L77b 1111 0732270 0582352 774
254 (SAND EROSION TEST DATA Continued)
17.345 3140. O
17.508 3170 .O
17.667 3200.0
18.121 3285.0
18.350 3329. O
18.404 3339.0
18.717 3398.0
18.725 3400 .O
18.950 3442.0
19.067 3464.0
19.367 3521.0
19.500 3547.0
19.750 3594.0
19.779 3600.0
20.033 3647.0
20.392 3713.0
20.553 3743.0
20.658 3762.0
20.858 3800.0
21.050 3832.0
21.361 3883.0
21.375 3886.0
21.408 3891.0
22.002 3990.0
22.058** 4000.0
22.429 4033.0
22.529 4042.0
22.808 4067.0
23.207 4102.0
23.239 4105.0
23.267 4108.0
Sanù I’ruhc- l);ii il - .- ---- .--. Elapsed Sand Bullplugged f i e l d Bullplugged w i ì t c ’ ï
T i m e , Flow, tee weight l o s s , tee weight l o s s , Sriiid I’ r c h * N~iiiihc* r hours pounds grams grams
183.8 F a i l
185.9 206# 188. O
194.4 F a i l
197.7
198.4
202.9
203.0
205.1
206.2
272.11 1 1 5 78
209.1
210.4
212.7
213. O
215.8
219.8
221.6
222.8
225.0
226.6
229.2
229.3
229.6
234.5 235. O
238.8
239.8
242.7
246.8
247.1
247.4
l
249% 4 F a i l A 1528
19 2#
F a i l
1708 I
2396 4 14811
1 F a i l
1428
F a i l
1 ‘ t .
1 7211
J t
F a i l
2 2 811 F a i l
F a i l
181f I
F a i l
I 159f
F a i l
F a i l
100%
I F a i l
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185B f
(SAND EROSION TEST DATA Continued)
Sand Probe Unta Sand Probe Number --- Elapsed Sand Bullplugged f i e l d Bullplugged water
Time, Flow, tee weight l o s s , tee weight loss , hours pounds grams -_ - grams i i 2 3 4
I 25.11 i
F a i l
40 i1
F a i l
I t F a i l
23.467 4125.0
23.547 4133.0
23.936 4159.0
24.002 4167.0
24.244 4173.0
24.297 4200.0
24.347 4209. O
24.654 4266. O
25.049 4339.0
25.056 4340.0
25.057 4341.0
25.089 4347.0
25.250 4377.0
25.374 4400.0
25.788 4480. O
26.004 4522.0
26.058 4532.0
26.404 4600. O
26.539 4625.0
26.613 4638.0
26.718 4658.0
27.060 4722.0
27.167 4742.0
249.5
250.3
253.3
254.3
255. O
258.0
258.6
262.0
266.4
266.4
266.4
266.8
268.6
270.0
274.4
276.7
277.3
281.0
282.4 1
283.1
284.2
287.7
288.8
292.0
292.0
292.6
296.2
298.3
298.4
301.3
302. O
5 4 t t
F a i l
2 1411
107#
I F a i l
F a i l
1 174i' 132.11 f
1731 I F a i l
F a i l lili ' F a i l
1 139#
F a i l 1 I
145#
F a i l t
14511
F a i l + 40 31) 136t 190#
1 F a i l
F a i l
1 141#
F a i l Y
F a i l
Fa .1 1868
I 27.478 4799.0
27.479 4800.0
27.539 4811.0
27.929 4884.0
28.154 4926.0
28.158 4927.0
28.472 4986.0
28.547 5000.0
246#
1288
F a i l
13 8.11 4 I
364.11
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(SAND EROSION TEST DATA Continued)
Elapsed Sand Bullplugged f i e l d Time, Flow, tee weight l o s s , hours pounds grams
256
Bullp lugged water tee weight loss , Sand Probe Number
prams
--- Sand Probe Data
28.900 5068.0
29.100 5106.0
29.183 5122.0
29.196 5125.0
29.333 5151.0
29.500 5184.0
29.583 5200.0
30.167 5306.0
30.279 5327.0
30.293 5329.0
30.347 5339.0
30.679 5400.0
30.714 5406.0
30.942 5448.0
31.200 5496.0
31.250 5505.0
31.499 5551. O
31.658 5581.0
31.759 5600.0
32.169 5675.0
32.329 5705.0
32.428 5723.0
32.843 5800.0
32.926 5815.0
33.000 5828.0
33.167 5859.0
33.357 5894.0
33.500 5920.0
33.932 6000.0
306.4
308.9
310. O
310.1
311.9
314.0
315. O
321.9
323.3
323.3
324.1
328.0
328.5
331.9
335.7
336.5
340.1
342.5
344.0
346.6
347.7
348.3
351.0
351.5
351.9
352.8
353.8
354.6
357.0*
t. F a i l
133# t 1 F!il Frl 1 179#
F a i l 1
1425
i F a i l
E 171#
F a i l
t
F a i l
1 308# I
215#
F a i l
*FAILURE **Replacement of a l l p i p e and f i t t i n g s (except test f i t t i n g s )
i
F a i l 409 /I
F a i l
F a i l I Average sand flow rate: 180.3 l b / h r 3.0 lb/min (Bullplugged water t e e )
176.8 l b / h r 2.95 lb/min (Bullplugged f i e l d t e e )
The extended d u r a t i o n of t h e test of t h e bul lplugged f i e l d tee l e a d t o t h e v a r i a t i o n i n t h e sand flow rates.
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25 7
Weight Losses of Bullplugged F i l l Liig Coinpoiiciits
I n i t i a l Weight F i n a l Weight Weight Loss Weight Loss grams grams grams grams F i e l d Tee
Plug 1317. O 1301.0 16.0 1%
Tee 1976.0 1635. O 341. O 1 7 %
T o t a l 3293 .O
Water Tee
Plug
T e e
T o t a l
390. O
1468.0
1858.0
2936. O 357.0 11%
282.0
1379 .O
1661.0
108.0
89.0
197.0
28%
6%
11%
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STD.API/PETRO 2-ENGL L97b m 0732290 058235b 33T -
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259
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STD-API/PETRO 2-ENGL 1 9 7 b m 0732290 0 5 8 2 3 5 8 L O 2 m
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STD.API/PETRO 2-ENGL 1 9 7 b 0732270 0582357 O 4 7 - I
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S T D - A P I / P E T R O ~~
2-ENGL 0732270 0 5 8 2 3 b 0 8bO
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STD.API/PETRO 2-ENGL L97b H O732290 05823LL 7 T 7
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STD.API/PETRO 2-ENGL 197b 0732290 0 5 8 2 3 b 2 b33 9
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STD-API/PETRO 2-ENGL 1976 O732ZqO 0582363 5 7 T
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II II II
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STD.API/PETRO 2-ENGL 1 7 7 b B 0732290 05823b5 342
Water Ell 267 :e
U
Flow
267 Failure
I 1 Plugged water tee
Failure
F low -
t
f I, Flow
Failure
Bullplugged Field Tee
I Flaw
A Schematic of F a h r e
Locations For Three
5 .Test Fitt ings
I
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268
Data taken b e f o r e replacement of worn p i p e and f i t t i n g s
Sand Probe Bi
Sand Flow P a s t Probe, lb:
119, 128, 131, 135, 138, 140, 141, 142, 143, 144, 145, 146, li-
148, 149, 150, 152, 154, 156, 157, 158, 159, 160, 166, 170,
1 7 1 , 180 (27 f a i l u r e s )
Range 119-180 (61) Average 149.6 Standard Deviat ion 13.8
Sand Probe 82
Sand Flow P a s t Probe, lb:
208, 213, 215, 216, 225, 231, 232, 239, 249, 251, 255, 272,
295, 383, 402, (15 f a i l u r e s )
Range 208-402 (194) Average 259.1 Standard Deviat ion 59.2
Sand Probe # 3
Sand Flow P a s t Probe, l b :
169, 188, 189, 191, 196, 206, 211, 215, 218, 219, 228, 238,
250, 262, 266, 299, 446 (17 f a i l u r e s )
Range 169-446 (277) Average 234.7 Standard Deviat ion 63.8
Sand Probe #4
Sand Flow P a s t Probe, lb:
124, 136, 143, 145, 148, 166, 169, 170, 171 , 182, 192,
197, 209, 221, 229, 236, 238, 244, 265, 298 (20 f a i l u r e s )
Range 124-298 (174) Average 294.1 Standard Deviation 47.2
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~~ ~ -~
STD.API/PETRO 2-ENGL L97b 0732270 05823b7 115
269
(SAND PROBE DATA Continued)
Sand Probe f 5
Sand Flaw Past Probe, lb:
279, 302, 306, 313, 314, 323, 368, 380, 388, 422, 437
(11 f a i l u r e s )
Range 279-437 (158) Average 348.4 Standard Deviation 53.0
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STD.API/PETRO 2-ENGL 1 7 7 b 0732290 05823bâ 051
2 70
SAND PROBE DATA
Data taken a f t e r replacement of worn p ipe and f i t t i n g s
Sand Probe i11
Sand Flow P a s t Probe, l b :
116, 121, 128, 133, 136, 138, 141, 142, 143, 145, 171
( i l f a i l u r e s )
Range 116-171 (55) Average 137.9 Standard Deviat ion 14.5
Sand Probe 112
Sand Flow P a s t Probe, l b :
212, 217, 238, 246, 298, 308 (6 f a i l u r e s )
Range 212-308 (96) Average 253.2 Standard Deviat ion 40.7
Sand Probe 83
Sand Flow P a s t Probe, l b :
181, 185, 194, 199, 199, 200, 204, 215 (8 f a i l u r e s )
Range 181-215 (34) Average 196.6 Standard Deviat ion 10.9
Sand Probe # 4
Sand Flow P a s t Probe, l b :
139, 145, 153, 165, 167, 175, 178, 179, 186 (9 f a i l u r e s )
Range 139-186 (47) Average 165.2 Standard Deviat ion 16.3
Sand Probe f 5
Sand Flow P a s t Probe, lb:
300, 364, 403, 409 (4 f a i l u r e s )
Range 300-409 (109) Average 369. O Standard Deviat ion 50.1
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STD-API/PETRO 2-ENGL L97b W 0732290 0582373 b4b
273 DISCUSSION OF RESULTS
Run 8-100 (A and B)
The use of bu l lp lugged tees provided the most durable f i t t i n g s
t e s t e d s o f a r .
