Search results for: semi-open casing

Authors: Khalid. M. O. Elmabrok, M. L. Burby, G. G. Nasr

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Flow instability during gas lift operation is caused by three major phenomena – the density wave oscillation, the casing heading pressure and the flow perturbation within the two-phase flow region. This paper focuses on the causes and the effect of flow instability during gas lift operation and suggests ways to control it in order to maximise productivity during gas lift operations. A laboratory-scale two-phase flow system to study the effects of flow perturbation was designed and built. The apparatus is comprised of a 2 m long by 66 mm ID transparent PVC pipe with air injection point situated at 0.1 m above the base of the pipe. This is the point where stabilised bubbles were visibly clear after injection. Air is injected into the water filled transparent pipe at different flow rates and pressures. The behavior of the different sizes of the bubbles generated within the two-phase region was captured using a digital camera and the images were analysed using the advanced image processing package. It was observed that the average maximum bubbles sizes increased with the increase in the length of the vertical pipe column from 29.72 to 47 mm. The increase in air injection pressure from 0.5 to 3 bars increased the bubble sizes from 29.72 mm to 44.17 mm and then decreasing when the pressure reaches 4 bars. It was observed that at higher bubble velocity of 6.7 m/s, larger diameter bubbles coalesce and burst due to high agitation and collision with each other. This collapse of the bubbles causes pressure drop and reverse flow within two phase flow and is the main cause of the flow instability phenomena.

Keywords: gas lift instability, bubbles forming, bubbles collapsing, image processing

Procedia PDF Downloads 421

Authors: Jelena S. Kiurski, Vesna S. Kecić, Snežana M. Aksentijević

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The identification and evaluation of organic and inorganic pollutants were performed in a flexographic facility in Novi Sad, Serbia. Air samples were collected and analyzed in situ, during 4-hours working time at five sampling points by the mobile gas chromatograph and ozonometer at the printing of collagen casing. Experimental results showed that the concentrations of isopropyl alcohol, acetone, total volatile organic compounds and ozone varied during the sampling times. The highest average concentrations of 94.80 ppm and 102.57 ppm were achieved at 200 minutes from starting the production for isopropyl alcohol and total volatile organic compounds, respectively. The mutual dependences between target hazardous and microclimate parameters were confirmed using a multiple linear regression model with software package STATISTICA 10. Obtained multiple coefficients of determination in the case of ozone and acetone (0.507 and 0.589) with microclimate parameters indicated a moderate correlation between the observed variables. However, a strong positive correlation was obtained for isopropyl alcohol and total volatile organic compounds (0.760 and 0.852) with microclimate parameters. Higher values of parameter F than F_critical for all examined dependences indicated the existence of statistically significant difference between the concentration levels of target pollutants and microclimates parameters. Given that, the microclimate parameters significantly affect the emission of investigated gases and the application of eco-friendly materials in production process present a necessity.

Keywords: flexographic printing, indoor air, multiple regression analysis, pollution emission

Procedia PDF Downloads 200

Authors: Mohamed Ahmed Khalil

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The number of deep well anode ground beds (GBs) have been retrieved due to unoperated anode chains. New identical magnetite anode chains (MAC) have been installed at Raslanuf complex impressed current Cathodic protection (ICCP) system, distributed at different plants (Utility, ethylene and polyethylene). All problems associated with retrieving and installation of MACs have been discussed, rectified and presented. All GB-associated severely corroded wellhead casings were well maintained and/or replaced by new fabricated and modified ones. The main cause of the wellhead casing's severe internal corrosion was discussed and the conducted remedy action to overcome future corrosion problems is presented. All GB-connected anode junction boxes (AJBs) and shunts were closely inspected, maintained and necessary replacement and/or modifications were carried out on shunts. All damaged GB concrete foundations (CF) have been inspected and completely replaced. All GB-associated Transformer-Rectifiers Units (TRU) were subjected to thorough inspection and necessary maintenance was performed on each individual TRU. After completion of all MACs and TRU maintenance activities, each cathodic protection station (CPS) has been re-operated, alternative current (AC), direct current (DC), voltage and structure to soil potential (S/P) measurements have been conducted, recorded and all obtained test results are presented. DC current outputs have been adjusted and DC current outputs of each MAC have been recorded for each GB AJB.

