Experimental and numerical study on the high-speed gas-solid nozzle erosion of choke manifold material in high pressure and high production gas well

• Published in: Powder technology Vol. 438; p. 119628
• Main Authors: Deng, Kuanhai, Zhou, Niantao, Lin, Yuanhua, Cheng, Jinliang, Bing, Liu, Jing, Zeng
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 01.04.2024
• Subjects: CFD erosion model; Choke manifold; erosion rate; Gas-solid nozzle erosion; High pressure and high production gas well; Particle motion model; Choke manifold; erosion rate; Gas-solid nozzle erosion; High pressure and high production gas well; Particle motion model; CFD erosion model
• DOI: 10.1016/j.powtec.2024.119628
• ISSN: 0032-5910

High pressure difference, high flow rate, and high sand content in throttling manifolds of high-pressure and high-production gas wells make the problems of high-speed gas-solid erosion wear especially prominent. The failure of the throttling manifold is frequent, which is easy to induce overflow, kick, and blowout accidents, aggravates well-controlled risks, and brings safety risks. Therefore, according to ASTM G76–2013, this paper adopts the gas-solid nozzle erosion test method and air jet erosion test rig. The high speed (107 m/s-49 m/s) gas-solid nozzle erosion test of 30CrMo alloy steel was carried out under different inlet pressures (0.06 MPa–0.15 MPa) and impact Angle (15°-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 the discrete phase model (DPM) and gas-solid two-phase coupling calculation method, a three-dimensional CFD erosion model of the “reduced-tuber-nozzle-erosion cavity” was established. The erosion simulation of the gas-solid nozzle of 30CrMo alloy steel, a throttling manifold material, was carried out at different impact angles (15°-90°) and inlet pressure (0.06 MPa–0.15 MPa), and the distribution characteristics of the flow field, particle movement trajectory, impact velocity distribution, and slip characteristics were revealed. The accuracy and reliability of the CFD erosion model and simulation results have been validated by test data. [Display omitted] •High-speed gas-solid erosion test of choke manifold material is conducted.•Erosion rate equation of 30CrMo suitable for high-speed particle impact is created.•Optimal particle motion model suitable for high-speed compressible flow is presented.•3D CFD erosion model of “reducing tube-spray nozzle-erosion chamber” is established.•Flow field, particle trajectory, erosion morphology and erosion rate are obtained.