i n which t h e k i n e t i c ene rgy .o f t h e sand p a r t i c l e s is g r e a t l y reduced.
S ince t h i s chamber i s loca ted immediately next t o t h e bend i n the
flowpath of t h e a i r j s a n d mixture , t he sand p a r t i c l e s do not have
enough t r a v e l l eng th t o accelerate t o a speed a t which t h e k i n e t i c
energy of the p a r t i c l e s is g r e a t enough t o cause r ap id wear of t h e
f i t t i n g s .
f i t t i n g s , t he plug of t h e f i e l d tee experiences v i r t u a l l y no wear
whi le t he tee i t s e l f wears and even tua l ly f a i l s . Conversely, t h e
tee s e c t i o n of t h e water tee wears s l i g h t l y whi le t h e p lug l o s e s
enough material t o f a i l .
geometries of bo th water tee and f i e l d tee i n t o a s i n g l e f i t t i n g
with a g r e a t l y improved s e r v i c e l i f e . Also of i n t e r e s t is t he
l o c a t i o n of t h e f a i l u r e of t h e f i e l d tee under t h e coupl ing groove.
The test f i t t i n g w a s c u t i n h a l f t o examine t h e c r i t i c a l wear areas
and i t w a s noted t h a t i f t h e coupl ing groove had been c l o s e r t o t h e
bend of the tee, t h e f i t t i n g would have l a s t e d s u b s t a n t i a l l y longer .
The p l o t s of t h e wear rates c l e a r l y i n d i c a t e t h e s u p e r i o r i t y of t h e
bul lplugged f i t t i n g over t h e s t anda rd f i t t i n g .
E s s e n t i a l l y , a bul lplugged tee has a small chamber
I n observing t h e wear of t h e components of t h e bul lplugged
It may b e p o s s i b l e t o inco rpora t e t h e
During t h e course of t h i s run , va r ious f i t t i n g s and p i p e
s e c t i o n s began t o w e a r through s o t h a t i t became necessary t o
r e p l a c e a l l p ipe and f i t t i n g s not be ing t e s t e d about two-thirds
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STD*API/PETRO 2-ENGL L77b D 0732290 0582372 582 =
274
through t h e test.
d a t a w a s extremely d i s r u p t i v e . Overa l l , t he sand probe d a t a f o r
t h i s run w a s no t c o n s i s t e n t enough t o b e of much use i n p r e d i c t i n g
t h e impending f a i l u r e of any f i t t i n g .
b e f o r e and a f t e r t h e p ipe and f i t t i n g replacements w a s q u i t e
d i f f e r e n t f o r probes 2, 3 , and 4 s o t h a t t h e e f f e c t of a "worn in"
p i p e on t h e sand probe d a t a becomes ev ident . The w o r n p ip ing w a s
c u t i n h a l f f o r v i s u a l i n spec t ion and the sand e ros ion e f f e c t w a s
e a s i l y observed. The p i p e wa l l s a t many s e c t i o n s had become very
t h i n wh i l e t h e w a l l s a t o t h e r s e c t i o n s were only s l i g h t l y worn.
wear p a t t e r n caused t h e p a r t i c l e d i s t r i b u t i o n t o b e unsteady on the
average and the re fo re t h e sand probe d a t a is i n c o n s i s t e n t . S ince
it i s n ' t l i k e l y t h a t a method w i l l be found to evenly d i s t r i b u t e
t h e p a r t i c l e s over t he c ross -sec t ion of t h e p ipe , cons idera t ion i s
now be ing given t o a p o s s i b l e redes ign of t h e sand probes.
The e f f e c t of t h i s replacement on t h e sand probe
The sand probe d a t a taken
This
(It should be noted t h a t Run 8-100 w a s made before Run 7-100
s o t h a t r e s u l t s from Run 7-100 do no t appear i n t h i s run.)
i
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~ ~~ ~~
S T D - A P I / P E T R O 2-ENGL L97b m
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27 I EXTRAPOLATION DATA (90" ELL)
I n i t i a l Weight, F i n a l Weight, Run grams grams
2-70 1065.0 998.2
3- 70-A 1075.6 1003,O
4- 70-A 1093.8 1022.0
5- 70-A 1069.5 978.0
5-70-B 1050.5 939.2
5-70-C 1088.6 987.4
6-100-A 1119. o 1029 .O
Weight Loss , grams
66.8
72.6
71.8
91.5
111.3
101.2
90.0
% Weight Lost
6.27
6.75
6.56
8.56
10.59
9.30
8.04
F a i l u r e of t h e 90" e l l occurs a f t e r an average weight l o s s of 8.01%
**For Run 1-50, i n i t i a l weight = 1061.5 grams
Ext rapola ted weight a t f a i l u r e = 1061.5 - (1061.5)(.0801) = 976.4 g r m
Weight l o s s = W = 1061.5 - 976.4 = 85.1 grams
Sand flow = S = W/.017 = 85.1/.017 = 5005 lb
Elapsed t i m e = t = W/3.18 = 85.1/3.18 = 26.76 h r
For Run 4-70-B, i n i t i a l weight = 1092.7 grams
Ext rapola ted weight a t f a i l u r e = 1092.7 - (1092.7)(.0801) = 1005.2 gram
Weight l o s s = W = 1092.7 - 1005.2 = 87.5 grams
Sand flow = S = W/.035 = 87.5/.035 = 2500 l b
Elapsed t i m e = t = W/4.02 = 87.5/4.02 = 21.77 h r
For Run 4-70-C, i n i t i a l weight = 1060.0 grams
Ext rapola ted weight a t f a i l u r e = 1060.0 - (1060.0)(.0801) = 975.1 grams
Weight loss = W = 1060.0 - 975.1 = 84.9 grams
Sand flow = S = W/.030 = 84.9/.030 = 2830 l b
Elapsed t i m e = t = W/3.46 = 84.9/3.46 = 24.54 h r
For Run 3-70-B, i n i t i a l weight = 1068.2 grams
Ext rapola ted weight a t f a i l u r e = 1068.2 - (1068.2)(.0801) = 982.6 grams
Weight loss = W = 1068.2 - 982.6 = 85.6 grams
Sand flow = S = W/.048 = 85.6/.048 = 1783 l b
Elapsed t i m e = t = W/8,96 = 85.6/8,96 = 9.55 h r
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277 (EXTWOLATION DATA (90" ELL) Continued)
For Run 6-100-B, i n i t i a l weight = 1101.5 grams
Extrapolated weight a t f a i l u r e = 1101.5 - (1101.5)(.0801> = 1013.3 grans
Weight loss = W = 1101.5 - 1013.3 = 88.2 grams
Sand flow = S = W/.076 88.2/.076 = 1160 lb
Elapsed t i m e = t = W/11.82 = 88.2/11.82 = 7.46 h r
For Run 6-100-C, i n i t i a l weight = 1078.0 grams
Extrapola ted weight a t f a i l u r e = 1078.0 - (1078.0)(.0801) = 991.7 grams
Weight loss = W = 1078.0 - 991.7 = 86.3 grams
Sand f low = S = W/.087 = 86.3/.087 = 992 lb
Elapsed t i m e = t = W/13.49 = 86.3/13.49 = 6.40 h r
The e f f e c t of u s ing an "average" l i f e accounts for the discrepancy i n
Run 6-100 (B and C) i n which the f i t t i n g i s p red ic t ed t o f a i l long
be fo re a c t u a l f a i l u r e occurs.
