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Summary. The electrical submersible pump (ESP) is a high-speed rotating device. Its operational life in oil wells can depend on
the type and quantities of abrasives present in the produced fluid. This paper reports on a set of experiments performed in a specialized
abrasive test loop. In the test, the size and quantity of abrasives were varied along with flow rate through the pump. This paper also
examines recent literature on sand production and explores some of the practical problems in sand measurement.
Introduction
More than 80% ofthe earth's crust is composed of abrasive or poten- the sand bridges and arches to break when production is resumed.
tially abrasive materials. I These abrasive materials are the The key to sand control is the establishment, or lack of destruc-
predominant cause of failure downhole, where pumps are lubri- tion, of stable sand arches or bridges. Gravel packing establishes
cated by fluids often heavily laden with abrasives. A large amount bridges in an area in or near the wellbore, and flow control retains
of material loss is not required to destroy a unit; a slight change or establishes bridges in the formation.
of a critical dimension often will lead to catastrophic failure. Several The major uses of the ESP involve high-volume production, low
different mechanisms are at work simultaneously when a pump un- bottomhole pressures, waterfloods, and sometimes cycling. This
dergoes abrasive wear. The isolation and investigation of these in- places the ESP directly in the path of high sand production.
dividual phenomena will lead to a better understanding of the
problems and possible solutions. Sand Measurement
Sand production varies over a well's life; great quantities of sand
Sand Production From 011 Wells are often produced at the start and gradually taper off. Operators
Two methods are generally accepted to control sand production: at most locations have very little incentive to measure sand pro-
gravel pack and flow control. The gravel-pack method uses select- duction unless a well is suffering significant sand-related problems.
ed sand and gravel held in position in a slotted liner to block the An accurate picture of a particular well's sand production requires
sand so that it is retained in the formation. With the flow-control that the rate of sand production be monitored for weeks or months
method, the well's flow is regulated to a point where sand produc- afte production startup.
tion ceases. Both methods have been successful but neither is cheap. One method of obtaining sand production data requires use of
The money that is lost when production is reduced, however, may a cyclone separator. The size of particles that can be separated by
be much greater than the money spent for gravel packing. a cyclone is a function of particle density (compared to fluid densi-
Recent papers 2- 5 attempt to explain the mechanics of oilwell ty) and differential pressure drop. Fig. 1 shows a typical solids re-
sand production. These papers propose theories to explain some jection curve for a cyclone separator. The actual rejection rate in
of the observations that accompany the sand production-e.g., that the field depends on how close the actual conditions are to the curve
(1) sand tends to be produced at high flow rates, (2) the volume conditions. Nonspherical particles are not separated as easily. Heavy
of sand tends to increase as water breaks through, (3) sand pro- brine reduces the difference in the densities. Oil-wet particles have
duction rate increases when flow rate changes, and (4) catastroph- the tendency to float and to pass through the separator. Small par-
ic sand production can occur that may not stop even when the flow ticles have much lower settling velocities and higher dispersion
rate is reduced. coefficients. Fluid viscosity also reduces the device's efficiency.
Rock mechanics is the basis for understanding sand production. The cyclone separator is not 100% effective, but is a rugged and
Sand is not produced from naturally completed oil wells until the simple device.
cavity in the formation surrounding the perforation becomes un- The sand samples are usually analyzed by sieve analysis. The
stable. The formation rock can fail during tension or shear. The particles can be washed and then run through a series of sieves.
shear forces on the rock are related to overburden. The weight of The percentage of the weight that is retained in each sieve is record-
all the rock above the formation and the tensile forces are related ed. Table 1 presents the relationships between sieve size and actu-
to flow. As reservoir pressure is decreased, the unbalanced over- al dimension, and Fig. 2 shows the sieve analysis for an actual well.
burden pressure can induce shear failure in the rock. As flow rate It is likely that some fines are suspended and lost during washing.
increases, the pressure drop through the rock produces tensile forces It is quite possible that a portion of the sand, the extremely fine
that can induce failure. particles, will be missed. They are the hardest to catch with a cy-
Sand production invariably follows water breakthrough. Water clone and the easiest to lose with a sieve analysis.
