Erosion Effects in Flowmeters

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1 Subsea EXPO 2015 Conference, Aberdeen 11-12th February 2015 Erosion Effects in Flowmeters John Peters, NEL Tariq Boussouara, NEL Slide 1

2 Presentation Contents Project Objective Flowmeter Details, Test Programme Overview of Erosion Facility Factors Which Affect Erosion Results and Conclusions Recommendations CFD Erosion Modelling Summary Slide 2

3 NEL Holds UK National Standards for fluid flow & density measurement A global centre of excellence in flow measurement, flow systems and fluid dynamics World class research, development, modelling, calibration, consultancy, measurement and testing Energy, Oil & Gas Low Carbon Technologies Environment Slide 3

4 Sand Particle Erosion, - Damage, Wear A major issue world-wide in oil & gas exploration & production piping systems Causes major wear, damage to piping, equipment, components Potentially significant errors in flow metering systems Slide 4

5 NMS Flow Programme Project National Measurement System Supported the project: To assess the effects of erosion on flowmeters using performance and diagnostic data. Undertaken by NEL This presentation outlines the results, findings, conclusions Slide 5

6 Flowmeters 3 different meter types supplied for operation in erosive flow conditions Test Group 1: Turbine meter- 50 DN, nitrite coating Venturi meter- 50 DN Βeta ratio 0.75, st/steel Test Group 2: Two 80 DN Coriolis meters ( A & B) Bent measuring tubes (different internal designs) One meter (A) had Diagnostic parameters through advanced signal condition monitoring. Slide 6

7 Test Programme Determine flow meter performance using clean water with calibrated reference meters. Install in water/ sand erosive flow facility. Run the meters under controlled accelerated erosive flow conditions sand concentration ~6% by weight Graded semi-rounded sand, D50 particle size ~275 microns Particles range from <125 microns up to 550 microns Clean meters, repeat calibration on clean water. Process then repeated Review, assess meter performance, Report findings Slide 7

8 NEL Erosive Flow Facility Clean water tank Pump 1 Pump 2 Meter B Mixing Tank Electromagnetic ref meter Sample Point Meter A Control Valve Slide 8

9 Factors Which Affect Erosion Slide 9

10 Erosion Basics Particle Velocity Erosion highly dependent upon particle impact velocity... E = K.f V 2.6 Slide 10

11 Factors Affecting Erosion Levels Particle velocity; wear = f (velocity) 2.6 Particle size Materials of construction Particle Impact Angle Quantity (mass) of sand, sand concentration, duration Sand shape, sharpness, hardness Fluid flow regime - liquid, gas, multiphase Piping configuration, flow path profile, shape, complexity Equipment, component design Slide 11

12 Results Slide 12

13 Discharge Coefficient Venturi Meter- Erosion results Before test 1 After test 1 After test 2 After test Flowrate (l/min) Test 1 Test 2 Test 3 90 hrs 55 hrs 52 hrs 1136 l/min 1050 l/min (rev) 1214 l/min -0.55% -0.55% -1.1% Discharge Coefficient (Cd) drift Pressure-tappings eroded internally (edge not sharp); -ve shift in Cd Throat diameter 0.1mm increase Divergent section 0.4mm increase Slight evidence of ripple erosion marks on parts of wall. Pressure tapping erosion most significant factor. Slide 13

14 Turbine k factor (p/l) Turbine Meter- Erosion results Before erosion After Erosion Flowrate (l/min) Blades eroded badly Clean water End Test 1 Meter factor 14.3 pulses/l 13.8 pulses/l Shift in K factor % Test 1: 1050 l/min, 6% sand Bearing support badly eroded Slide 14