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-
STD.API/PETRO 2-ENGL L97b m 0732290 058237b 1 2 8 m
278
SAND EROSION TEST DATA
Run 9-100 (A and B) Date: 9-26-75
Sand: 40/60 f r a c (dry) I n i t i a l weights:
Test f i t t i n g s : S tagnat ion chamber E l l A 1115 grams
with two 90" water e l ls E l l B 1070.5 grams
Flow Veloci ty: 100 f t / s e c Average flowstream temperature 118" F
E lapsed T i m e , hours
o. O00
1.075
2.150
3.200
4.250
*Fai lure
Sand Flow,
pounds
0.0
200. o 400. O
600 .O 800.0
E l l A weight loss,
grams
0.0
19.0
42.1
87 .3
105.3*
E l l B weight l o s s ,
grams
0.0
22.5
52.9
79.3
100.6*
Average sand flow rate: 188.2 l b / h 4 3.13 lb/min
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i
S T D - A P I / P E T R O 2-ENGL 177b D 0732270 0582377 0bq I
I u o ;
. ' 2 73
n œ
å e Y
O
I 4
- 0 I
9 d
U
. . .
I I
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STD.API/PETRO 2-ENGL 197b m 0732290 0582378 T T O m
h
280
B e l l reducer 4 inch I. D. B e l l reducer
2 inch I. D.
I Flow RU^ 9-100
1 Flow Run 10-100
Stagnation Chamber Schematic
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' STD-API/PETRO 2-ENGL 177b E 0732270 0582377 737 E -
28 i O
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M u
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~- STD*API/PETRO 2-ENGL 197b m 0732290 0582380 b 5 9 m -
I t
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282
U 4 w
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111
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STD.API/PETRO 2-ENGL L77b 0732290 0582383 595 I
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~-
STD.API/PETRO 2-ENGL L77b 0732290 0582382 4 2 1
284 O . .
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1
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STD.API/PETRO 2-ENGL L 7 7 b 0 7 3 2 2 7 0 0582384 2 T 4
O N rl
O O O m a m o
O O O 4
O O m
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4
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287 The DLSCUSSION OF RESULTS for Run 9-100 is included w i t h t l i v
discussion at t h e end of Run 10-100,
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~ ~
STD.API/PETRO 2-ENGL L 9 7 b = 0732290 058238b O77 S
SAND EROSION TEST DATA
Run 10-100 (A and B)
Sand: 40/60 f rac (dry)
Date: 10-3-75
I n i t i a l weights:
Test f i t t i n g s : S t agna t ion chamber E l l A 1069.8 grams
with two 90" water e l ls E l l B 1075.1 grams
Flow v e l o c i t y : 100 f t / sec Average flowstream temperature 1 1 7 " F
E lapsed Sand E l l A E l l B T i m e Flow, weight l o s s , weight l o s s , hours pounds grams grams
o. O00
0.917
2.000
3.084
3.434
4.748
5.844
6.544
7.612
8.719
9.758
0.0
175.0
375 .O
575.0
638. O
838.0
1038.0
1164. O
1364.0
1564. O
1764.0
0.0
15.5
24.3
32.5
35.1
42.8
51.6
58.3
67.6
76.3
83.8*
0.0
14.1
41.9
73.1
84.8*
*Fa i lu re
Average sand flow rate: 180.8 l b / h r 3.013 lb/min
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STD-APIIPETRO 2-ENGL L97b 9 0 7 3 2 2 7 0 0 5 8 2 3 8 7 T O 3 9
I c I M
pi
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u v)
289
' .
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i-
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STD.API/PETRO 2-ENGL 1 9 7 b D 0 7 3 2 2 9 0 0582389 ô ô b
291 3 b D 3 a N
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~- ~ ~
STD.API/PETRO 2-ENGL 197b m 0732290 0582370 5Tô m
29 2 n
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* C C Y U U 4 C Y H W U * Y I - d C C I + I - l H ~ C C , * U ~ i Y U U + I 1 1 I I I
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l I l I I
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m + r t W W U c . ( I I l l I I l 1 +CIL.YUcI I I I
+ I I I l I l I I 8 L I I I l I I I I I I I l l I l I + ~ w œ u ~ + u œ u ~ u + u H u œ u + u ~ u u ~ I I I l l I l I l I I l
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STD.API/PETRO 2-ENGL 1 7 7 b 0732270 0582373 4 3 4 I
n n n c' ni
29 3
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294
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STD.API/PETRO 2-ENGL L97b 9 0 7 3 2 2 9 0 0 5 8 2 3 7 3 207
I 2 II
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STD.API/PETRO 2-ENGL L97b m 0732290 0 5 8 2 3 9 9 143 m
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L97b I O 7 3 2 2 9 0 0582395 O A T
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STD.API/PETRO 2-ENGL L97b 0732290 058239b TZb
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O v) 4
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STD.API/PETRO 2-ENGL 1 9 7 b = U732270 0582397 952 W
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STD-API/PETRO 2-ENGL L77b m 0 7 3 2 2 9 0 0582378 877 m i
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STD-API/PETRO 2-ENGL 177b 0732290 0582397 725
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m N r\l
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~ ~ -~
STD.API/PETRO 2-ENGL 197b 0 7 3 2 2 7 0 0582400 277
30 2 DLSCUSSION OF RESULTS
i% .i
Runs 9-100 (A and B) and 10-100 (A and B)
The informat ion obtained i n Runs 7-100 and 8-100 confirmed the
d e s i r a b i l i t y of decreas ing t h e k i n e t i c energy of t h e sand p a r t i c l e s
by a p a r t i c u l a r geometry.
i n t h e t e x t of Run 9-100 w a s cons t ruc ted and i n s e r t e d i n t o the flowpath.
I n Run 9-100, g l a s s p ipe s e c t i o n s of 14 inch l eng th were connected
t o both ends of t h e s t a g n a t i o n chamber i n an at tempt t o provide a
means of v i s u a l l y examining t h e flow. It w a s observed t h a t t h e sand
p a r t i c l e s qu ick ly accelerate back up t o the average flow v e l o c i t y
of t h e air upon l eav ing t h e chamber so t h a t t h e 20 inch s e c t i o n from
t h e chamber o u t l e t t o t h e test e l l e s s e n t i a l l y de fea t ed t h e a c t i o n
of t h e chamber.
s imultaneously as ind ica t ed i n t h e test da ta . I n Run 10-100, t h e
s t a g n a t i o n chamber w a s j o ined t o t h e test e l l wi th a 2 inch n i p p l e
t o reduce the l eng th of p ipe i n which the sand p a r t i c l e s could
accelerate be fo re reaching t h e test e l l .
which r e s u l t e d i n a wear rate even lmer than a bul lplugged f i e l d
tee as evidenced by t h e p l o t e n t i t l e d "A Comparison of Wear Rates
f o r Test F i t t i n g s " a t t h e end of Run 10-100. The test f i t t i n g i n
Run 10-100 w a s a water tee cons t ruc ted of a material s o f t e r than t h e
f i e l d tee. Therefore , t h e s e pre l iminary r e s u l t s i n d i c a t e t h a t t h e
s t a g n a t i o n chamber has a real p o t e n t i a l f o r s i g n i f i c a n t l y reducing
wear rates.
The s t a g n a t i o n chamber apparatus depic ted
A s a r e s u l t , e l l s A and B i n Run 9-100 f a i l e d
This produced a geometry
Due t o t h e r edes ign and cons t ruc t ion of t h e sand probes , sand
probe d a t a w a s n o t recorded i n Runs 9-100 and 10-100.
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30 3
SAND EROSION TEST DATA
Run 11-100 (A and B) Date: 10-14-75
Sand: 40/60 f r a c (dry) I n i t i a l weights:
Test f i t t i n g s : E l l and 30" p l a t e 1162.7 graus*
1171.9 gram* 90" water e l l w i t h 30" p l a t e a t A
90" water e l l w i th 60" p l a t e a t B
Ell and 60" p l a t e
Flow Velocity: 100 f t / s e c
*Includes t h e e l l and p l a t e (wear f i t t i n g s ) b u t n o t the clamp assembly
(non-wear f i t t i n g ) . Ell and 30" plate: e l l 887.7 grams, p l a t e 275.0 grars .
E l l and 60" p l a t e : e l l 895.6 grams, p l a t e 276.3 grams.
