A Numerical Study on Erosion Model Selection and Effect of Pump Type and Sand Characters in Electrical Submersible Pumps by Sandy Flow

2019 ◽  
Vol 141 (12) ◽  
Author(s):  
Haiwen Zhu ◽  
Jianjun Zhu ◽  
Risa Rutter ◽  
Hong-Quan Zhang
Keyword(s):  
Particle Density ◽  
Numerical Study ◽  
Petroleum Industry ◽  
Affecting Factors ◽  
Discrete Phase Model ◽  
Erosion Model ◽  
Erosion Rates ◽  
Artificial Lift ◽  
Erosion Models ◽  
Electrical Submersible Pumps

AbstractThe electrical submersible pump (ESP) is one of the most widely used artificial lift methods in the petroleum industry. Although not recommended to be used in sand production well, ESP is still applicable in high producing well with a minimal percentage of solid concentration. Besides, the temporarily produced fracture sand from the proppant backflow can also severely reduce ESP boosting ability in weeks or months. Therefore, it is crucial to study the wear in ESP stages under sandy flow condition. Various erosion equations and models were developed for different materials and affecting factors. However, the predictions of these erosion models in ESPs need to be evaluated to make a proper selection. Comparisons of wear patterns and erosion rates were conducted using the computational fluid dynamics (CFD) software ANSYS. In order to validate the simulation results, an experimental facility was designed and constructed to study the sand erosion process in an ESP. Stages were painted to obtain erosion patterns, and the weight loss was measured. Six erosion models were implemented in the simulations to select the most accurate one in predicting ESP erosion rates. Then, three ESPs, including two mixed-type pumps and one radial-type pump, were modeled to study the effect of pump types with the selected erosion model. Finally, the steady-state discrete phase model (DPM) erosion simulations were carried out to investigate particle density and size effects.

scholarly journals Comparing measurements, 7Be radiotracer technique and process-based erosion model for estimating short-term soil loss from cultivated land in Northern Germany

2017 ◽  
Vol 12 (No. 3) ◽  
pp. 177-186 ◽  
Author(s):  
D. Deumlich ◽  
A. Jha ◽  
G. Kirchner
Keyword(s):  
Soil Loss ◽  
Short Term ◽  
Radiotracer Technique ◽  
Erosion Model ◽  
Weather Patterns ◽  
Erosion Rates ◽  
Soil Redistribution ◽  
Erosion Models ◽  
Event Based ◽  
Agricultural Areas

Due to changing climate and irregular weather patterns, event-based soil loss and sediment yield have become important issues in the agricultural areas. Several mathematical models and prediction methodologies have been used to estimate event-based soil loss and soil redistribution based on soil types, land management, hydrology and local topography. The use of short-lived beryllium-7 as a means of estimating event-based soil erosion/deposition rates has become an alternative to the traditional soil loss measurement methods. A new erosion model taking into account the movement of <sup>7</sup>Be in soils has been presented recently. In order to direct the attention to the potential offered by this technique (measurements and mathematical model), a two-year study was performed at the erosion plots in Müncheberg, Germany, and twelve individual erosion rates were estimated. This paper presents a systematic comparison of the non-steady state <sup>7</sup>Be model with the process-based erosion model EROSION-3D and measured data. The results demonstrate a close consistency between the erosion rates estimated by erosion models and the estimates provided by the <sup>7</sup>Be model and can therefore be seen as a promising contribution to validating the use of this radionuclide to document short-term soil redistribution within the plot and deposited sediment at the bottom of the plot.   

A Numerical Study of Turbulence Model and Rebound Model Effect on Erosion Simulations in an Electrical Submersible Pump (ESP)

2019 ◽  
Author(s):  
Haiwen Zhu ◽  
Jun Zhang ◽  
Jianjun Zhu ◽  
Risa Rutter ◽  
Hong-Quan Zhang
Keyword(s):  
Erosion Rate ◽  
Numerical Study ◽  
Fluid Dynamic ◽  
Turbulence Models ◽  
Centrifugal Pumps ◽  
Discrete Phase Model ◽  
Ansys Fluent ◽  
Simulation Methodology ◽  
Electrical Submersible Pumps ◽  
Cfd Method

Abstract Sand production is one of the most serious problems of electrical submersible pumps (ESPs). It is important to predict erosion rate and pump life under sand flow condition. However, erosion experiments on centrifugal pumps are difficult, expensive and time-consuming. Besides, the erosion on pump blades and shrouds are hard to be quantified. It is difficult to measure or scan the thickness of an inside flow channel. Therefore, computational fluid dynamic (CFD) method is a convenient way to forecast erosion failures of the pump. Although various erosion simulations were carried out for simple geometries, including pipelines, elbows, tees, and etc., erosion simulation methodology in a turbomachinery geometry should be carefully evaluated. Therefore, the effect of different turbulence models and rebound models are investigated in a 3-stage mixed type ESP by ANSYS Fluent Discrete Phase Model (DPM) simulations. The erosion rate is calculated and particle impact parameters are extracted by a User Define Function (UDF). Preliminary erosion simulation methodology recommendations were given in this study.

