Testing and validation of a new state-of-the-art erosion control technology in multiphase flow

Abstract

Raw petroleum products are produced at on and offshore production wells. Piping systems are used to transport these products to refineries. During this process, erosion of transportation infrastructures because of sand particles entrained in produced fluids presents a challenge that results in equipment failure, production downtime, unplanned maintenance, and safety concerns. Erosion-resistant coatings, reduction of flowrates, and replacement of piping components are traditional controls to manage erosion. In this work, an innovative erosion control technology (ECT) is proposed which conditions the flow in such a way that most sand particles are captured and re-directed to avoid direct impact of particles with geometries. Hence this solution is based on fluid dynamics rather than focusing on the typical material improvement approach. ECT is a pipe insert used for flow conditioning. The effect of ECT on erosion for a 90-degree standard elbow in the annular flow has been investigated because erosion is more severe in gas dominated multiphase flows such as annular and mist flows than liquid dominated bubbly and slug flows. Flow visualizations, paint-removal studies, and multiphase erosion experiments are performed to verify the effectiveness of ECT. Flow visualization studies show that ECT has been successful in conditioning the flow. Sand particles within the gas core have been captured and re-directed towards the liquid film. Paint removal studies show no removal of paint at high flow velocities of 20–30 m/s. Finally, thickness loss results show a significant reduction in erosion magnitude by a factor of more than 10. Hence, ECT was successful in a significant reduction of erosion in real-time.