E lapsed T ime , hours
o. O00
1.107
2.192
3.404
3.945
4.915
5.028
6.080
7.135
8.240
8.743
Sand Flow ,
pounds
0.0
200.0
400. O
600. O
700. O
874. O
900. o 1100. o 1300. O
1500. O
1590. O
Water e l l and 30" p l a t e weight l o s s ,
grams
(0.0/0.0) O.O**
(10.0/6.8) 16.8
(21.2/15.1) 36.3
(31.5/23.0) 54.5
(38.2/27.4) 65.6
(49.7/33.4) 83.1***
Water e l l and 60" p l a t e weight loss,
grams
(O.O/O.O) o.o** (4,6/8.3) 12.9
(8.8/15.9) 24.7
(12.6/24,3) 36.9
(16.5/29.0) 45 .5
(20.1/37.8) 57.9
(24.1/46.4) 70.5
(28.4/53.7) 82.1
(33.7/61.8) 95.5
(33.9/65.9) 99 .a***
**The water ell and the p l a t e were weighed s e p e r a t e l y t o determine
t h e i r r e s p e c t i v e weight losses. The d a t a i s recorded as
(weight l o s s of e l l / w e i g h t l o s s of p l a t e ) t o t a l weight loss .
***Failure
Average sand flow rate: 181.9 lb/hr 3.03 lb/min
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304
(SAiiD EROSION TEST DATA Continued - Run 11-100)
The p l a t e material w a s U. S. S t e e l HR Alloy P l a t e Type T-1, Quenched
and Tempered (321 minimum B r i n e l l hardness) .
For t h e modified e l l wi th a 30" p l a t e :
83.1 grams or 7.15% of t h e o r i g i n a l weight.
o r 5.6% of i ts o r i g i n a l weight whi le t h e p l a t e lost 33.4 grams o r
12.1% of i t s o r i g i n a l weight.'
The t o t a l weight l o s s w a s
The e l l l o s t 49.7 grams
For tee modified e i l w i t h a 60" p l a t e :
99.8 grams or 8.5% of t h e o r i g i n a l weight.
or 3.79% of i t s o r i g i n a l weight whi le t h e p l a t e l o s t 65.9 grams o r
23.85% of i ts o r i g i n a l weight.
The t o t a l weight l o s s w a s
The ell l o s t 33.9 grams
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r
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STD.API/PETRO 2-ENGL 1 9 7 b M 0 7 3 2 2 9 0 D582LiOb 7 9 5 M
308
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t YCHr(H + CLIB-4C.Y t H C 4 U U C I I I l I I 1 I 1
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STD.API/PETRO 2-ENGL
3 i
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3 3 2 N
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~ ~
~
STD.API/PETRO 2-ENGL 1 9 7 b D 0732270 0562LiLO 1Lb t
Flw 1
P e i
Failure t - Failure t -
thick
U). plate
- Plate Material
HB Alloy Plate Type T-1,
Quenched and Tempered (321
pinimm Brinel l hardness)
U. S. Stee l
t Flaw - Failure
thick
65" plate
60" plate
Failure Locations O f A
Water E l l Fitted With
30", 45" , and 6W Plates
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STD-API/PETRO 2-ENGL L77b
O O o
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a) N
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vi fi
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0732290 0582411 052
Li c L
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U U
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c O 4 U ld C M m LI m
5 r( 3 rl rl al
al LI
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ul M C rl U U -4 Lr,
U (P al w Li O Cu m al u 0 d Li m 3" Y( O C O m rl Li ld a
U z 4
313
I
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STD-APIiPETRO
u
w \
O O O \o
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m M r: d U U 4 Lr u UI al H $4 O Lr m al U m d L, m
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U
4
8
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~ ~~ ~~
STD.API/PETRO 2-ENGL L77b 0 7 3 2 2 9 0 0582433 725
F A I L
Run: 11-100
Sand: 40/60 f r a c (dry)
Flow v e l o c i t y : 100 f t / sec
I
E lapsed t i m e , hours
0.000
1.001
1.109
1.351
1.495
1.735
1.950
1.959
2.025
2.458
2.542
2.568
2.723
2.795
2.889
3.057
3.202
3.685
3.715
3.883
3.922
4.208
4.286
4.430
4.775
4.790
4.823
Sand
pounds
0.0
182.0
201.0
245.0
271.0
315 .O
354.0
356. O
368.0
447. O
462. O
467.0
495.0
508.0
525. O
556. O
582. O
653.0
668.0
681.0
693.0
765. O
779.0
805.0
855. O
861.0
867.0
flow,
T 201#
I F A I L
I I
153#
FA I L
1 4 U
I F A I L
19 81
F A I L
168#
I F A I L
I
u3 1821
I F A I L
I
186f
F A I L
214K
F A I L
183t
I FA I L
139B
I
3 15 SAND PROBE TEST DATA
Date: 10-14-75
525#
F A I L
342B
F A I L
F A I L
T 2459
I F A I L
2175
F A I L
219.11
F A I L
2 2 311
f 2458
I F A I L
201#
I F A I L
206t
F A I L
2025
F A I L
35611
F A I L
3120
I
F A I L
32 8#
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316
1300.0 75B
1328.0
1344.0 FAIL I
SAND PROBE TEST DATA (Continued) Run 11-100
FAIL
Elapsed t i m e , hours
5.029
5.479
5.561
5.589
5.629
5.844
5.900
6.408
6.592
6.901
6.978
7.103
7.135
7.301
7.390
7.404
7.412
7.673
7.749
8.008
8.119
8.172
8.232
8.743
4
Sand flow,
996 .O
1011.0 162# 7! 1016.0 15911 1023.0 FAIL
1063.0 FAIL
1073.0 136f 1165.0 246#
1199. o FAIL 1255. O
1269.0 FAIL
I I
I I
54211
I I
FAIL
I -
i1
1346. O
1348. O
1395.0
1409. O
1456. O
1476.0
1486. o 1497.0
1590. O
1408
I FAIL
2 5 8i1
FAIL
2858
FAIL
FAIL
24411
FAIL
2 2 li1
FAIL
FAIL
261#
FAIL
29 111
FAIL
i 2 18.11
FAIL
2 19 i/
I FAIL
205#
FAIL
I
T FAIL
3; t
FAIL
T FAIL
33211
FAIL
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STD.API/PETRO 2-ENGL 1 9 7 b 0732290 0582LiL5 7 T 8
317 SAND PROBE DATA
Sand Probe #IA
Sand Flow P a s t Probe, lb :
75, 141, 153, 162, 168, 198, 201, 246 (8 f a i l u r e s )
Range 75-246 (171) Average 168 Standard Deviat ion 50.3
Sand Probe B1B
Sand Flow P a s t Probe, l b :
136, 139, 140, 147, 159, 182, 183, 186, 214 (9 f a i l u r e s )
Range 136-214 (78) Average 165 Standard Deviat ion 27.28
Sand Probe #2A
Sand Flow P a s t Probe, l b :
342, 525, 542 (3 f a i l u r e s )
Range 342-542 (200) Average 470 Standard Deviat ion 110.88
Sand Probe # 2 B
Sand Flow P a s t Probe, l b :
508, 792 ’ ( 2 f a i l u r e s )
Range 508-792 (284) Average 650 Standard Deviat ion 200.82
Sand Probe 8 3 A
Sand Flow P a s t Probe, l b :
249, 258, 271, 285, 287 (5 f a i l u r e s )
Range 249-285 (36) Average 270 Standard Deviation 16.09
Sand Probe #3B
Sand Flow P a s t Probe, l b :
221, 222, 232, 244, 245, 312 (6 f a i l u r e s )
Range 221-312 (91) Average 246 Standard Devia t ion 33.94
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S T D * A P I / P E T R O 2-ENGL 1 7 7 b m 0732270 0582L i lb b34 m
318 (SAND PROBE DATA Continued)
Sand Probe 84A
Sand Flow Pas t Probe, l b :
217, 219, 223, 245, 261, 291 (6 f a i l u r e s )
Range 217-291 (74) Average 243 Standard Deviat ion 29.27
' Sand Probe #4B
Sand Flow P a s t Probe, lb :
201, 202, 205, 206, 218, 219, 245 (7 f a i l u r e s )
Range 202-245 (43) Average 214 Standard Deviat ion 15.47
Sand Probe #5A
Sand Flow Past Probe, lb:
315, 338, 363, 379 (4 f a i l u r e s )
Range 315-379 (64) Average 349 Standard Devia t ion 28.12
Sand Probe R5B
Sand Flaw Pas t Probe, l b :
312, 328, 332, 356 (4 f a i l u r e s )
Range 312-356 (44) Average 332 Standard Deviat ion 18.18
. -.
- -
I '
I -I _ - . . _ .
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I. t :.* I _ f
2
1
319
Sand Probe #U
100 200 300 400 500 600 700 ai
Sand Probe #3A .- -' I I I I I ; *
2 t Sand Probe tlñ !, I ' . .