Sand Erosion Model Prediction, Selection and Comparison for Electrical Submersible Pump (ESP) Using CFD Method

2018 ◽  
Author(s):  
Haiwen Zhu ◽  
Jianjun Zhu ◽  
Risa Rutter ◽  
Jiecheng Zhang ◽  
Hong-Quan Zhang
Keyword(s):  
Ductile Material ◽  
Submersible Pump ◽  
Affecting Factors ◽  
Complex Flow ◽  
Erosion Model ◽  
Flow Geometry ◽  
Erosion Models ◽  
Electrical Submersible Pump ◽  
Flow Domain ◽  
The Impact

Electrical submersible pump (ESP) is one of the most widely used artificial lift methods in the petroleum industry. It is crucial to study the wear in ESP stages with sand production, which can severely reduce pump performance and life span. Usually, experiments and simulation studies were conducted for simple flow geometry such as direct impingement and pipe elbow. Various erosion equations and models were developed for different material and affecting factors. However, the predictions of these erosion models for complex flow geometry need to be evaluated in order to make a proper selection. This study will compare the wear patterns and erosion rates of six different erosion models in three ESPs by using commercial Computational Fluid Dynamics (CFD) software ANSYS Fluent. The results will offer engineers a brief guidance of erosion model selection for complicated flow domain. In this paper, stages of three ESPs, DN1750, TE2700 and Flex31, are modeled. For each pump, the flow domain of two stages are selected and high-quality structured meshes, comprising around 1.2 to 1.8 million hexahedral grids per stage, are generated by ICEM or Turbogrid. Six erosion models, Ahlert (1994), Haugen (1995), Zhang (2007), Oka (2007), Mansouri (2014) and DNV (2015), are simulated under pump best efficiency point. Among six selected erosion models, Ahlert (1994) gives a much higher wear rate than others, while DNV predicts lowest, Besides, the impact angle functions show that all models, except Haugen (1995), assume steel to be a ductile material. Furthermore, the erosion pattern, location, and distribution of all three pumps are different, which indicates different solid particle handling capabilities and failure reasons of radial type and mixed type ESPs.

Troubleshooting Cable Deployed Thru Tubing Electrical Submersible Pumps: A Case Study from South East Asia

2021 ◽  
Author(s):  
Saurabh Anand ◽  
Eadie Azahar B Rosland ◽  
Elsayed Ouda Ghonim ◽  
Latief Riyanto ◽  
Khairul Azhar B Abu Bakar ◽  
...  
Keyword(s):  
Low Cost ◽  
Power Cable ◽  
Related Data ◽  
Root Cause ◽  
Artificial Lift ◽  
Electrical Submersible Pumps ◽  
Cause Of Failure ◽  
Water Cut ◽  
Discharge Pressure

Abstract PETRONAS had embarked on an ambitious thru tubing ESP journey in 2016 and had installed global first truly rig less offshore Thru Tubing ESP (TTESP) in 2017. To replicate the success of the first installation, TTESP's were installed in Field – T. However, all these three TTESP's failed to produce fluids to surface. This paper provides the complete details of the troubleshooting exercise that was done to find the cause of failure in these wells. The 3 TTESP's in Field – T were installed as per procedure and was ready to be commissioned. However, during the commissioning, it was noticed that the discharge pressure of the ESP did not build-up and the TTESP's tripped due to high temperature after 15 – 30 mins of operation. Hence none of the 3 TTESP's could be successfully commissioned. Considering the strategic importance of TTESP's in PETRONAS's artificial lift plans, detailed troubleshooting exercise was done to find the root cause of failure to produce in these three wells. This troubleshooting exercise included diesel bull heading which gave some key pump performance related data. The three TTESP's installed in Field – T were of size 2.72" and had the potential to produce an average 1500 BLPD at 80% water cut. The TTESP deployment was fully rigless and was installed using 0.8" ESP power cable. The ESP and the cable was hung-off from the surface using a hanger – spool system. The entire system is complex, and the installation procedure needs to be proper to ensure a successful installation. The vast amount of data gathered during the commissioning and troubleshooting exercise was used for determining the failure reason and included preparation of static and dynamic well ESP model. After detailed technical investigative work, the team believes to have found the root cause of the issue which explains the data obtained during commission and troubleshooting phase. The detailed troubleshooting workflow and actual data obtained will be presented in this paper. A comprehensive list of lessons learnt will also be presented which includes very important aspects that needs to be considered during the design and installation of TTESP. The remedial plan is finalized and will be executed during next available weather window. The key benefit of a TTESP installation is its low cost which is 20% – 30% of a rig-based ESP workover in offshore. Hence it is expected that TTESP installations will pick-up globally and it's important for any operator to fully understand the TTESP systems and the potential pain points. PETRONAS has been a pioneer in TTESP field, and this paper will provide details on the learning curve during the TTESP journey.

