Development of a Rigorous Erosion Prediction Physical Model for Thermal Standalone Sand Control Screens

Abstract

Abstract Erosion of standalone screens in thermal wells can lead to significant damage and reduction in production. The dominant failure mechanism is the development of localized high-velocity hot spots in the screen due to steam breakthrough or flashing of the steam across the screen. This study provides methods to assess the erosion potential of screen material devices to determine the allowable production conditions which avoid erosion. In this study the effects of impact angle, flow rate, sand concentration, particle size, and fluid viscosity on erosion are systematically investigated through a multivariable study. Experimental impingement testing is performed on screens in different orientations. Erosion is accessed by collecting weight loss data of the screen. Empirical erosion models are calibrated to provide predictions of functional relationships between erosion rate and varied parameters. Computational Fluid Dynamic (CFD) simulations are performed prior to the experimental work to visualize particle flow paths through the screen and determine local flow and impact velocities and wear patterns. The performance of five existing erosion models is assessed through experimental testing of sand control screens. In order to translate short-term, high-velocity laboratory test results into field erosion predictions, an empirical erosion model is then developed and employed to provide well flow guidelines and minimize erosion potential. This suggests that the use of erosion prediction models in situations in which due to lack of time/data tuning is not possible, may still provide a reasonable estimate for the rate of material loss of the screen. The model is used to obtain threshold superficial velocity curves for several conditions. The main concern associated with existing erosion models is that they do not consider sand production, nor do they account for many other factors that affect erosion process. An erosion model, coupled with CFD simulation, has been developed, that account for factors such as geometry, size, material, fluid properties and rate, sand size, shape, and density in downhole flow conditions.