Keywords: magnetite anodes, deep well, ground beds, cathodic protection, transformer rectifier, impressed current, junction boxes

Procedia PDF Downloads 127

Authors: Mohamed. A. Saad

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The paper represents a case study regarding the conversion of Electro-Static Precipitators (ESP`s) into Fabric Filters (FF). Seven cement production companies were established in Egypt during the period 1927 to 1980 and 6 new companies were established to cope with the increasing cement demand in 1980's. The cement production market shares in Egypt indicate that there are six multinational companies in the local market, they are interested in the environmental conditions improving and so decided to achieve emission reduction project. The experimental work in the present study is divided into two main parts: (I) Measuring Efficiency of Filter Fabrics with detailed description of a designed apparatus. The paper also reveals the factors that should be optimized in order to assist problem diagnosis, solving and increasing the life of bag filters. (II) Methods to mitigate dust emissions in Egyptian cement plants with a special focus on converting the Electrostatic Precipitators (ESP`s) into Fabric Filters (FF) using the same ESP casing, bottom hoppers, dust transportation system, and ESP ductwork. Only the fan system for the higher pressure drop with the fabric filter was replaced. The proper selection of bag material was a prime factor with regard to gas composition, temperature and particle size. Fiberglass with PTFE membrane coated bags was selected. This fabric is rated for a continuous temperature of 250 C and a surge temperature of 280C. The dust emission recorded was less than 20 mg/m3 from the production line fitted with fabric filters which is super compared with the ESP`s working lines stack.

Keywords: Engineering Electrostatic Precipitator, filtration, dust collectors, cement

Procedia PDF Downloads 259

Authors: Tarek Sabri Duzan

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Knowledge of the magnitude of Geo-pressures (Pore, Fracture & Over-burden pressures) is vital especially during drilling, completions, stimulations, Enhance Oil Recovery. Many times problems, like lost circulation could have been avoided if techniques for calculating Geo-pressures had been employed in the well planning, mud weight plan, and casing design. In this paper, we focused on the relationships between Geo-pressures and wave velocities (P-Wave (Vp) and S-wave (Vs)) in shallow Libyan carbonate reservoir in the western part of the Sirte Basin (Dahra F-Area). The data used in this report was collected from four new wells recently drilled. Those wells were scattered throughout the interested reservoir as shown in figure-1. The data used in this work are bulk density, Formation Mult -Tester (FMT) results and Acoustic wave velocities. Furthermore, Eaton Method is the most common equation used in the world, therefore this equation has been used to calculate Fracture pressure for all wells using dynamic Poisson ratio calculated by using acoustic wave velocities, FMT results for pore pressure, Overburden pressure estimated by using bulk density. Upon data analysis, it has been found that there is a linear relationship between Geo-pressures (Pore, Fracture & Over-Burden pressures) and wave velocities ratio (Vp/Vs). However, the relationship was not clear in the high-pressure area, as shown in figure-10. Therefore, it is recommended to use the output relationship utilizing the new seismic data for shallow carbonate reservoir to predict the Geo-pressures for future oil operations. More data can be collected from the high-pressure zone to investigate more about this area.

Keywords: bulk density, formation mult-tester (FMT) results, acoustic wave, carbonate shalow reservoir, d/jfield velocities