A numerical study of snow accumulation on the bogies of high-speed trains based on coupling improved delayed detached eddy simulation and discrete phase model

2018 ◽  
Vol 233 (7) ◽  
pp. 715-730 ◽  
Author(s):  
Mingyang Liu ◽  
Jiabin Wang ◽  
Huifen Zhu ◽  
Sinisa Krajnovic ◽  
Guangjun Gao
Keyword(s):  
High Speed ◽  
Numerical Study ◽  
Snow Accumulation ◽  
Phase Model ◽  
Detached Eddy Simulation ◽  
Discrete Phase Model ◽  
Eddy Simulation ◽  
Delayed Detached Eddy Simulation ◽  
Flow Mechanisms ◽  
Discrete Phase

A numerical simulation method based on the improved delayed detached eddy simulation coupled with a discrete phase model is used to study the influence of the snow on the performance of bogies of a high-speed train running in snowy weather. The snow particle trajectories, mass of snow packing on the bogie, and thickness of snow accumulation have been analyzed to investigate the flow mechanisms of snow accumulation on different parts of the bogies. The results show that the snow accumulation on the first bogie of the head vehicle is almost the same as that of the second bogie, but the total accumulated snow on the top side of the second bogie is more than 74% higher than that of the first bogie. Among all the components of the bogies, the motors were found to be strongly influenced by the snow accumulation. The underlying flow mechanisms responsible for the snow accumulations are discussed.

An Improved Computational Fluid Dynamics (CFD) Model for Erosion Prediction in Oil and Gas Industry Applications

2014 ◽  
Author(s):  
Deval Pandya ◽  
Brian Dennis ◽  
Ronnie Russell
Keyword(s):  
Fluid Dynamics ◽  
Computational Fluid Dynamics ◽  
Surface Velocity ◽  
Particle Model ◽  
Model Parameters ◽  
Cfd Model ◽  
Erosion Model ◽  
Erosion Prediction ◽  
Erosion Models ◽  
Computational Fluid Dynamics Cfd

In recent years, the study of flow-induced erosion phenomena has gained interest as erosion has a direct influence on the life, reliability and safety of equipment. Particularly significant erosion can occur inside the drilling tool components caused by the low particle loading (<10%) in the drilling fluid. Due to the difficulty and cost of conducting experiments, significant efforts have been invested in numerical predictive tools to understand and mitigate erosion within drilling tools. Computational fluid dynamics (CFD) is becoming a powerful tool to predict complex flow-erosion and a cost-effective method to re-design drilling equipment for mitigating erosion. Existing CFD-based erosion models predict erosion regions fairly accurately, but these models have poor reliability when it comes to quantitative predictions. In many cases, the error can be greater than an order of magnitude. The present study focuses on development of an improved CFD-erosion model for predicting the qualitative as well as the quantitative aspects of erosion. A finite-volume based CFD-erosion model was developed using a commercially available CFD code. The CFD model involves fluid flow and turbulence modeling, particle tracking, and application of existing empirical erosion models. All parameters like surface velocity, particle concentration, particle volume fraction, etc., used in empirical erosion equations are obtained through CFD analysis. CFD modeling parameters like numerical schemes, turbulence models, near-wall treatments, grid strategy and discrete particle model parameters were investigated in detail to develop guidelines for erosion prediction. As part of this effort, the effect of computed results showed good qualitative and quantitative agreement for the benchmark case of flow through an elbow at different flow rates and particle sizes. This paper proposes a new/modified erosion model. The combination of an improved CFD methodology and a new erosion model provides a novel computational approach that accurately predicts the location and magnitude of erosion. Reliable predictive methodology can help improve designs of downhole equipment to mitigate erosion risk as well as provide guidance on repair and maintenance intervals. This will eventually lead to improvement in the reliability and safety of downhole tool operation.