increases the stress on the rock and simultaneously decreases its
strength. Some possible explanations for this occurrence are that Sand Wear
(1) water diminishes or destroys the capillary pressure holding the The literature concerning abrasive wear is large and often confus-
sand grains together, (2) water dissolves the material cementing ing. MiIler 6 identifies 18 types of abrasive wear in slurry pipeline
the sand grains together, or (3) flow friction increases because water equipment. Abrasion and erosion are often used to describe the same
saturation lowers the oil relative permeability. phenomenon. In this paper, erosion is the removal of material by
One indirect cause of sand production with water breakthrough abrasive particles carried by or suspended in a fluid when it acts
is the tendency for the operator to increase the total volume of fluid against a surface; abrasion is the removal of material by particles
to maintain the well's profitability. The higher flow rate increases sliding, rolling, or crushing between two surfaces, or by particles
the pressure gradient and fines migration, which increases the plug- embedded in one surface sliding against a second surface.
ging rate. Hardness is a material's resistance to indentation, cutting, scratch-
Increased sand production has also been related to cycling. If the ing, or abrasion. Fig. 3 shows some of the more common hard-
rock is plastically deformed when the well is cycled, sand produc- ness scales. They are categorized as follows.
tion will increase. The rock regains the elastic portion of the strain 1. Penetration depth. The most widely known penetration scale
when the stresses are relieved, but the plastic portion is never re- is the Rockwell scale, which relates a material's hardness to the
covered. This change in shape weakens the formation and allows penetration depth that a specific size sphere will make under a spe-
Copyright 1990 Society of Petroleum Engineers cific load.
-:; 70 Screen
Diameter
is
60
\ in. Itm
Mesh
Equivalent Common Name
".t
0
Uquld SP. GR.-I.O ---
0 Solid. SP. CR.-2.5
0.00004 1 clay, colloids
0 50 0.0002 5
C!
z
40
\ EII.-In Excl•• of
90-95l1: 0.0004
0.0018
10
44
1,470
325
fine silt
0.003 74 silt
0
It:
200
0 30 0.004 105 140
:E very fine sand
.:::. 20 ~ 0.005
0.006
125
149
120
100
fine sand
'"
CI'I
z .(' CONE 0.010 250 60
0 10
-..... 0.012 297 50
It:
0
:E
10 15 20 25 30 35 40 45 50 55
-
60
0.020
0.023
0.039
500
595
1,000
35
30
18
medium sand
coarse sand
0.047 1,190 16
DIFFERENTIAL PRESSURE, PSIG very coarse sand
0.079 2,000 10
0.094 2,380 8
fine gravel
Fig. 1-Cyclone separator performance. 0.265 6,730 3
2. Indentation area. These scales relate a material's hardness to out by particles. Several factors determine the rate at which the
the volume of material displaced by an indenter of specific geome- material removal occurs-e.g., hardness of the material and the par-
try. The Brinell scale uses spheres; Knoop and Vickers' scale uses ticle; ductility of the surface; and size, shape, and toughness ofthe
pyramids. The readings are reported in units of kilograms per square particle.
millimeter. It is commonly believed that an abrasive cannot wear a material
3. Scratch hardness. The Mohs scale rates hardness on the basis harder than itself. According to Mohs's definition, a softer materi-
of what mineral will scrach what other mineral. Diamond is the al cannot scratch a harder material; in the more complex phenom-
hardest and has a Mohs rating of 10; talc is the softest and has a enon of grinding abrasion, however, both the harder and the softer
rating of 1. This arbitrary scale spaces materials rather oddly com- material show loss. Rabinowicz 8 states that wear rate is inversely
pared with some of the others. It is used mainly for minerals and proportional to hardness and that a plot of the product of wear and
is seldom applied to metals. hardness vs. hardness should be a straight line. Fig. 4 shows that
as the material approaches the hardness of the abrasive, the wear
Erosion. In erosion, the particles impinge on a surface. The severity rate drops but does not totally disappear.
of erosion is a function of particle velocity, fluid viscosity, angle The size of the abrasive particle significantly affects wear. Wear
of attack, and the physical characteristics of the surface and parti- increases as the particle size increases. It is suggested that with fine
cle. During slurry transportation, 7 the erosion was found to be abrasives the load be more evenly distributed along the surface of
proportional to the cube of the particle velocity. The smaller parti- the material to reduce the possibility of a particle critically damag-
cles are less damaging. As the particle size is reduced, fluid drag ing the material.
forces become large enough to prevent the particles from contact-
ing the material surface with sufficient force to remove any material. Sand and ESP's
The ESP is an extremely specialized device. Because of its slender-
Abrasion ness and high operational speed, loss of radial stability can destroy
Abrasion occurs when particles are crushed between, slid, or
dragged along a surface. When contact is made, the surface of the 10.000
material is deformed in one of two ways: by plastic deformation, 10 Diamond
in which material either is extruded from the grooves formed along 5.000
the path of the particle or forms around a particle that indents the
surface, or by direct separation, in which material is directly gouged :::g:::::::::::
AIunIina- 2.000
Tungeton Corl>Ide -
l-
9 _.