Procedia PDF Downloads 291

Authors: Xi Zhang, Shazed Aziz, Zhonghua Zhu

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Superabsorbent polymers (SAPs) hold significant applications in agriculture or construction applications due to their remarkable absorbency. With the increased demand of SAPs market, the development of SPA has become more mature and stable. Although SAPs can absorb water up to hundreds of times their own weight, they undergo a time-consuming process to discharge or recycle the absorbed water. For example, the absorbed water is typically released through evaporation or mechanical compression. However, evaporation is highly dependent on the surrounding environment, and compression can damage the polymer microstructure. Therefore, microstructure modification to enhance both fast absorption and efficient discharge is highly desired. In this work, a SAP hydrogel was synthesized through freeze-casting and cryo-polymerization of acrylamide. The hydrogel precursor was placed onto a metal finger immersed in liquid nitrogen, allowing ice pillars to form upward from the bottom via unidirectional freeze casting. The frozen sample then underwent cryo-polymerization to form a three-dimensional, cross-linked structure. After removing the ice pillars, a well-aligned porous structure remained. The fabricated polyacrylamide with an aligned porous structure enables rapid water uptake within seconds. Moreover, the absorbent water can be easily squeezed out without damaging the structure. The compressed sample can also reswell, allowing for cyclic hydration and dehydration processes. This soft superabsorbent polymer with fast and easy water uptake and discharge properties holds promise for use in hygiene, agriculture and construction fields.

Keywords: absorbency, cryo-polymerization, freeze-casing, superabsorbent polymers

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Authors: Mohammad Reza Dousti, Yaman Boluk, Vivek Bindiganavile

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During the past few decades, oil and natural gas consumption have increased significantly. The limited amount of hydrocarbon resources on earth has led to a stronger desire towards efficient drilling, well completion and extracting, with the least time, energy and money wasted. Well cementing is one of the most crucial and important steps in any well completion, to fill the annulus between the casing string and the well bore. However, since it takes place at the end of the drilling process, a satisfying and acceptable job is rarely done. Hence, a large and significant amount of time and energy is then spent in order to do the required corrections or retrofitting the well in some cases. Oil well cement paste needs to be pumped during the cementing process, therefore the rheological and flow behavior of the paste is of great importance. This study examines the use of innovative cellulose-based nanomaterials on the flow properties of the resulting cementitious system. The cementitious paste developed in this research is composed of water, class G oil well cement, bentonite and cellulose nanocrystals (CNC). Bentonite is used as a cross contamination component. Initially, the influence of CNC on the flow and rheological behavior of CNC and bentonite suspensions was assessed. Furthermore, the rheological behavior of oil well cement pastes dosed with CNC was studied using a steady shear parallel-plate rheometer and the results were compared to the rheological behavior of a neat oil well cement paste with no CNC. The parameters assessed were the yield shear stress and the viscosity. Significant changes in yield shear stress and viscosity were observed due to the addition of the CNC. Based on the findings in this study, the addition of a very small dosage of CNC to the oil well cement paste results in a more viscous cement slurry with a higher yield stress, demonstrating a shear thinning behavior.

Keywords: cellulose nanocrystal, flow behavior, oil well cement, rheology

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Authors: Ambra Giovannelli, Erika Maria Archilei

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The electrical power consumption related to refrigeration systems is evaluated to be in the order of 15% of the total electricity consumption worldwide. For this reason, in the last years several energy saving techniques have been suggested to reduce the power demand of refrigeration and air conditioning plants. The research work deals with the development of an innovative internal power recovery system for industrial cryogenic cooling plants. Such system is based on a Compressor-Expander Group (CEG). Both the expander and the compressor have been designed starting from automotive turbocharging components, strongly modified to take refrigerant fluid properties and specific system requirements into consideration. A preliminary choice of the machines (radial compressors and expanders) among existing components available on the market was realised according to the rules of the similarity theory. Once the expander was selected, it was strongly modified and performance verified by means of steady-state 3D CFD simulations. This paper focuses the attention on the development of the second CEG main component: the compressor. Once the preliminary selection has been done, the compressor geometry has been modified to take the new boundary conditions into account. In particular, the impeller has been machined to address the required total enthalpy increase. Such evaluation has been carried out by means of a simplified 1D model. Moreover, a vaneless diffuser has been added, modifying the shape of casing rear and front disks. To verify the performance of the modified compressor geometry and suggest improvements, a numerical fluid dynamic model has been set up and the commercial Ansys-CFX software has been used to perform steady-state 3D simulations. In this work, all the numerical results will be shown, highlighting critical aspects and suggesting further developments to increase compressor performance and flexibility.