100 200 MO 400 500 600 700 1
2 t Sand Probe #U
1 I 1 . - > - 1
t .- 100 200 300 400 500 600 700 B o :
2 t Sand Probe #2B
b
Sand Probe #4A z
L - I I I I I I , I *
100 200 300 400 500 600 700
2 t Sand Probe 64B 1 11111 1 I
100 200 30 O 400 500 600 700 8(
Sand Probe 6% 1 1 1 1 1 :
100 200 300 400 soo 600 700
Sand Probe #5B 1 1 II I 4
100 200 300 400 500 600 700 8(
Sand F1m Past Probe, lb
RUI 11-100
100 ft/sec 40/60 frac sand (dry)
Graphical Representation O f Sand Probe Failure Data
1
f
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~ ~~ ~~
STD.API/PETRO 2-ENGL L77b 0732290 05824Lô 407
Pressu re
70 p s i g
Bushing
Probe s e c t i o n "B"
c
320
Probe s e c t i o n "A"
Probe s e c t i o n A is l o c a t e d immediately i n f r o n t of probe s e c t i o n B. The probe s e c t i o n i s made of 304 welded s t a i n l e s s s t e e l tubing, 3/16" OD with a .035" t h i c k w a l l .
Sand Probe Schematic
I
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STD.API/PETRO 2-ENGL L77b W 0732290 0582439 343
32 1 DISCUSSION OF RESULTS
Run 11-100 (A and B)
This run completed t h e tests of w a t e r ells f i t t e d wi th d e f l e c t i o n
p l a t e s a t 30°, 45" , and 60'. A s i nd ica t ed i n t h e ske tch of t h e
f a i l u r e l o c a t i o n s , t h e p o i n t of f a i l u r e moved f u r t h e r a long t h e
wear s u r f a c e as t h e i n c l i n a t i o n angle increased. As the percentage
of t h e sand p a r t i c l e s impacting on t h e p l a t e i nc reased , t h e wear
rate decreased as i n d i c a t e d by t h e s l o p e of t h e lines on t h e
Wear Rate p l o t s . However, t h e service l i f e of the f i t t i n g s d i d
n o t correspondingly increase once t h e i n c l i n a t i o n ang le became
g r e a t e r than 45".
observa t ions made wi th t h e g l a s s p ipe flowloop.
flowloop confirmed t h a t a p a r t i c l e s t r i k i n g a s u r f a c e i n c l i n e d a t
45" rebounded a t an ang le of almost 4 5 " .
t h a t once t h e i n c l i n a t i o n ang le of t h e p l a t e w a s such t h a t t h e
ma jo r i ty of t h e sand p a r t i c l e s h i t t h e p l a t e , t h e maximum f i t t i n g
l i f e would b e achieved s i n c e t h e p l a t e would s u f f e r almost a l l t h e
wear f o r any i n c l i n a t i o n angle g r e a t e r than 4 5 ' . The composite
Wear Rate p l o t s f o r Runs 7 , 8, 9 , 10, and 11 s t i l l confirms t h e
lowest wear rate f o r t h e s t a g n a t i o n chamber geometry.
This r e s u l t had been p rev ious ly f o r e c a s t from
T h e g l a s s p ipe
It was t h e r e f o r e expected
Sand probe d a t a us ing t h e redesigned sand probe s e c t i o n w a s
s t i l l not i n d i c a t i v e of any t r end by which impending f a i l u r e of a
f i t t i n g could be pred ic ted . The l a r g e d i s p a r i t y i n t h e amount of
sand flow p a s t a probe necessary t o cause f a i l u r e of the probe
i n d i c a t e s t h a t more uniform r e s u l t s could poss ib ly b e achieved i f
t h e probe s e c t i o n w e r e made of a s o f t e r material.
w i l l be made t o test t h e v a l i d i t y of t h i s idea.
A f u t u r e run
i
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322
SAND EROSION TEST DATA
Test f i t t i n g s :
90" water e l l at
90' f i e l d e l l a t
Flow v e l o c i t y : 100
Run: 12-100 (A and B) Date: 10-30-75
Sand: 40/60 f r a c sand (dry) I n i t i a l w e i g h t s : Water e l l and c o a t i n g 1151.9 grai
F i e l d e l l and c o a t i n g 1422.2 grai
p o s i t i o n A w i t h flame sp ray coa t ing "A"
p o s i t i o n B w i t h flame spray coa t ing "A"
f t/sec
E lapsed t i m e , hours
0.0 1.076
2.226
3.368
4.410
5.377
5.892
*Fa i lu re
Sand
pounds
0.0
200. o 400 .O
600.0
798.0
1000.0
1093.0
flow, Water e l l w i t h flame
spray c o a t i n g "A" weight l o s s , grams
0.0
22.7
41.6
58.9
75.0*
F i e l d e l l w i t h f l a m e sp ray coa t ing "A"
weight l o s s , grams
0.0
26.4
54.6
79.4
103.6
126.5
140.2*
Average sand f l o w rate: 185.51 l b / h r 3.09 lb/min
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* . 323 u 9 n W
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STD.API/PETRO 2-ENGL L77b O732290 0582Lt22 738
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STD-API/PETRO 2-ENGL 197b 0732290 0582423 8 7 4 = I
325
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326 + C H U C C 4 + U W M C Y + r l W C Y P 4 + Y W L U Y + c i c ( c + c c . I I l I I 1 l I l I I I I l I I I l I I I I l I l
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I
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STD.API/PETRO 2-ENGL 1 9 7 b m 0 7 3 2 2 7 0 0 5 5 2 4 2 b 553 S
212.0
216.0
SAND PROBE TEST DATA
312/1
Run: 12-100
Sand: 40/60 frac (dry)
F l o w v e l o c i t y : 100 f t / sec
291.0
304.0
312.0
Elapsed t i m e , hours
1138 FAIL
o .o00
O. 754
0.912
0.986
1.104
1.109
1.189
1.245
1.528
1.674
1.747
1.792
1.936
2.059
2.149
2.174
2.200
2.236
2.651
2.974
3.030
3.176
3.331
3.357
3.589
3.633
3.829
3.833
531.0 FAIL
556.0
Sand
pounds
0.0
140. O
169.0
183. O
205. O
f low,
416#
140# I
FAIL
583.0
14011 I
FAIL
125#
1698 I
T
587.0 19178
682.0
690 .O FAIL
728.0 FAIL
1 29 lt
358.0 337-0 142f ' I I l 374.0
I FAIL
47 711
T 212%
FAIL
1 7 li/
FAIL
204#
FAIL
T 20 5i1
FAIL
153%
FAIL
19 8#
FAIL
219#
I
18311 I
FAIL
15 4i1
FAIL
184 t
FAIL
227#
328
Date: 10-30-75
T 169f
I FAIL
135f
I FAIL
160i1
FAIL
2 18#
FAIL
207#
I FAIL
16 711
FAIL
209#
FAIL
2 2 4i1
2 1611
FAIL
248#
FAIL
I 2938
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~~ ~ ~
STD.API/PETRO 2-ENGL L97b 0 7 3 2 2 9 0 0 5 8 2 4 2 7 4 L T W
FAIL
329
FAIL 1658
FAIL
FAIL
(SAND PROBE TEST DATA Continued)
2108
Elapsed Sand time, f lcw, hours pounds
3.934
4.080 757.0
4.154 768.0 1021
4.224 775.0
4.358 784.0 FAIL
4.369 790.0
4.456 807.0
4.517 820.0 13 71)
4.560 830.0 FAIL
4.958 913.0 3 4 211
5.000 921.0 152# FAIL
5.292 982.0 FAIL I I
250#
5.306 985.0
5.416 1007.0
5.437 1011.0
5.592 1039.0
5.646 1049.0
5.674 1054.0
5.763 1070.0
5.892 1093.0
I FP
I 12af
I FAIL
247f
I l
FAIL
249#
FAIL
FAIL
1 FP
FAIL
FAIL
L
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~~ ~ _ _ _ _ _ ~ ~
STD-APIIPETRO 2-ENGL L77b 0 7 3 2 2 7 0 0 5 8 2 4 2 8 35b D
i
330 SAND PROBE DATA
Sand Probe #U
Sand flow p a s t probe, l b
102, 125, 126, 140, 142, 152, 197
Range 102-197 (95) Average 140.3
Sand Probe #U3
(7 f a i l u r e s )
Standard Deviation 29.6
Sand flow p a s t probe, l b
94, 113, 125, 137, 138, 140, 143, 169 (8 f a i l u r e s )
Range 94-169 (75) Average 131.1 Standard Deviat ion 22.2
Sand Probe %2A
Sand flow p a s t probe, l b
312, 342, 416 (3 f a i l u r e s )
Range 312-416 (104) Average 356.7
Sand Probe f2B
Sand flow p a s t probe, l b
291, 477 (2 f a i l u r e s )
Range 291-477 (186) Average 384.0
Standard Deviat ion 53.5
Standard Deviat ion 131.5
Sand Probe #3A
Sand flow p a s t probe, l b
171,203, 204, 212, 249 ( 5 f a i l u r e s )
Range 171-249 (78) Average 20 7.8 Standard Deviat ion 27.9
Sand Probe #3B
Sand flow p a s t probe, l b
153, 198, 205, 210, 219 (5 f a i l u r e s )
Range 153-219 (66) Average 19 7. O S tandard Devia t ion 25.8
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~~
~
STD.API/PETRO 2-ENGL L î 7 b m 0732290 0 5 8 2 4 2 9 292 D
331
(SAND PROBE DATA Continued)
Sand Probe #4A
Sand flow p a s t probe, lb
154, 165, 183, 184, 227 (5 failures) Range 154-227 (73) Average 182.6 Standard Devia t ion 27.8
Sand Probe #4B
Sand f l o w p a s t probe, l b
135, 138, 160, 169, 191, 218 ( 6 f a i l u r e s )
Range 135-218 (83) Average 168.5 Standard Devia t ion 31.9
Sand Probe #5A
Sand flow p a s t probe, lb 167, 207, 209, 224, 247 (5 f a i l u r e s )
Range 167-247 (80) Average 210.8 Standard Deviat ion 29.2
Sand Probe #5B
Sand flow past probe, l b
216, 248, 250, 293 (4 failures)
Range 216-293 (77) Average 251.8 Standard Devia t ion 31.6
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2 t
I: 2 .’
