Pneumatic Erosion Test System for Natural Gas Components
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Solution Overview
Problem
Natural gas wells face abrasive erosion due to particulate material, leading to component degradation and potential failure, necessitating improved test systems and methods for evaluating erosion resistance.
Innovation Solution
A test system comprising a particulate distribution structure, a particulate acceleration structure, and a test sample fixture, which uniformly distributes and accelerates particulate material to simulate erosion on test samples, allowing for the measurement and quantification of abrasive wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gravel packs and screens are used to prevent particulate material from entering the wellbore, then the potential for particulate material to enter the wellbore is decreased, but the gravel packs and screens themselves are eroded by the particulate material
Solution Approach 1:
The patent creates a scaled-down replica test system that copies the essential features of actual wellbore components (gravel packs, screens, tubulars) to simulate erosion conditions. By testing smaller-scale models under controlled conditions, the system predicts erosion behavior of full-scale components without exposing them to damaging conditions during testing.
Solution Approach 2:
The patent replaces complex field testing mechanics with a controlled laboratory-based pneumatic system. Instead of testing components in actual wellbore conditions, the system uses a pneumatic delivery mechanism to transport particulate material through test sections under controlled pressure and flow conditions, substituting mechanical field testing with a controllable pneumatic analog.
2Reliability
If components are designed with predetermined life expectancy, then component reliability is improved, but accurate prediction of erosion requires sophisticated test systems
Solution Approach 1:
The test system is divided into distinct functional segments: a particulate delivery system, a test section with interchangeable components, a collection system, and a measurement system. This segmentation allows each component to be optimized independently and facilitates easy replacement of test samples while maintaining the overall system structure.
Solution Approach 2:
The system enables control and variation of key erosion parameters including particulate material flow rate, particle size distribution, gas pressure, and test duration. By systematically changing these parameters, the system can simulate different field conditions and predict component performance under various operational scenarios.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the prediction and modeling of erosion in natural gas well components, facilitating the design of components with predetermined life expectancy by accurately evaluating their abrasion resistance.
Implementation Method 1
The particulate acceleration structure is configured to receive the distributed particulate stream via the motive gas inlet and to receive a motive gas stream of a motive gas via the motive gas inlet. The particulate acceleration structure also is configured to combine the distributed particulate stream with the motive gas stream to accelerate the particulate material and generate an accelerated particulate stream.
Data Source
AI summary
Test systems and methods for evaluating erosion of a test sample. The test systems include a particulate distribution structure configured to receive a supplied particulate stream and to discharge a distributed particulate stream. The test systems also include a particulate acceleration structure configured to receive the distributed particulate stream and to generate an accelerated particulate stream. The test systems further include a test sample fixture configured to hold the test sample at a test sample location positioned such that the accelerated particulate stream is incident upon the test sample location. The methods include methods of operating the test systems.