Keywords: vapour compression systems, energy saving, refrigeration plant, organic fluids, centrifugal compressor

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Authors: Lancelot Boulet, Pierre Benard, Ghislain Lartigue, Vincent Moureau, Nicolas Chauvet, Sheddia Didorally

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International aeronautic standards demand a fire certification for engines that demonstrate their resistance. This demonstration relies on tests performed with prototype engines in the late stages of the development. Hardest tests require to place a kerosene standardized flame in front of the engine casing during a given time with imposed temperature and heat flux. The purpose of this work is to provide a better characterization of a kerosene/air certification burner in order to minimize the risks of test failure. A first Large-Eddy Simulation (LES) study of the certification burner permitted to model and simulate this burner, including both adiabatic and Conjugate Heat Transfer (CHT) computations. Carried out on unstructured grids with 40 million tetrahedral cells, using the finite-volume YALES2 code, spray combustion, forced convection on walls and conduction in the solid parts of the burner were coupled to achieve a detailed description of heat transfer. It highlighted the fact that conduction inside the solid has a real impact on the flame topology and the combustion regime. However, in the absence of radiative heat transfer, unrealistic temperature of the equipment was obtained. The aim of the present study is to include the radiative heat transfer in order to reach the same temperature given by experimental measurements. First, various test-cases are conducted to validate the coupling between the different heat solvers. Then, adiabatic case, CHT case, as well as CHT including radiative transfer are studied and compared. The LES model is finally applied to investigate the heat transfer in a flame impaction configuration. The aim is to progress on fire test modeling so as to reach a good confidence level as far as success of the certification test is concerned.

Keywords: conjugate heat transfer, fire resistance test, large-eddy simulation, radiative transfer, turbulent combustion

Procedia PDF Downloads 225

Authors: Mhenga Agneta, Li Zhaomin, Zhang Chao

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When velocity is high enough, gas can entrain fluid and carry to the surface, but as time passes by, velocity drops to a critical point where fluids will start to hold up in the tubing and cause liquid loading which prevents gas production and may lead to the death of the well. Foam injection is widely used as one of the methods to unload liquid. Since wells have different characteristics, it is not guaranteed that foam can be applied in all of them and bring successful results. This research presents a technology to optimize the efficiency of foam to unload liquid by air compression. Two methods are used to explain optimization; (i) mathematical formulas are used to solve and explain the myth of how density and critical velocity could be minimized when air is compressed into foaming agents, then the relationship between flow rates and pressure increase which would boost up the bottom hole pressure and increase the velocity to lift liquid to the surface. (ii) Experiments to test foam carryover capacity and stability as a function of time and surfactant concentration whereby three surfactants anionic sodium dodecyl sulfate (SDS), nonionic Triton 100 and cationic hexadecyltrimethylammonium bromide (HDTAB) were probed. The best foaming agents were injected to lift liquid loaded in a created vertical well model of 2.5 cm diameter and 390 cm high steel tubing covered by a transparent glass casing of 5 cm diameter and 450 cm high. The results show that, after injecting foaming agents, liquid unloading was successful by 75%; however, the efficiency of foaming agents to unload liquid increased by 10% with an addition of compressed air at a ratio of 1:1. Measured values and calculated values were compared and brought about ± 3% difference which is a good number. The successful application of the technology indicates that engineers and stakeholders could bring water flooded gas wells back to production with optimized results by firstly paying attention to the type of surfactants (foaming agents) used, concentration of surfactants, flow rates of the injected surfactants then compressing air to the foaming agents at a proper ratio.