3 1 o) Fi
rl -4
3 32 Sand Probe #JA
Sand Probe #3A * ’ 11 1 i
1 I II II 1 1 I
100 200 300 400 500
2 t Sand Probe #lB 1 I ! I I 1111 1 4
100 20 o 300 400 500
2 t Sand Probe # 2 A 1 I 1 1 I
100 200 300 400 500
2 t Sand Probe #2B
100 200 300 400 500
Sand Probe 84A 1 1 : I -I
100 200 30 O 400 500
2 t Sand Probe #4B 1 II I I I : I I
100 200 300 40p 500
2 t Sand Probe #SA 1 1 I I 1 1 I
10 o 200 300 400 500
2 t Sand Probe #5B 1 1 II I: I
100 200 300 400 500
Sand Flow Past Probe, lb
Run 12-100 100 f t / s e c 40160 Frac sand (dry)
GRAPHICAL REPRESENTATION OF SAND PROBE FAILURE DATA
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333
The DISCUSSION OF RESULTS for Run 12-100 is included in t h e
discussion at t h e end of Run 13-100.
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- ~-
STD-API/PETRO 2-ENGL 197b m 0732290 0582432 8 8 7
334 SAND EROSION TEST DATA
Run: 13-100 (A and B) Date: 11-10-75
Sand: 40/60 f r a c sand ( d r y ) I n i t i a l weights:
Water e l l and coa t ing
F i e l d e l l and coa t ing 1239.9 grams
1380.3 grams T e s t f i t t i n g s :
90" water e l l a t p o s i t i o n A w i t h flame sp ray coa t ing "B"
90" f i e l d e i l a t p o s i t i o n B w i t h f lame sp ray c o a t i n g "B"
Flow v e l o c i t y : 100 f t / s e c
Average flowstream temperature: 118°F
E lapsed T i m e , hours
o .o 1.083
2.144
3.210
4.241
5.411
6.490
7.560
7.616
8.810
9.991
Sand Flow,
pounds
0.0
200. o 400. O
600. O
800. O
1020. o 1220.0
1410.0
1420. O
1640. O
1840. O
Water e l l w i t h flame sp ray c o a t i n g "B"
weight loss, grams
0.0
20.9
37.1
54.3
70.9
86.7
104.4
122.4"
. .-
F i e l d e l l with flame spray coa t ing "B"
weight loss, grams
0.0
29.1
50.3
74.8
99.3
123.3
150. O
!
175.9
199.4
226.5*
*Fa i lu re
Average sand f l o w rate: 184.16 l b / h r 3.07 lb/min
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STD.API/PETRO 2-ENGL L97b m 0 7 3 2 2 7 0 0582433 713 I
* . U
3 35
4 W
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~ ~ ~~ ~~ ~
STD.API/PETRO 2-ENGL L77b 0732290 0 5 8 2 4 3 4 b 5 T
O
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O o JI
336 + c 8 4 r r m + I - " H c u + m M u u ~ + r C I r - I C . H + C C ( L I ~ Y +
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1 5 1 I I I I
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l I I l I I 1.. a I I I l u l I I I I I I I I I *CIY-"C..+C.ii.ril
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STD.API/PETRO 2-ENGL L ï 7 b 6 0732270 0 5 8 2 4 3 5 5 î b I
33 7
l I l
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c;i CI .c Do r ( c E d
Q: cn m N d
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O
O v-4
338 + l - W U H C l +c.uuur + CkYUC + l I 1 I
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STD.API/PETRO 2-ENGL 1976 0732270 0 5 6 2 4 3 7 3 b î I
339
. . # .: i=;; i ? . i. .
.. . .. . . . . .
M E. d L)
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~
STD.API/PETRO 2-ENGL L77b 0 7 3 2 2 9 0 0582Li38 2T5 PI
251. O
261. O
340 SAND PROBE TEST DATA
FAIL
Run: 13-100
Sand: 40/60 frac (dry)
F l o w v e l o c i t y : 100 f t / s ec
516.0
531.0
Elapsed Time, hours
0.0.0
0.725
0.772
0.913
0.967
1.021
1.126
1.172
1.331
1.383
1.524
1.758
1.860
1.888
2.024
2.058
2.086
2.200
2.206
2.596
2.620
2.749
2.828
3.000
3.080
3.251
FAIL
Sand Flow, - T $ 0.0
134.0 1438 FAIL I
143.0 FAIL I
563.0 FAIL
578 .O
608 .O
169 .O
179.0
34511
I
1258
221.0 144.11 ' I 189 .O
212.0
287.0 FAIL I 331.0
351.0
356.0
382.0 129f
3 82#
I FAIL
I I
386.0 12611
390. O I FAIL
413.0 FAIL I 414.0
487.0 I l,',
B -
Date: 11-10-75
i 2128
FAIL
35 i#
FAIL
30011
20 2#
FAIL
201B
T 189#
I FAIL
197P
FAIL
192#
FAIL
I
179#
I FAIL
1695
I FAIL
2 2 li/
FAIL
5B -
2 5 I.#
1621'1 I FAIL I 1 7 7#
FA I L
17 5.11
FAIL
FAIL
162f
FAIL
1618
19 311
FAIL
194#
I FAIL
2368 f
FAIL
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~ ~~ ~ ~~~
STD.API/PETRO 2 - E N G L L77b m 0732270
18611
FAIL
341
(SAND PROBE TEST DATA Continued)
Elapsed Time, hours
3.287
3.473
3.481
3.483
3.763
3.824
3.866
3.898
4.133
4.195
4.221
4.404
4.458
4.659
4.794
5.128
5.294
5.411
5.503
5.544
5.554
5.747
5.797
5.979
6.211
6.392
6.400
6.453
6.521
6.560
6.619
6.690
6.944
~ ~
Sand Flow,
615.0
651.0 1
653. O
654.0
707.0
719.0
727 .O
733.0
779.0
791.0
796.0
828. O
838.0
875.0
901.0
964. O
995.0
1020.0
1037 .O
1045. O
1046 .O
1082.0
1092.0
1125 .O
1168 .O
1202. o 1203. O
1213.0
1226 .O
1232. O
1243. O
1256. O
130 1 .O
FAIL
1 4 2#
FAIL
16 28
FAIL
1 3 1B
FAIL
133#
FAIL
13811
FAIL
137#
I FAIL
I I I
173#
FAIL
128#
FAIL
I 12u
I FAIL
1278
I
i FAIL
39 a//
FAIL
FAIL
369#
FAIL
3 13#
+- FAIL
213#
I FAIL
218#
I FAIL
19 7 #
FAIL
I
176 f
I FAIL
io FAIL
FAIL I 185 l
241# 1 207 H I
FAIL
182#
FAIL
I 1 8 l#
I FAIL
I FAIL
158#
~
r 18 811
FAIL
2 2 411
I FAIL
206f
I 1
FAIL
23 2#
FAIL
276f
FALL
I
2 37 !\
I FAIL
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~ ~~ - ~~~
STD.API/PETRO 2-ENGL L97b 0732290 0 5 8 2 4 4 0 953
342 (SAND PROBE TEST DATA Continued)
Elapsed Sand T i m e , Flow,
pounds -?- T- FAIL T T T T T-
hours
T I
7.128
7.163
7.297
7.438
7.596
7.804
7.898
7.911
7.950
8.035
8.248
8.503
8.523
8.722
8.734
8.790
9.224
9.290
9.416
9.417
9.494
9.564
9.575
9.793
. 9.839
9.991
1333.0
1340. O
1363.0
1388. O
1415 .O
1455. O
1472.0
1474. O
1482.0
1497.0
1536.0
1583. O
1587. O
1624.0
1626.0
1636.0
1710. O
1721.0
1743.0
1744. O
1756.0
1768.0
1770.0
1806. O
1814. O
1840 .O
411#
FAIL 229# 159# 1548 FAIL 248#
FAIL
FAIL FAIL 140# 2 5 3
FAIL 220#
FAIL
4109 FAIL
13 29 211# FZL t !
