An Experimental and Simulation Study on Material Erosion of Orifice Manifold at High Speed

doi:10.11885/j.issn.1674-5086.2023.09.18.02

Abstract

Abstract: High pressure difference, high flow rate and high sand content in throttling manifold of high pressure and high production gas wells make the problems of high speed gas-solid erosion wear especially prominent, and the failure of throttling manifold is frequent, which is easy to induce overflow, kick and blowout accidents, aggravating well control risks and bringing safety risks. Therefore, according to ASTM G76—2013, this paper adopts gas-solid nozzle erosion test method and air jet erosion test rig. The high speed (107 to 149 m/s) gas-solid nozzle erosion test of 30CrMo alloy steel was carried out under different inlet pressure (0.06 to 0.15 MPa) and impact angle (15° to 90°), and the erosion rate of 30CrMo alloy steel under different experimental conditions was obtained. The erosion rate equation of 30CrMo alloy steel suitable for high speed solid particle impact is established. Based on the results of erosion experiments, the optimal particle motion model for high speed compressible flow is constructed. Combined with discrete phase model and gas-solid two-phase coupling calculation method, a three-dimensional CFD erosion model of “reduced-tuber-nozzle-erosion cavity” was established. The erosion simulation of gas-solid nozzle of 30CrMo alloy steel, a throttling manifold material, was carried out at different impact angles and inlet pressure, and the distribution characteristics of flow field, particle movement trajectory, impact velocity distribution and slip characteristics were revealed. The accuracy and reliability of the simulation results are verified by the experimental results.

Key words: high pressure and high production gas wells, choke manifold, gas-solid nozzle erosion, CFD erosion model, erosion rate

CLC Number:

TE28
TE931

ZENG Jing, DENG Kuanhai, ZHOU Junping, LIU Bing, LIN Yuanhua. An Experimental and Simulation Study on Material Erosion of Orifice Manifold at High Speed[J]. Journal of Southwest Petroleum University(Science & Technology Edition), 2025, 47(5): 166-180.

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URL: http://journal15.magtechjournal.com/Jwk_xnzk/EN/10.11885/j.issn.1674-5086.2023.09.18.02

http://journal15.magtechjournal.com/Jwk_xnzk/EN/Y2025/V47/I5/166

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[12] 杨向前,王虹富,樊建春. 35CrMo钢冲蚀磨损性能和机制的研究[J]. 石油机械, 2017, 45(7):72-77. doi:10.16082/j.cnki.issn.1001-4578.2017.07.015 YANG Xiangqian, WANG Hongfu, FAN Jianchun. Study on erosion wear property and mechanism of 35CrMo steel[J]. China Petroleum Machinery, 2017, 45(7):72-77. doi:10.16082/j.cnki.issn.1001-4578.2017.07.015
[13] 王国荣,熊柯睿,黄亮,等. 40Cr在高压液固两相流中的冲蚀行为[J]. 润滑与密封, 2018, 43(2):1-5, 11. doi:10.3969/j.issn.0254-0150.2018.02.001 WANG Guorong, XIONG Kerui, HUANG Liang, et al. Erosion behavior of 40Cr in high pressure liquid-solid two phase flow[J]. Lubrication Engineering, 2018, 43(2):1-5, 11. doi:10.3969/j.issn.0254-0150.2018.02.001
[14] VYAS A, MENGHANI J, PATEL P, et al. Characterization and optimization of slurry erosion behavior of SS 316 at room temperature[J]. Transactions of the Indian Institute of Metals, 2021, 74(4):1-11. doi:10.1007/s12666-020- 02169-3
[15] NGUYEN Q B. Slurry erosion characteristics and erosion mechanisms of stainless steel[J]. Tribology International, 2014, 79(1):1-7. doi:10.1016/j.triboint.2014.05.014
[16] 刘冰,邓宽海,林元华,等. 高速固体颗粒冲击下30CrMo钢的冲蚀机理测试研究[J]. 表面技术, 2023, 52(9):135-145. doi:10.16490/j.cnki.issn.1001- 3660.2023.09.010 LIU Bing, DENG Kuanhai, LIN Yuanhua, et al. Erosion mechanism of 30CrMo steel impacted by high speed solid particles[J]. Surface Technology, 2023, 52(9):135-145. doi:10.16490/j.cnki.issn.1001-3660.2023.09.010
[17] NGUYEN V B, NGUYEN Q B, LIU Z G, et al. A combined numerical-experimental study on the effect of surface evolution on the water-sand multiphase flow characteristics and the material erosion behavior[J]. Wear, 2014, 319(1-2):96-109. doi:10.1016/j.wear.2014.07.017
[18] LIN N, ARABNEJAD H, SHIRAZI S A, et al. Experimental study of particle size, shape and particle flow rate on erosion of stainless steel[J]. Powder Technology, 2018, 336:70-79. doi:10.1016/j.powtec.2018.05.039
[19] LAGUNA-CAMACHO J R, MARQUINA-CHáVEZ A, MéNDEZ-MéNDEZ J V, et al. Solid particle erosion of AISI 304, 316 and 420 stainless steels[J]. Wear, 2013, 301(1-2):398-405. doi:10.1016/j.wear.2012.12.047
[20] NGUYEN Q B, NGUYEN V B, LIM C, et al. Effect of impact angle and testing time on erosion of stainless steel at higher velocities[J]. Wear, 2014, 321:87-93. doi:10.1016/j.wear.2014.10.010
[21] 祝效华,刘少胡,童华. 气体钻井钻杆冲蚀规律研究[J]. 石油学报, 2010, 31(6):1013-1017. doi:10.7623/syxb- 201006025 ZHU Xiaohua, LIU Shaohu, DONG Hua. A study on the drill pipe erosion law in gas drilling[J]. Acta Petrolei Sinica, 2010, 31(6):1013-1017. doi:10.7623/syxb2010-06025
[22] WANG G R, CHU F, TAO S Y, et al. Optimization design for throttle valve of managed pressure drilling based on CFD erosion simulation and response surface methodology[J]. Wear, 2015, 338-339:114-121. doi:10.1016/j.wear.2015.06.001
[23] LIU Haixiao, ZHOU Zhongwei, LIU Mingyang. A probability model of predicting the sand erosion profile in elbows for gas flow[J]. Wear, 2015, 342-343:377-390. doi:10.1016/j.wear.2015.09.012
[24] 邱亚玲,邹凤彬,祝效华,等. 页岩气压裂双弯头弯管冲蚀规律研究[J]. 润滑与密封, 2016, 41(9):97-101. doi:10.3969/j.issn.0254-0150.2016.09.018 QIU Yaling, ZOU Fengbin, ZHU Xiaohua, et al. Study on erosion wear of shale gas fracture on double elbows bend[J]. Lubrication Engineering, 2016, 41(9):97-101. doi:10.3969/j.issn.0254-0150.2016.09.018
[25] ZHAO Xuebin, TANG G H, LIU Zhigang, et al. Finite element analysis of anti-erosion characteristics of material with patterned surface impacted by particles[J]. Powder Technology, 2019, 342:193-203. doi:10.1016/j.powtec.2018.09.083
[26] ZHANG Ri, ZHAO Xiaofeng, ZHAO Guanhua, et al. Analysis of solid particle erosion in direct impact tests using the discrete element method[J]. Powder Technology, 2021, 383:256-269. doi:10.1016/j.powtec.2021.01.034
[27] PENG Wenshan, CAO Xuewen, HOU Jian, et al. Numerical prediction of solid particle erosion under upward multiphase annular flow in vertical pipe bends[J]. Inter