Keywords: air compression, foaming agents, gas well, liquid loading

Procedia PDF Downloads 138

Authors: Imad Khan, Imran Shafi, Sarmad Farooq

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Large diameter pipes, barrels, tubes, and ducts are used in a variety of applications covering civil and defense-related technologies. This may include heating/cooling networks, sign poles, bracing, casing, and artillery and tank gun barrels. These large diameter assemblies require regular inspection and cleaning to increase their life and reduce replacement costs. This paper describes the design, development, and testing results of an efficient yet simplified, low maintenance mechanical design controlled with minimal essential electronics using an electric motor for a non-technical staff. The proposed solution provides a simplified user interface and an automated cleaning mechanism that requires a single user to optimally clean pipes and barrels in the range of 105 mm to 203 mm caliber. The proposed system employs linear motion of specially designed brush along the barrel using a chain of specific strength and a pulley anchor attached to both ends of the barrel. A specially designed and manufactured gearbox is coupled with an AC motor to allow movement of contact brush with high torque to allow efficient cleaning. A suitably powered AC motor is fixed to the front adapter mounted on the muzzle side whereas the rear adapter has a pulley-based anchor mounted towards the breach block in case of a gun barrel. A mix of soft nylon and hard copper bristles-based large surface brush is connected through a strong steel chain to motor and anchor pulley. The system is equipped with limit switches to auto switch the direction when one end is reached on its operation. The testing results based on carefully established performance indicators indicate the superiority of the proposed user-friendly cleaning mechanism vis-à-vis its life cycle cost.

Keywords: pipe cleaning mechanism, limiting switch, pipe cleaning robot, large pipes

Procedia PDF Downloads 116

Authors: Siyamak Sarafraz, Reza Esmaeil Pour, Saeed Jamshidi, Asghar Molaei Dehkordi

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Cutting transport is one of the major problems in directional and extended reach oil and gas wells. Lack of sufficient attention to this issue may bring some troubles such as casing running, stuck pipe, excessive torque and drag, hole pack off, bit wear, decreased the rate of penetration (ROP), increased equivalent circulation density (ECD) and logging. Since it is practically impossible to directly observe the behavior of deep wells, a test setup was designed to investigate cutting transport phenomena. This experimental work carried out to scrutiny behavior of the effective variables in cutting transport. The test setup contained a test section with 17 feet long that made of a 3.28 feet long transparent glass pipe with 3 inch diameter, a storage tank with 100 liters capacity, drill pipe rotation which made of stainless steel with 1.25 inches diameter, pump to circulate drilling fluid, valve to adjust flow rate, bit and a camera to record all events which then converted to RGB images via the Image Processing Toolbox. After preparation of test process, each test performed separately, and weights of the output particles were measured and compared with each other. Observation charts were plotted to assess the behavior of viscosity, flow rate and RPM in inclinations of 0°, 30°, 60° and 90°. RPM was explored with other variables such as flow rate and viscosity in different angles. Also, effect of different flow rate was investigated in directional conditions. To access the precise results, captured image were analyzed to find out bed thickening and particles behave in the annulus. The results of this experimental study demonstrate that drill string rotation helps particles to be suspension and reduce the particle deposition cutting movement increased significantly. By raising fluid velocity, laminar flow converted to turbulence flow in the annulus. Increases in flow rate in horizontal section by considering a lower range of viscosity is more effective and improved cuttings transport performance.

Keywords: cutting transport, directional drilling, flow rate, hole cleaning, pipe rotation

Procedia PDF Downloads 288

Authors: Rishi Richa, N. C. Shahi, J. P. Pandey, S. S. Kautkar

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Citrus fruits rank third in area and production after banana and mango in India. Sweet oranges are the second largest citrus fruits cultivated in the country. Andhra Pradesh, Maharashtra, Karnataka, Punjab, Haryana, Rajasthan, and Uttarakhand are the main sweet orange-growing states. Citrus fruits occupy a leading position in the fruit trade of Uttarakhand, is casing about 14.38% of the total area under fruits and contributing nearly 17.75 % to the total fruit production. Malta is grown in most of the hill districts of the Uttarakhand. Malta common is having high acceptability due to its attractive colour, distinctive flavour, and taste. The excellent quality fruits are generally available for only one or two months. However due to its less shelf-life, Malta can not be stored for longer time under ambient conditions and cannot be transported to distant places. Continuous loss of water adversely affects the quality of Malta during storage and transportation. Method of picking, packaging, and cold storage has detrimental effects on moisture loss. The climatic condition such as ambient temperature, relative humidity, wind condition (aeration) and microbial attack greatly influences the rate of moisture loss and quality. Therefore, different agro-climatic zone will have different moisture loss pattern. The rate of moisture loss can be taken as one of the quality parameters in combination of one or more parameter such as RH, and aeration. The moisture contents of the fruits and vegetables determine their freshness. Hence, it is important to maintain initial moisture status of fruits and vegetable for prolonged period after the harvest. Keeping all points in views, effort was made to store Malta at ambient condition. In this study, the response surface method and experimental design were applied for optimization of independent variables to enhance the shelf life of four months stored malta. Box-Benkhen design, with, 12 factorial points and 5 replicates at the centre point were used to build a model for predicting and optimizing storage process parameters. The independent parameters, viz., scavenger (3, 4 and 5g), polythene thickness (75, 100 and 125 gauge) and fungicide concentration (100, 150 and 200ppm) were selected and analyzed. 5g scavenger, 125 gauge and 200ppm solution of fungicide are the optimized value for storage which may enhance life up to 4months.