15 Volumetric Error (%) Coriolis Meters- Erosion results overall-volumetric Error Test 1 Test 2 (reverse) Test Coriolis Meter A Coriolis Meter B Erosion Hours Test 1 Test 2 Test 3 90 hrs 55 hrs 52 hrs 1330 l/min 1050 l/min (rev) 1214 l/min Test 1: Meter A, Tube velocity 13.2 m/s Meter B, Tube velocity 8.7 m/s Meter B drifts much less than A Rate of Drift proportional to velocity Meter A stopped working in Test 3- later found severe erosion damage of measuring tubes. Slide 15

16 Mass flow Error (%) Mass Flow Error (%) Coriolis Meters- Mass Flow Error Drift Mass Flow Error Drift - Meter A Mass Flow Error Drift Meter B after test 2 After test 1 Specification Flowrate (kg/s) After test 3 after test 2 After test 1 Specification Flowrate (kg/s) Clean, within 0.1% Test 1, +16% drift Test 2, +18% drift Test 3, meter fails- eroded through Clean, within 0.1% Test 1, +2.7% drift Test 2, +3.0% drift Test 3, +3.6% drift Slide 16

17 Density Error (%) Density Error (%) Coriolis Meters- Density Error Density Error Drift - Meter A Density Error Drift Meter B Specification After test 1 After test Flowrate (kg/s) After test 3 After test 2 After test 1 Specification Flowrate (kg/s) Clean, within 0.05% Test 1, -15% drift Test 2, -17% drift Test 3, meter fails- eroded through Clean, within 1.3% Test 1, +3.1% drift Test 2, +3.5% drift Test 3, +4.3% drift Slide 17

18 Volumetric Flow Error (%) Volumetric Flow Error (%) Coriolis Meters- Volume Error Drift Volume Error Drift - Meter A Volume Error Drift Meter B After test 2 After test Volume Flowrate (l/min) After test 3 After test 2 After test Volume Flowrate (l/min) Clean, within 0.08% Test 1, +35% drift Test 2, +43% drift Test 3, meter fails- eroded through Clean, within 0.02% Test 1, -0.55% drift Test 2, -0.53% drift Test 3, -0.65% drift Slide 18

19 % Deviation (SCP-S) Diagnostic Data- Coriolis Meter A SCP-S Stiffness Diagnostic Parameter SCP- A Asymmetry Diagnostic Parameter Calibration Erosion Test 1 Erosion Test 2 SCP-S Sensitive to erosion wear rate within meter Clean, 0% deviation During Test 1, -7% deviation During Test 2, -1% change,-8% deviation total SCP-A Sensitive to Difference in amplitude between inlet and outlet sensor Clean, 0% Deviation During Test 1, -4.5% deviation During Test 2, +0.5% change, Slide 19

20 PCP-M Reading Diagnostic Data -Coriolis Meter A PCP-M Multiphase Condition Parameter Sand Concentration (%) PCP-M Multiphase Condition Parameter Clean, 0 reading 5-6% sand concentration, reading SUBSEA UK CONFERENCE ABERDEEN Slide 20

21 Coriolis Meter A- Inspection end of Tests Erosion grooves along inside wall of measuring tube Inlet tube Outlet tube Severe wear on outer radius of tube. Erosion scars on outlet bend of inner measuring tubes Slide 21

22 Coriolis meters- Conclusions Before Erosion Thickness Stiffness Mass After Erosion Mass Flow = f.(stiffness) Erosion reduces stiffness, increases twist in tubes, +ve drift in mass flow Density = f(stiffness/mass) Density drift highly dependent upon meter design, where erosion occurs Both meters drifted in opposite directions Erosion = f (velocity )^2.6 Velocity in Meter A tubes (13.2 m/s) approx 1.5 times higher than Meter B This equates to ~ 3 x rate of erosion of Meter B Slide 22

23 Coriolis meters: Conclusions- Diagnostic Data -Meter A Three Diagnostic parameters monitored : Flow tube stiffness, Flow asymmetry Multiphase (multicomponent condition) of the fluid All sensitive to erosive conditions, wear rate and sand content in the meter Potentially use diagnostics to determine when wear has reached a critical level before risk of rupture Diagnostics can potentially detect the presence of sand in the flowstream. Slide 23

