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Outline
Introduction
Aggressive oil applications (aoa)
Problems in (aoa)
Materials engineering approach
Experimental
Field trials
Aggressive Oil?
light oil, above 35 API, often warmer
medium oils with aromatics
coal bed methane with CO2 gas.
light aromatics (benzene, xylene, toluene)
sour: CO2 + H2S
corrosion inhibitors, amines
chemical stimulation fluids
elastomer/metal degradation
excessive hardening or softening
bond deterioration
corrosion (rotors, tube)
degradation caused by
elastomer/metal chemical reaction
amines, corrosion inhibitors
water (Hydrolysis, salts, PH)
O2 (thermal degradation)
H2S
5
Swelling by fluids
A physical phenomenon governed by
polymer-solvent solubility
temperature
solvent viscosity and shape
activity of multicomponent fluids
elastomer thickness
elastomer composition
Mass Change(%)
12.0%
10.0%
6.1%
8.0%
0.8%
Top Layer
Second Layer
6.0%
12 mm
0.8%
Middle Layer
Middle layer
4.0%
second layer
0.8%
6.1%
2.0%
Top layer
0.0%
0
10
12
14
16
18
Time (day)
ED mechanism
gas dissolves and diffuses into elastomer
high pressure, absorbed gas at equilibrium
pressure releases, gas comes out of solution
pressure differential: gas expansion - swelling
at critical elastomer internal pressure: bubbles or
cracks are inevitable
internal pressure depends on elastomer
composition
10
ED variables
a complex phenomena, too many variables
temperature
gas/fluid mixture
differential pressure magnitude
time of exposure
depressurization rate, dwell time
depressurization cycles
thickness, geometry, constraints
elastomer composition
11
Historical Application.
fluid analysis + compatibility testing (sometimes)
select best elastomers
rotor sizing to accommodate swell (trial and error)
sizing iterations based on performance
12
Materials Engineering
elastomer composition vs. critical properties
DOE
lab mixing and testing
manufacturing trials
full scale product testing
field testing
commercialization
13
Materials Engineering.
a tool for design
balanced properties
compatibility tests
predictive rotor sizing
materials fit for service
RESULTS
16
25.00
Elastomer B
%Vol
20.00
New
development
15.00
10.00
5.00
0.00
0%
5%
10%
15%
20%
25%
30%
35%
%Toluene
17
Location
1
Colombia
2
Romania
3
Africa
4 Czech Republic
5
Canada
Water
cut
API
15%
90%
30%
50%
38%
21
30-40
22
32.5
36
Aromatics
(%mol)
ND
ND
3%
ND
9%
BHT
DegC
48
50
60
50
48
BHP
(psi)
1500
2200
1500
1500
1100
% Volume swell
A
8.1
6.3
16.5
5.6
4.8
Hardness change
(pts)
A
C
-3.0
NT
-3.0
NT
-13.0
%Vol.
20.00
18.00
Elastomer A
16.00
Elastomer B
14.00
12.00
10.00
8.00
New
development
6.00
4.00
2.00
0.00
0
10
20
Time (hours)
30
40
19
Length
Elastomer A
3
1900
240
70
20.93
-1
4.3
Elastomer B
3
1900
240
70
7.35
-3
4.4
Elastomer A
Elastomer B
20
Viton
1.63
0.63
24.22
15.40
1.94
0.34
7.09
3.48
-1
-15
-4
21
operational conditions
API gravity: 21, water cut 15%
CO2: not determined
GOR: above 200 scf/bbl
BHT: 48o C, BHP: 1500 psi.
Elastomer A: 6 months
Elastomer B: 15 months
23
operational conditions:
API gravity: 26.2, water cut 98%
CO2: 22% molar, H2S: 0.7%
GOR: 200 m3/m3 BHT: 30o C BHP: 100 psi.
change to elastomer B
pump model: 47-1500
24
Summary
PC pump elastomer limiting factor in AOA
swelling and ED are the main problem
elastomer can be engineered for AOA
fit for purpose elastomer:
simplify pump application process
improves performance
expands application range
26
Questions????
27