Keywords: Malta fruit, scavenger, packaging, shelf life

Procedia PDF Downloads 282

Authors: Sina Kazemi, Farshid Torabi, Todd Peterson

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Drilling in shale formations is frequently time-consuming, challenging, and fraught with mechanical failures such as stuck pipes or hole packing off when the cutting removal rate is not sufficient to clean the bottom hole. Crossing the heavy oil shale and sand reservoirs with active shale and microfractures is generally associated with severe fluid losses causing a reduction in the rate of the cuttings removal. These circumstances compromise a well’s integrity and result in a lower rate of penetration (ROP). This study presents collective results of field studies and theoretical analysis conducted on data from South Pars and North Dome in an Iran-Qatar offshore field. Solutions to complications related to drilling in shale formations are proposed through systemically analyzing and applying modeling techniques to select field mud logging data. Field data measurements during actual drilling operations indicate that in a shale formation where the return flow of polymer mud was almost lost in the upper dolomite layer, the performance of hole cleaning and ROP progressively change when higher string rotations are initiated. Likewise, it was observed that this effect minimized the force of rotational torque and improved well integrity in the subsequent casing running. Given similar geologic conditions and drilling operations in reservoirs targeting shale as the producing zone like the Bakken formation within the Williston Basin and Lloydminster, Saskatchewan, a drill bench dynamic modeling simulation was used to simulate borehole cleaning efficiency and mud optimization. The results obtained by altering RPM (string revolution per minute) at the same pump rate and optimized mud properties exhibit a positive correlation with field measurements. The field investigation and developed model in this report show that increasing the speed of string revolution as far as geomechanics and drilling bit conditions permit can minimize the risk of mechanically stuck pipes while reaching a higher than expected ROP in shale formations. Data obtained from modeling and field data analysis, optimized drilling parameters, and hole cleaning procedures are suggested for minimizing the risk of a hole packing off and enhancing well integrity in shale reservoirs. Whereas optimization of ROP at a lower pump rate maintains the wellbore stability, it saves time for the operator while reducing carbon emissions and fatigue of mud motors and power supply engines.

Keywords: ROP, circulating density, drilling parameters, return flow, shale reservoir, well integrity

