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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

COPYRIGHT 2003; American Petroleum Institute

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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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4

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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8

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-APIIPETRO 2-ENGL L77b = 0732290 0582LLL 30T =

13

. .

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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STD.API/PETRO 2-ENGL L97b D 0732290 0582LL5 T 5 5 E

17

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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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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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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 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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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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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 t

F l o w

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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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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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54

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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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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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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Q

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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STD.API/PETRO 2-ENGL 197b m 0732290 05821b2 871 m i

I 64 . .

. . I

. .

I

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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72

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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73

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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74

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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75

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



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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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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.



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.


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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STD.API/PETRO 2-ENGL 1 7 7 b W 0 7 3 2 2 7 0 0 5 8 2 1 8 7 1Li1

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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STD.API/PETRO 2-ENGL 1 9 7 b I 0 7 3 2 2 7 0 0582389 T 1 4 M

91


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 .


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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~ ~ ~ ~~

STD.API/PETRO 2-ENGL 1 9 7 b = 0 7 3 2 2 9 0 0 5 8 2 1 9 1 b72 I

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


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


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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10 2

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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STD*API/PETRO 2-ENGL L77b W 0732290 0582202 288 =

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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~

STD.API/PETRO 2-ENGL L77b 0732290 058220b 9 2 3

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?


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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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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~~ ~~~- ~ -~

STD*API/PETRO 2-ENGL 197b 0732290 0582208 7Tb

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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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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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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~ ~~

STD.API/PETRO 2-ENGL L77b 0732290 0582232 1 2 7

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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~~ ~ ~ ~

STD.API/PETRO 2-ENGL 377b = 0732290 0562233 Ob3


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 .


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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~- ~~ ~

~

STD.API/PETRO 2-ENGL L77b 0732290 0582215 93b


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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~~~ ~~

STD*API/PETRO 2-ENGL 1 7 7 b 0732290 058221b 872

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


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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~~~ ~

STD*API/PETRO 2-ENGL L97b = 0732290 0582218 b45 =

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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~~ ~~ ~ ~~-

STD.API/PETRO 2-ENGL L97b = 0732290 0 5 8 2 2 2 9 5 8 1

12 1


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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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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~~

~ -~

STD.API/PETRO 2-ENGL 1 9 7 b 0 7 3 2 2 9 0 0 5 8 2 2 2 2 07b

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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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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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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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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~~

STD.API/PETRO 2-ENGL L97b 0 7 3 2 2 9 0 0582229 4 2 0 m

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


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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STD-API/PETRO 2-ENGL 197b - O732290 0 5 8 2 2 3 3 087

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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S T D - A P I / P E T R O 12-ENGL L97b = 0732290 0582237 57'7

139


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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STD.API/PETRO 2-ENGL L97b 0732290 0582293 A T O 9

a al rl d 4 w C

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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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

147


RUI 3-70-A


T e s t s e c t i o n : 90° e l l


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


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

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STD.API/PETRO 2-ENGL L77b O732290 0582248 382 .

C 15 O i C.- C- c i c-

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STD.API/PETRO 2-ENGL 177b m 0732290 0582250 T30 m

152


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

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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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STD.API/PETRO 2-ENGL L97b m 0732290 0582258 2 2 1

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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


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

16 5


RU 4 - 7 0 - A


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

. . 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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170


RU^ 4 - 7 0 - B


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


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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STD.API/PETRO 2-ENGL L77b 073ZZY0 0 5 8 2 2 7 3 538

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Test s e c t i o n : 90’ e l l

SAND EROSION TEST DATA . .


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



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/PETRO 2-ENGL L77b 9 0732270 0 5 8 2 2 8 5 2 5 T

18 7


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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STD.API/PETRO 2-ENGL L77b 0732290 0582288 T b ï

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 !

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19 1 SAND EROSION TEST DATA

A

Run 5 - 70 (A, B , and C)


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

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3 O O co

FA I L

P 4 o co rD

1 FAIL

t 5Ì N d rn

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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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STD.API/PETRO 2-ENGL L77b 0732270 0 5 8 2 2 7 5 LT7

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STD.API/PETRO 2-ENGL L77b m 0732290 058227b 035 m

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, STD.API/PETRO 2-ENGL 177b 0732270 0582277

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STD.API/PETRO 2-ENGL 1 9 7 b 0732290 0582300 39b I

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~ -~ ~

STD.API/PETRO 2-ENGL 1 7 7 b H 11732290 0582303 U T 5

205


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

206 SAND EROSION TEST DATA

FA L

FAIL

* m

Run 6-100 (A, B , and C)


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

208



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STD.API/PETRO 2-ENGL 377b W 073229û 0 5 8 2 3 3 2 0 0 8

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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

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STD.API/PETRO 2-ENGL L î 7 b m 0732290 0582320 184

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STD-APIIPETRO

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2-ENGL 197b 0732290 0582323

U hi

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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 .

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~ ~-

~

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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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~~ ~~~ ~~

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

64

Run 2-70

Location of Test Points

229



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

STDOAPIIPETRO 2-ENGL Lî7b H 0 7 3 2 2 9 0 0582328 475

230


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~ _ _ . ~ ~ - -

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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/


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


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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STD-APIIPETRO 2-ENGL L97b m 0732290 0582337 q88 m

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STD-API/PETRO 2-ENGL L77b 9 0732290

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3 3 3 5

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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

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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


Sand Probe f 3


193, 199, 203, 207, 222, 229, 230


Sand Probe # 4


151, 158, 159, 161, 164, 165, 168, 172, 183


1

Sand Probe 115


237, 240, 252, 257, 265, 275

Range 237-275 (38) Average 254.3 Standard Devia t ion 14.6



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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.