i
142# FAIL
2481 FAIL FAIL
FAIL 2388
FAIL 2478 FAIL
120# FAIL
! 17311 FAIL 181B 1
27 3B
FAIL
FAIL
180# FAIL FAIL
1781'1 FAIL FAIL
FAIL
I
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343 SAND PROBE DATA
Run 13-100
Sand Probe #lA
Sand flow p a s t probe, l b
126, 131, 132, 133, 142, 143, 144, 150, 154, 162, 170, 181 (12 f a i l u r e s )
Range 126-181 (55) Average 147.3 Standard Deviat ion 16.9
Sand Probe # 1 B
Sand flow p a s t probe, l b
120, 121, 125, 126, 127, 128, 129, 134, 137, 138, 140, 142, 173
(13 f a i l u r e s )
Range 120-173 (53) Average 134.2 Standard Deviat ion 13.7
Sand Probe #2A
Sand flow p a s t probe, l b
345, 382, 398, 411 (4 f a i l u r e s )
Range 345-411 (66) Average 384.0
Sand Probe #2B
Sand f l m p a s t probe, l b
300, 313, 351, 369, 410 (5 f a i l u r e s )
Range 300-410 (110) Average 348.6
Standard Deviat ion 28.6
Standard Deviat ion 44.2
Sand Probe #3A
. Sand flow p a s t probe, l b
197, 201, 202, 212, 213, 218, 229, 238 (8 f a i l u r e s )
Range 197-238 (41) Average 2 13.8 Standard Deviat ion 14.3
Sand Probe #3B
Sand flow p a s t probe, l b
178, 182, 186, 189, 192, 197, 201, 241, 248 (9 f a i l u r e s )
Range 178-248 (70) Average 201.6 Standard Deviat ion 25.4
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S T D - A P I / P E T R O 2-ENGL L77b D 0732290 0582442 72b I
344 (SAND PROBE DATA Continued)
Sand Probe #4A
Sand flow p a s t probe, l b
159, 174, 175, 176, 177, 179, 180, 181, 194, 211 (10 f a i l u r e s )
Range 159-211 (52) Average 180.6 Standard Deviat ion 13.7
Sand Probe #4B
Sand flow p a s t probe, l b
158, 160, 161, 162, 163, 169, 173, 185, 207, 220 (10 f a i l u r e s )
Range 158-220 (62) Average 175.6 Standard Deviat ion 21.8
Sand Probe # 5 A
Sand f low p a s t probe, l b
188, 193, 194, 206, 221, 224, 247, 248 (8 f a i l u r e s )
Range 188-248 (60) Average 215.1 Standard Devia t ion 23.8
Sand Probe #5B
Sand f low p a s t probe, l b
232, 236, 237, 251, 265, 273, 276 (7 f a i l u r e s )
Range 232-276 (44) Average 252.9 Standard Deviation 18.5
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STD.API/PETRO 2-ENGL L97b 0732290 0 5 8 2 4 4 3 bb2 m 1
2 * '
1
, . .% . '
y
. -~
Sand Probe b l A "
@
345
1 - - Sand Probe #lB
lRlInl1111 I I j $ I '
. .. . :
1 * ' I 11:I 4 i
1 a )
Sand Probe #3A
I I I 200 300 400 500 100
I I I I 1 I * 1
Sand Probe #3B 1 U I I1111l I l t
300 400 500 2
100 200
2 "
1 Sand. Probe #4A
* ' > I 111111l I 1 4
2 "
1 Sand Probe #4B
"
> IlIlIll I :I I I I 1
. . : ::
2 .. 1
Sand Probe #5A .' I Ill I II II I I
2 -. 1 Sand Probe # 5 B
* - Ill I I Il : __1
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STD.API/PETRO 2-ENGL 197b m O732290 0582444 5 T 9 I
F O O rl
I P l rl
--
I O.
h
m
h
\o
v)
m I
34 6
. . . . u U 3 l - m
4
I
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1 PJ l-l
. - . A r (
O O O N
O
4 8
O O
rl
I
> > 4
3 > 3 -4
O O FD
O O ro
O O U
5: P J .
O N O ln r(
O 3
O in
O
347
I r n rn rn
51 u m
4
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348
DISCUSSION OF RESULTS
Runs 12-100 and 13-100
Runs 12-100 and 13-100 were the f i r s t of a series of runs
designed t o test t h e w e a r resistance of materials t h a t could be
used as wear s u r f a c e s i n s i d e of f i t t i n g s .
"Bei were commercially a v a i l a b l e flame spray c o a t i n g s app l i ed t o t h e
i n t e r n a l s u r f a c e s of a water e l l and f i e l d e l l . The wear rates of
bo th coa t ings "A" and "B" are only margina l ly b e t t e r than a s t a n d a r d
f i e l d e l l and are h a r d l y worth t h e t i m e and expense t o employ.
composite graphs f o r t h e wear rates f o r coa t ings "A" and "B" i n d i c a t e
no apprec i ab le advantage f o r one coating over the o t h e r .
Spray coa t ings "A" and
The
The sand probe d a t a shown on the b a r graph f o r Run 12-100
covers a range of sand flows p a s t the probe much wider than d e s i r e d .
However, when c o n t r a s t e d wi th t h e sand probe d a t a from Run 13-100,
t h e reg ions of sand probe f a i l u r e are q u i t e c o n s i s t e n t . Th i s t r e n d
could allow t h e minimum va lue f o r t h e sand flow p a s t t h e probe b e f o r e
f a i l u r e t o b e used t o p r e d i c t t h e impending f a i l u r e of a f i t t i n g .
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~ ~~ ~
STD.API/PETRO 2-ENGL L77b 0732290 0582447 208
349 SAND EROSION TEST DATA
Run: 14-100 (A and B) Date: 12/10/75
Sand: 40/60 f r a c (dry) Average flowstream temperature: 116°F
.Flow ve loc i ty : 100 f t /sec
Test f i t t i n g s : 90' water e l l a t pos i t i on . I n i t i a l weight 1094.3 grams
P l a t e coated 90" water e l l wi th 45" p l a t e a t p o s i t i o n B. w i t h polyphenylene s u l f i d e 1/32" thick.
of e l l 840.7 grams.
291.6 grams.
I n i t i a l weight
I n i t i a l weight of coated p l a t e
E 1 aps ed t ime, hours
0.000
1.023
2.155
3.182
4.204
e
Sand flow,
pounds
O
200
400
600
785
.. The d a t a As recorLdd
t o t a l weight loss ** F a i l u r e
o .o 26.9
60.3
83.2
113.3 **
Water e l l Water e l l and 45" weight loss , coated p la te weight l o s s ,
grams grams *
(O.O/O.O) 0.0
(5.319.1) 14.4
(il. 6/23.2) 34.8
(16.5/30.7) 47.2
(21.5/42.5) 64.0***
as (weight ,JSS O e l l / w e i g h t l o s s of p l a t e )
*** Test terminated wi thout f a i l u r e . The coa t ing w a s qu ick ly worn o f f
s o t h a t t h e test f i t t i n g was t h e same as t h e p l a t e and e l l of
Run 7-100-B
Average sand flow rate: 186.7 l b / h r 3.11 lb/min
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I \". u r l da11 p l g i Y r l Q
t m c œ
bl @4
'o
tn
Po
9
rl
b l . 4 u
"Y E " 3
% i *
8 '0
d W
O
I .t rl
3 8 4 -:r G 3
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351 O
i
L, w O 41 bl c .. n
71 c W
-u o rn a a
'o
U 8 u
rl al 6 3
r( w o
n) & yc 3? O \o \ O U a a
rl rl ad v(
7 3 O
I U d
m O rl c
5 d
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STD.API/PETRO 2-ENGL L57b m 0732290 0582450 AT2 m
35 2
Y d
I
3
I I I I \ !
I I \: l
I I I
I I L) 9) OD % Y w
I I I
O O 4
I I
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9 " PI 3
1 I I
I . I ' '
. Y w
$ 3 : Y U I I
I ! U U
Q o) ri " m w
M d 4 Q) a
Y M
m i m o I
I . M d d LI LI rl
m U .
I l ! O
O Qi
Qi O d Lr
. .