Procedia PDF Downloads 91

Authors: Simon Caba, Raja Abou Ackl, Svend Rasmussen, Nicholas E. Pedersen

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It is a challenge to directly monitor cavitation in a pump application during operation because of a lack of visual access to validate the presence of cavitation and its form of appearance. In this work, experimental investigations are carried out in an inline single-stage centrifugal pump with optical access. Hence, it gives the opportunity to enhance the value of CFD tools and standard cavitation measurements. Experiments are conducted using two impellers running in the same volute at 3000 rpm and the same flow rate. One of the impellers used is optimized for lower NPSH₃% by its blade design, whereas the other one is manufactured using a standard casting method. The cavitation is detected by pump performance measurements, vibration measurements and high-speed image recordings. The head drop and the pump casing vibration caused by cavitation are correlated with the visual appearance of the cavitation. The vibration data is recorded in an axial direction of the impeller using accelerometers recording at a sample rate of 131 kHz. The vibration frequency domain data (up to 20 kHz) and the time domain data are analyzed as well as the root mean square values. The high-speed recordings, focusing on the impeller suction side, are taken at 10,240 fps to provide insight into the flow patterns and the cavitation behavior in the rotating impeller. The videos are synchronized with the vibration time signals by a trigger signal. A clear correlation between cloud collapses and abrupt peaks in the vibration signal can be observed. The vibration peaks clearly indicate cavitation, especially at higher NPSHA values where the hydraulic performance is not affected. It is also observed that below a certain NPSHA value, the cavitation started in the inlet bend of the pump. Above this value, cavitation occurs exclusively on the impeller blades. The impeller optimized for NPSH₃% does show a lower NPSH₃% than the standard impeller, but the head drop starts at a higher NPSHA value and is more gradual. Instabilities in the head drop curve of the optimized impeller were observed in addition to a higher vibration level. Furthermore, the cavitation clouds on the suction side appear more unsteady when using the optimized impeller. The shape and location of the cavitation are compared to 3D fluid flow simulations. The simulation results are in good agreement with the experimental investigations. In conclusion, these investigations attempt to give a more holistic view on the appearance of cavitation by comparing the head drop, vibration spectral data, vibration time signals, image recordings and simulation results. Data indicates that a criterion for cavitation detection could be derived from the vibration time-domain measurements, which requires further investigation. Usually, spectral data is used to analyze cavitation, but these investigations indicate that the time domain could be more appropriate for some applications.

Keywords: cavitation, centrifugal pump, head drop, high-speed image recordings, pump vibration

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Authors: Heather Mroz

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Geothermal fluids can provide a nearly unlimited source of renewable energy but are often highly corrosive due to dissolved carbon dioxide (CO2), hydrogen sulphide (H2S), Ammonia (NH3) and chloride ions. The corrosive environment drives material selection for many components, including piping, heat exchangers and pressure vessels, to higher alloys of stainless steel, nickel-based alloys and titanium. The use of these alloys is cost-prohibitive and does not offer the pressure rating of carbon steel. One solution, explosion cladding, has been proven to reduce the capital cost of the geothermal equipment while retaining the mechanical and corrosion properties of both the base metal and the cladded surface metal. Explosion cladding is a solid-state welding process that uses precision explosions to bond two dissimilar metals while retaining the mechanical, electrical and corrosion properties. The process is commonly used to clad steel with a thin layer of corrosion-resistant alloy metal, such as stainless steel, brass, nickel, silver, titanium, or zirconium. Additionally, explosion welding can join a wider array of compatible and non-compatible metals with more than 260 metal combinations possible. The explosion weld is achieved in milliseconds; therefore, no bulk heating occurs, and the metals experience no dilution. By adhering to a strict set of manufacturing requirements, both the shear strength and tensile strength of the bond will exceed the strength of the weaker metal, ensuring the reliability of the bond. For over 50 years, explosion cladding has been used in the oil and gas and chemical processing industries and has provided significant economic benefit in reduced maintenance and lower capital costs over solid construction. The focus of this paper will be on the many benefits of the use of explosion clad in process equipment instead of more expensive solid alloy construction. The method of clad-plate production with explosion welding as well as the methods employed to ensure sound bonding of the metals. It will also include the origins of explosion cladding as well as recent technological developments. Traditionally explosion clad plate was formed into vessels, tube sheets and heads but recent advances include explosion welded piping. The final portion of the paper will give examples of the use of explosion-clad metals in geothermal energy recovery. The classes of materials used for geothermal brine will be discussed, including stainless steels, nickel alloys and titanium. These examples will include heat exchangers (tube sheets), high pressure and horizontal separators, standard pressure crystallizers, piping and well casings. It is important to educate engineers and designers on material options as they develop equipment for geothermal resources. Explosion cladding is a niche technology that can be successful in many situations, like geothermal energy recovery, where high temperature, high pressure and corrosive environments are typical. Applications for explosion clad metals include vessel and heat exchanger components as well as piping.

Keywords: clad metal, explosion welding, separator material, well casing material, piping material

Procedia PDF Downloads 161