24 Accelerated Test v Field Conditions Equivalent Field Erosion Conditions Accelerated NEL Erosion Test (1) Potential Field Condition (1) Potential Field Condition (2) Duration (hrs) Sand conc. by weight (%) Slide 24

25 Recommendations- for flowmeters in erosive flows Consider a meter s maximum operating velocity Operate meters at lower velocities to reduce wear rate Increase meter size to locally lower velocities through meter Use erosion resistant materials to minimise wear Perform bench-mark erosion tests on other meter types, designs, e.g. straight Coriolis designs Venturi with lower Beta value Consider using diagnostics in meters (where possible) Slide 25

26 Benefits of Erosive Flow Testing Erosion testing of equipment, components is very beneficial. A good performance on test is a good omen for a good performance in the field. Testing is essential to test seals, bearings and all moving parts Accelerated field conditions are simulated under controlled conditions Testing quickly identifies any design weak points Testing identifies any local erosion hot-spots Testing may show surprises, not evident from CFD modelling Slide 26

27 CFD Erosion Modelling Slide 27

28 Example Erosion Equation e.g. DNV RPO501- Bend erosion equation erosion m sand. F( ).sin( ). C. A t pipe l. G. K. U n n.~ 2.6 mass of sand bend geometry Particle velocity particle size effect material properties Slide 28

29 CFD View: Cone Flowmeter Water/Sand Erosion Test CFD Slide 29

30 Summary Slide 30

31 Summing Up Flowmeters may wear significantly in erosive flow conditions Potentially significant shifts in error Potential for significant wear of meter internals, loss of meter integrity. Wear greatly influenced by meter design, local particle velocities and operating conditions. Erosive flow testing is often essential to understand the wear characteristics of components and validate equipment performance CFD can optimise designs for erosion; predict the wear life of components in field conditions Part of the tool-box for equipment and pipeline integrity, risk and maintenance management Slide 31

32 Thank You for Listening Any Questions? Slide 32

33 NEL Contacts NEL Contact Tel: + 44 (0) Audit & Allocation Alick MacGillivray alick.macgillivray@tuv-sud.co.uk CFD Neil Bowman neil.bowman@tuv-sud.co.uk Densitometers Norman Glen norman.glen@tuv-sud.co.uk Erosion John Peters john.peters@tuv-sud.co.uk Flow Consortium Phil Mark phil.mark@tuv-sud.co.uk Heavy Oil Chris Mills chris.mills@tuv-sud.co.uk Measurement Consultancy Craig Marshall craig.marshall@tuv-sud.co.uk Chris Mills chris.mills@tuv-sud.co.uk Measurement Uncertainty Alick MacGillivray alick.macgillivray@tuv-sud.co.uk Meter Diagnostics Craig Marshall craig.marshall@tuv-sud.co.uk MeterVue Jess Burke jess.burke@tuv-sud.co.uk Multiphase Holly Ramsay holly.ramsay@tuv-sud.co.uk PPDS Norman Glen norman.glen@tuv-sud.co.uk Single Phase Metering Sarah Pedley sarah.pedley@tuv-sud.co.uk Training John Dods john.dods@tuv-sud.co.uk Umbilicals Lisa Aagesen lisa.aagesen@tuv-sud.co.uk Valve Testing John Dods john.dods@tuv-sud.co.uk Wet Gas Emmelyn Graham emmelyn.graham@tuv-sud.co.uk For general queries contact the sales team on sales@tuvnel.com Slide 33

34 Forthcoming Training Courses Principles and Practice of Flow Measurement Training Course May, East Kilbride SUBSEA UK CONFERENCE ABERDEEN Slide 34

35 Contact us + 44 (0) info@tuvnel.com

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