90
r
8 Topaz 1.000
SILICA SANO~ 80
R....t. Iron 7
Abta.U)ft Quartz 110
SO.OS 28S Chrome
e Feldepar 500
40
40.o"
6 Apatite
20
f,m ..~
100
IRON SULFlDE~;Bf~ _ _ 200
CALCIUM ~:4R-..i~
CalcIte
Rc 80
iS 30.0" 80 100
~ 40
SODIUM CHLORIDE 20
i
~ 20.0"
-[
RB
ROCKWELL
60
:. 2 Gypsum
20
10.OX
10
0.""
JOO '54 72
Slew ......, OpenIng. UIcrona (um)
. 1
MOHS
Talc KNOOP
(APP. BRINELU
200
A \
-- VI
I t
..
VI
VI Hardness of ....,g ~
~
c ..... abrasive EROSIONAL
100 WEAR AREAS
"O..!
"'0
Ou
51 0 2 1\ THRUST
.<: .. 50 (;lIo,'M' W EAR AREAS
~
'/'/"7:z:::Z
)(~
.. e
o:t:
"'-e 20 L DOWN THRUST
..
"'0 WASHERS
0 ...... 10
~
Fig. 5-Wear points on a pump stage.
5
100 200 500 1000 2000
Data of Alelnlkov (1957) are lubricated and cooled by the production fluid. The pump is de-
Hardness, kg/mm 2 signed so that the direction of the thrust is downward when the pump
is within its operating range. Abrasive particles that are trapped
Fig. 4-Wear rate times hardness vs. hardness (from Ref. 8). in or enter into the thrust bearing area abrade the thrust washer
material or the stage metal. Unlike radial bearing wear, thrust bear-
ing wear has been known to occur in isolation. Severe downthrust
the unit in a very short time. A majority of the pumps are classi- wear should never occur in clean fluid if the pump is within its
fied as "floating" impeller pumps because their impellers are not operating range. Many abrasion failures are incorrectly attributed
fixed axially to the pump shafts but are free to "float." Fig. 5 shows to a pump that is run out of its range.
the types of sand wear seen in these pumps-Le., radial bearing Erosion of the pump stage surfaces is caused by the abrasive par-
wear, thrust bearing wear, and erosional wear. ticles striking the material surface. Impingement erosion is most
Radial bearing wear refers to the loss of material on the pump's likely to occur in areas where the fluid changes direction, such as
radial bearings and sleeves. Slight loss of material in the radial bear- the entrances to the impeller and the diffuser. The sliding erosion
ing allows the shaft to rotate eccentrically (whip). This whip greatly occurs in the diffuser bowls and on the impeller vane tips. Erosion
increases the side load on the bearing, causing accelerated wear. is not considered a normal cause of failure because the pumps gener-
As the shaft moves off center, the thrust load on the shaft makes ally will fail for some other reason long before they erode to the
the shaft buckle, increasing the side load and wear. The vibrations point of failure.
are transmitted down the shaft into the seals, causing the seals to
leak wellbore fluid into the motor. Abrasive radial bearing wear Sand Problems
in floating impeller pumps never occurs in isolation; when it occurs, Abrasion can exist without obvious surface evidence, such as cut-
there is always some degree of thrust bearing wear. out chokes and elbows or silt in the tanks. Fig. 6 shows the pump
Thrust bearing wear is the wear on the thrust washers and their curve from one mysterious failure. The well had a· sand problem
mating surfaces in the pump stage. The thrust forces that are gener- early in its life. A gravel pack was installed, and the produced fluid
ated by a floating impeller are absorbed by thrust washers within appeared clean. The pump ran in its operating range for 7 hours
the stage. The industry standard for these thrust washers has been before it shut down on overload. A pit test determined that the unit
laminated phenolic. Like the radial bearings, these thrust surfaces was performing to the head capacity curve. The horsepower at the
..""
lifTERS
'tAO
FEET
PERFORMANCE CURVE ~AKE
HP.
PUMP
EFF,,,
JL
50
':::~
.....!L
12 40
plTtes ~
7I7i"E 1t0l1s
~.
.....
" "'" ""'-
,.....!.2....
-L
30
/"
./
...- - ........ r--. ~
...........
"
......
,
70
60
50
i---L
f--L
20
10
~
~ l---
J/
~
~ =-
un! ~EPO~ II
\t-.
~
, ........
\.