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STD.API/PETRO 2-ENGL L77b 0732270 0582Li51 737
353
3
3
al -u ?! - Y
m a CI
m m 0 c Y
m 3
ri 1 W
3 3 O
al \ U 'u
m M C
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d O a
u 4 3 a al
I Li c I
a c H I
Q Li 1 rl rl 4
W
a I
I I l
I
I
I I l
4 I I I I I I 1 I I I I l I I I l I . I
I I I I I l l + r.&l*C-.c. + w - - r i c + - *v . - . . - + .4-l--œ- t -.- z b - r i i l I I I I I I I l l l I
I I I I I . I
I
I
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V al
o. m rn
Iu I 3 I
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4 3 4 +
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8 4 b4 M
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U 9 4 2
al U u
5 2 4
m U u) a cc 4 cr:
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J O c O
O O
Ln r-
b O O 5) O in N
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STD.API/PETRO 2-ENGL 1976 0732290 0582452 b 7 5
354
3
x iI al
Y 3
!!i ID
al Y E m
M 2 d U LI 4 W
il u) Q) U
CI
5 :e c, U
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-4
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r( 4 al Lc al ia 3
3
il
m I O O d
m o Li
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al al u Q FI oi
M m N rn 4 F I
E O 3
I U d
U
CM il
U O o) I3
3 O
a O O .-(
'3 3
a i.? r-
3 3 O
ca cc,
I
. .
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355
The DISCUSSION OF RESULTS f o r Run 14-100 i n included i n t h e
d i s c u s s i o n at the end of Run 16-100.
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~~~ ~~ ~~~ ~ ~~~~
STD.API/PETRO 2-ENGL 197b 0732290 0 5 8 2 4 5 4 448
356
SAiUD EROSION TEST DATA
Run: 15-100 (A and 9) Date: 12/16/75
Sand: 40/60 frac (dry) Average flowstream temperature: 116°F
Flow v e l o c i t y : 100 f t / s e c
Test f i t t i n g s : 90" water e l l wi th 45" Inconel p l a t e at p o s i t i o n A.
P l a t e th ickness 1.25". P l a t e hardness 42 Rockwell C.
I n i t i a l weight of e l l 850.5 grams. I n i t i a l weight of
Inconel p l a t e 2759.9 grams.
Elapsed T i m e , hours
o. O00
1.052
2.140
3.248
4.589
5.663
6.725
7.809
8.927
.k
90" water e l l with 45" p l a t e at p o s i t i o n B. Plate
coated wi th t e f l o n 1/64" th ick . I n i t i a l weight of
e l l 824.2 grams.
268.5 grams.
I n i t i a l weight of coated p l a t e
Sand Flow,
pounds
O
200
400
6 O 0
800
1000
1200
1400
1600
Water e l l with 45" Inconel p l a t e weight l o s s ,
grams *
( O . o/o. O ) 0.0
(6.9 /8.3) 15.2
(14.3/20.5) 34.8
(20.2/30.3) 50.5
(25.3/40.6) 65.9
(30.7/52.1) 82.8
(33.4/63.0) 96.4
(38.5/71.8) 110.3
(43.5/81.2) 124.7**
Water e l l wi th 45" t e f l o n coated p l a t e weight l o s s ,
grams *
( O . o /o. O ) 0.0
(5.5/9.7) 15.2
(11.7/22.3) 34.0
(14.7/32.9) 47.6
(17.9/44.3) 62.2
(22.2/56.4) 78.6
(24.2/67.7) 91.9
(27.8/78.5) 106.3
(31.2/88. i ) 119.3**
The d a t a i s recorded as (weight loss of e l l / w e i g h t l o s s of p l a t e ) t o t a l
T e s t terminated wi thout f a i l u r e . Enough d a t a a v a i l a b l e t o determine
weight l o s s .
wear r a t e .
**
Average sand flow rate: 179.2 l b / h r 2.99 &/min
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35 7
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STD.API/PETRO 2-ENGL L77b W O732290 0 5 8 2 4 5 6 210 =
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STD.API/PETRO 2-ENGL 197b 0 7 3 2 2 9 0 05824b0 7q3
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36 3
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STD-APIIPETRO 2-ENGL L97b M 0732290 05824b2 514 s
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STD.API/PETRO 2-ENGL L97b 0732290 0582453 450 I
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STD.API/PETRO 2-ENGL L77b 0732270 05824b l i 397
366
The DISCUSSION OF RESULTS for Run 15-100 is included i n the
discussion at the end of Run 16-100.
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S T D * A P I / P E T R O 2-ENGL 197b W 0732270 0 5 8 2 4 b 5 2 2 3 O
36 7
SAND EROSION TEST DATA
Run: 16-100 (A and B) Date: 12/22/75
Sand: 40/60 f r a c (dry) Average flowstream temperature: 117°F
Flow v e l o c i t y : 100 f t /sec
T e s t f i t t i n g s : 90" water e l l wi th 45" tungs ten carb ide p l a t e a t p o s i t i o n
A. P l a t e th ickness .625". P l a t e hardness 55 Rockwell C.
I n i t i a l weight of e l l 825.6 grams.
tungs ten c a r b i d e p l a t e 916.3 grams.
I n i t i a l weight of
90" water e l l w i t h 45" polyurethane s h e e t backed w i t h a
p l a t e a t p o s i t i o n B. Polyurethane 1/4" th ick . I n i t i a l
weight of e l l 833.0 grams. I n i t i a l weight of
polyurethane s h e e t 58.0 grams.
Elapsed T i m e , hours
o. O00
1.064
2.131
3.169
4.292
5.425
6.522
7.570
8.638
9.726
10.792
11.871
12.960
Sand Flow,
pounds
O
200
400
600
800
1000
1200
1400
1600
1800
2000
2200
2400
Water e l l w i t h 45" tungs ten carb ide p l a t e weight l o s s y
grams *
(0 .0/0.0) 0.0
(9.1/6.5) 15.6
(15.2/12.3) 27.5
(20.6/18.8) 39.4
(24.9/24.6) 49.5
(29.3/31.0) 60.3
(33.9/36.5) 70.4
(42.6/44.3) 86.9
(53.6/49.3) 102.9
(54.6/56.5) 111.1
(61.3/64.1) 125.4
(68.6/74.5) 143.1
(75.8/82.9) 158.7 *
Water e l l w i t h 45" polyurethane s h e e t weight l o s s y
grams
( 0 . 0 / 0 . 0 ) 0.0
(5.4/. 9) 6.3
(9.2/.9) 10 .1
(12.3/1.1) 13.4
(13.2/1.3) 14.5
(16.U2.9) 19.0
(17.6/3.3) 20.9
(23.0/5.5) 28.5
(28.0/6.0) 34.0
(30.3/6.5) 36.8
(34.5/6.5) 41.0
(37.0/7.0) 44.0
(41.U7.9) 49.0*
*
* The d a t a i s recorded as (weight l o s s of e l l / w e i g h t l o s s of p l a t e ) t o t a l
weight l o s s . ** wear rate.
T e s t terminated without f a i l u r e . Enough d a t a a v a i l a b l e t o determine
I
Average sand flow rate: 185.2 l b / h r 3.08 lb/min
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STD.API/PETRO 2-ENGL L97b 0732290 0 5 8 2 4 b b LbT I
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369
D e L. c rn u + u c c1*, c 4 ., w c i c. c 4 c u p . C. .' + t. C. b'. c u e I I l I 1 I I
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S T D . A P I / P E T R O 2-ENGL L 7 7 b = 0?32290 05824bô T 3 2
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STD-APIIPETRO
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STD.API/PETKO 2-ENGL 1 7 7 b 0732270 0 5 8 2 4 7 1 527 RLIR
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STD.API/PETRO 2-ENGL 177b 0732290 0 5 8 2 4 7 2 4b3 1
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STD.API/PETRO 2-ENGL L97b W 0732270 0 5 8 2 4 7 7 T 4 5 8111
379
DISCUSSION OF RESULTS
Runs 14-100, 15-100, and 16-100
Runs 1 4 , 15, and 16 concluded t h e tests f o r t h i s phase of t h e
sand e r o s i o n program.
t o o b t a i n a d a t a base and modified f i t t i n g s were run wi th 45" p l a t e s
coated w i t h va r ious materials. On t h e l a s t run, a polyurethane
s h e e t on a 45" p l a t e gave a wear resistance 3 t i m e s g r e a t e r than
a tungs ten ca rb ide p l a t e . The comparisons of t h e wear rates f o r
Runs 14 , 15, and 16 c l e a r l y i n d i c a t e t h e s u p e r i o r i t y of t h e
polyurethane material i n r e s i s t i n g wear.
t e s t e d f i t t i n g s modif ied wi th a polyurethane l i n i n g would have a
g r e a t l y extended service l i f e . A hybr id f i t t i n g c o n s i s t i n g of a
bul lp lugged f i e l d tee wi th a v e l o c i t y reducing chamber immediately
upstream w i t h t h e inne r s u r f a c e of t h e f i t t i n g coa ted wi th
polyurethane should have an excep t iona l service l i f e and h igh
resistance t o sand eros ion .
In t h e s e runs, a 90' water e l l was t e s t e d
Any of t h e prev ious ly
Sand probe d a t a w a s n o t taken dur ing Runs 14 , 15 , and 16 .
. .
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