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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 ,



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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

. ..



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~

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


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~

S T D - A P I / P E T R O 2-ENGL L77b 1111 0732270 0582352 774


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

(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.



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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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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 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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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 )


Sand Probe 82


208, 213, 215, 216, 225, 231, 232, 239, 249, 251, 255, 272,

295, 383, 402, (15 f a i l u r e s )


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 )


Sand Probe #4


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~ ~ -~

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 )




--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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


116, 121, 128, 133, 136, 138, 141, 142, 143, 145, 171

( i l f a i l u r e s )


Sand Probe 112


212, 217, 238, 246, 298, 308 (6 f a i l u r e s )


Sand Probe 83


181, 185, 194, 199, 199, 200, 204, 215 (8 f a i l u r e s )


Sand Probe # 4


139, 145, 153, 165, 167, 175, 178, 179, 186 (9 f a i l u r e s )


Sand Probe f 5


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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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


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



Ext rapola ted weight a t f a i l u r e = 1068.2 - (1068.2)(.0801) = 982.6 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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

277 (EXTWOLATION DATA (90" ELL) Continued)


Extrapolated weight a t f a i l u r e = 1101.5 - (1101.5)(.0801> = 1013.3 grans


Sand flow = S = W/.076 88.2/.076 = 1160 lb


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


Sand f low = S = W/.087 = 86.3/.087 = 992 lb


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


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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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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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


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

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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




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STD-API/PETRO 2-ENGL 177b 0732290 0582397 725

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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.



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

30 3


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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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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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~ ~~ ~~


F A I L

Run: 11-100


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#



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

316

1300.0 75B

1328.0

1344.0 FAIL I

SAND PROBE TEST DATA (Continued) Run 11-100

FAIL


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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


136, 139, 140, 147, 159, 182, 183, 186, 214 (9 f a i l u r e s )


Sand Probe #2A


342, 525, 542 (3 f a i l u r e s )


Sand Probe # 2 B


508, 792 ’ ( 2 f a i l u r e s )


Sand Probe 8 3 A


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


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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 )


' 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 )


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 )


. -.

- -

I '

I -I _ - . . _ .



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~~ ~~

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

322


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*




--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

* . 323 u 9 n W

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9 d

L, 0 al

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CI H



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

STD.API/PETRO 2-ENGL L77b O732290 0582Lt22 738

..

I I I l l I l l I

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l l

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324

5

B LI

I

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I L I



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

STD-API/PETRO 2-ENGL 197b 0732290 0582423 8 7 4 = I

325

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I l

l l I I + I I I I I I I l

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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


F l o w v e l o c i t y : 100 f t / sec

291.0

304.0

312.0


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~ ~ ~

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~ ~ _ _ _ _ _ ~ ~

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


94, 113, 125, 137, 138, 140, 143, 169 (8 f a i l u r e s )


Sand Probe %2A


312, 342, 416 (3 f a i l u r e s )

Range 312-416 (104) Average 356.7

Sand Probe f2B


291, 477 (2 f a i l u r e s )

Range 291-477 (186) Average 384.0

Standard Deviat ion 53.5


Sand Probe #3A


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


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~

~

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 )


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 )


Sand Probe #5B

Sand flow past probe, l b

216, 248, 250, 293 (4 failures)




--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

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.



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

- ~-

STD-API/PETRO 2-ENGL 197b m 0732290 0582432 8 8 7


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"


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




--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

STD.API/PETRO 2-ENGL L97b m 0 7 3 2 2 7 0 0582433 713 I

* . U

3 35

4 W



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~ ~~ ~~ ~

STD.API/PETRO 2-ENGL L77b 0732290 0 5 8 2 4 3 4 b 5 T

O

O r(

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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l l

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1 I I I I I I I I 1

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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

I N I I 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)

I 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


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~~ ~ ~~~

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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~~ - ~~~


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



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

343 SAND PROBE DATA

Run 13-100

Sand Probe #lA


126, 131, 132, 133, 142, 143, 144, 150, 154, 162, 170, 181 (12 f a i l u r e s )


Sand Probe # 1 B


120, 121, 125, 126, 127, 128, 129, 134, 137, 138, 140, 142, 173

(13 f a i l u r e s )


Sand Probe #2A


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



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


178, 182, 186, 189, 192, 197, 201, 241, 248 (9 f a i l u r e s )




--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

- ~ ~~~~~

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


159, 174, 175, 176, 177, 179, 180, 181, 194, 211 (10 f a i l u r e s )


Sand Probe #4B


158, 160, 161, 162, 163, 169, 173, 185, 207, 220 (10 f a i l u r e s )


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 )


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 )




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348


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 .



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~ ~~ ~



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




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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.



--`,,,`,`,,`,`,`,`,,,`,```,,``,-`-`,,`,,`,`,,`---

~~~ ~~ ~~~ ~ ~~~~

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


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.


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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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


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.


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




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STD.API/PETRO 2-ENGL L97b W 0732270 0 5 8 2 4 7 7 T 4 5 8111

379


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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