Modeling Gas-Liquid Head Performance of Electrical Submersible Pumps

2004 ◽  
Author(s):  
Datong Sun ◽  
Mauricio Prado
Keyword(s):  
Petroleum Industry ◽  
Nuclear Industry ◽  
Two Phase ◽  
Liquid Model ◽  
Electrical Submersible Pumps ◽  
Pump Head ◽  
Fluid Properties ◽  
Interfacial Characteristic ◽  
Model Equations ◽  
Shock Loss

This study presents a new gas-liquid model to predict Electrical Submersible Pumps (ESP) head performance. The newly derived approach based on gas-liquid momentum equations along pump channels has improved the Sachdeva model [1, 2] in the petroleum industry and generalized the Minemura model [3] in the nuclear industry. The new two-phase model includes novel approaches for wall frictional losses for each phase using a gas-liquid stratified assumption and existing correlations, a new shock loss model incorporating rotational speeds, a new correlation for drag coefficient and interfacial characteristic length effects by fitting the model results with experimental data, and an algorithm to solve the model equations. The model can predict pressure and void fraction distributions along impellers and diffusers in addition to the pump head performance curve under different fluid properties, pump intake conditions, and rotational speeds.

scholarly journals Effect of Air Exchange Rate on Particle Decay in a Cleanroom: A Numerical Study

2019 ◽  
Vol 111 ◽  
pp. 01037
Author(s):  
Yunus Emre Cetin ◽  
Mete Avci ◽  
Orhan Aydin
Keyword(s):  
Exchange Rate ◽  
Turbulence Model ◽  
Recovery Time ◽  
Numerical Study ◽  
Particle Dispersion ◽  
Discrete Phase Model ◽  
Governing Equations ◽  
Air Exchange Rate ◽  
Particle Decay ◽  
Discrete Phase

In this study, particle decay in a cleanroom is investigated numerically. A commercial CFD package, FLUENT, is used in the analysis. The governing equations are solved by using the k-å turbulence model. For particle dispersion, the discrete phase model (DPM) is applied. Four different air change rates (3-10-25-43 ACH) with three particle diameters (0,5-5-10 ìm) are considered. It is shown that 10 ACH satisfies the needs in terms of recovery time.

Spray dynamics simulations for pulsatile injection at different ambient pressure and temperature conditions

2019 ◽  
Vol 234 (4) ◽  
pp. 500-519
Author(s):  
Anandteerth Muddapur ◽  
Sahu Srikrishna ◽  
T Sundararajan
Keyword(s):  
Numerical Study ◽  
Ambient Pressure ◽  
Operating Conditions ◽  
Discrete Phase Model ◽  
Ambient Conditions ◽  
Fuel Temperature ◽  
Shape Distortion ◽  
Penetration Length ◽  
Droplet Shape ◽  
System Pressure

A numerical study on the transient characteristics of a pulsatile, iso-octane spray issuing from a pressure-swirl atomizer is presented. The effects of system pressure and temperature, as well as the initial fuel temperature on spray dispersion and evaporation, are highlighted. The computations were carried out using ANSYS FLUENT-15.0, assuming the spray dispersion to be axisymmetric. Gas phase turbulence is simulated using the renormalized group k- ε model, while the discrete phase model is used for tracking fuel droplets. The linear instability sheet atomization model is adopted for the primary breakup of the liquid sheet, and the Taylor Analogy Breakup and Wave Breakup models are adopted for the secondary breakup, depending upon the operating conditions. The drag force on the droplet is evaluated, after incorporating the effects of evaporation and neighbouring droplets, along with droplet shape distortion. The significance of droplet collision on the evolution of droplet size distribution is examined. The local mean drop sizes and spray penetration length are in agreement with the experimental results of the literature. The predicted results indicate that the spray is narrower and penetrates less at higher ambient pressure. In this respect, the additional force on droplets due to local static pressure gradient is examined in detail. The effect of ambient conditions on the spray evaporation process is studied based on the spatio-temporal evolution of the equivalence ratio of the mixture of fuel vapour and air.

Numerical Study on Film Foam Flow Characteristics in a Straight Duct

2013 ◽  
Vol 561 ◽  
pp. 472-477 ◽  
Author(s):  
Dong Xing Du ◽  
Fa Hu Zhang ◽  
Dian Cai Geng ◽  
Ying Ge Li
Keyword(s):  
Drag Force ◽  
Pressure Difference ◽  
Numerical Study ◽  
Flow Behavior ◽  
Petroleum Industry ◽  
Flow Characteristics ◽  
Viscous Force ◽  
Ideal Condition ◽  
Surface Evolver ◽  
The Mathematical Model

Straight ducts capture some essential features of the motion of foam in porous media in petroleum industry. In this paper, Surface Evolver was employed to build the mathematical model to study the flow behavior of lamellas in the duct with different models. Numerical results show good agreement with experiments and some important features of lamella flow behavior in straight ducts are obtained. It is concluded that, the physical model with viscous force can adequately describe the flow characteristics of reality foam in the experiment. The actual pressure difference consists of the pressure difference caused by the curvature of the lamellas and the drag force on the boundary wall. Under the ideal condition of without drag force along the wall, the pressure drop for lamella flow in the duct is zero, and the shape and the velocity of the lamellas will maintain constant.

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