1.25
1.00
.75
.50
40
30
20
'0
0/
500
I
100
1000
BARRE~S
200
I
1500
PER DAY (42 U.s.
300
I
2000
.00
2500
I
GA~~ONS)
3000
I
500
3500
" I
600
4000
.25
~
t .•
CommercJal Fot.I'tdry Sand
oo.o~ . . . - - - - - - - - - - - - - - - - - - - - - I.J
/ L
1.2
j /
j /
I.t
<40.0" +--------------------- 7 /
E
--
j / ..-
~~ 0 .•
-j 7
.~" ~
0.8
7 7
30.0" +------....,.,_,.,..--¥H74----------
20.0X +------44..-,...;4-44..-,...;4-...,..,~,.,..------
'0
~~
•
0.7
0.'
0.'
/
,
7
-/
7
./~
.--
0.'
O.J
/ ~
/ ~-./
0.2
to.OX +------44..-,...;4-44..-,...;4--+7..-,...;4-------1 O.t /~/
~
TIME (Hou,..)
42J JOO 2t8 ttJ 72 C Min Flow + BEP Flow () Max Flow
t.J ./ t.2
t.2 ./ I.t
t.t ./
./ I 0 .•
:;~
1~ /
e" i
--
0 .• 0.8
,,
.~ ./' / ~
--- ---
.2:;,
--
0.8 ,~
0.7
.~ ~ ./ / ~
'0 0.7 ~t. 0 .•
~~ 0 .• ./ / • 0.5
• 0.5 ./ / / 0.'
.....- ~
~
-- ---
./ / ./ O.J
~
0.'
./ .-" . / "7
O.J
0.2 ./ .....- ~
0.2
O.t
~
7~
O.t
~ ./ .........
TIME (Houra)
Cl ~in Flow + BEP Flow () t.4ax Flow
Tlt.4E (Houf1I)
o Min Flow + BEP Flow () Mox Flow
"best efficiency point" (BEP), however, was 60% greater than nor- The pumps were tested at three different flow rates: the BEP and
mal and at shut-in was 140% greater. Examination of the disas- the maximum and minimum operating points. The tests were con-
sembled unit revealed little radial bearing wear; however, all the fined to a radial flow pump designed for III m 3 /d [700 BID]. No
thrust washers were worn away, and the stages were rubbing met- mixed flow stages were tested.
al to metal. A fluid sample from the well did not contain any visi-
ble sand. The sample was centrifuged and found to contain fine Test Results
silt. Many failures are attributed to severe downthrust simply on The first series of tests was run with a standard-configuration pump.
the evidence that the pump has worn through its downthrust wash- The radial bearing support was provided by the impeller hubs run-
ers. It is likely that many of these failures result from particles sus- ning in the diffuser bores. Thrust support was provided by the thrust
pended in the fluid. washers in the impellers riding on thrust pads in the diffuser. The
starting concentration was 0.5 wt% of the commercial sand. Sig-
Investigation nificant wear was noted after the first hour. By the end of the sec-
The purpose of this investigation was to determine whether abra- ond hour, the wear was so severe that the test was aborted. The
sive wear in the pump could be segregated into categories that would sand concentration was reduced to 0.25 wt%, and the pump was
help explain some of the failures. A flow test loop was constructed put through a series of 4-hour tests. The tests results shown in Figs.
that allowed for rapid change-out of the pump, the fluid, and the 8 and 9 indicate that a relation exists between the wear rate and
abrasive. The system was designed so that the pump could be quickly flow through the pump. The greatest wear occurred at the lowest
disassembled for critical measurements and then reassembled to con- flow rate (highest pressure). Significant eccentric wear was evi-
tinue the test. The test was designed to encourage premature failure. dent on the impeller hubs at the end of the first hour, which indi-
Sand concentrations were measured on a per-weight basis. The cated that the pumps had lost radial stability before the first hour
maximum attempted was 10%, and the minimum was 0.1 %. It was of the test was complete.
necessary to determine a concentration that would produce meas- The next series of tests was run to separate thrust bearing wear
urable wear in a reasonable test time. from radial bearing wear. The shaft was supported by a hard-
A commercial foundry sand was selected for general testing be- surfaced sleeve that ran throug~ an elastomeric (rubber) radial bear-
cause it approximated some of the formation sands (Fig. 7). Spe- ing. Again, a concentration of 0.25 wt% commercial sand was used.
cial sands were purchased and screened to obtain sand in a particular It was thought that radial stability would reduce the rate of thrust
size range. wear, but it actually eliminated thrust wear. There was no meas-