Article(id=1151591712162984483, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1151591705854751239, articleNumber=1003-3033(2024)05-0052-10, orderNo=null, doi=10.16265/j.cnki.issn1003-3033.2024.05.0364, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1699113600000, receivedDateStr=2023-11-05, revisedDate=1708272000000, revisedDateStr=2024-02-19, acceptedDate=null, acceptedDateStr=null, onlineDate=1752490459719, onlineDateStr=2025-07-14, pubDate=1716825600000, pubDateStr=2024-05-28, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1752490459719, onlineIssueDateStr=2025-07-14, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1752490459719, creator=13701087609, updateTime=1752490459719, updator=13701087609, issue=Issue{id=1151591705854751239, tenantId=1146029695717560320, journalId=1146031787341344770, year='2024', volume='34', issue='5', pageStart='1', pageEnd='251', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=0, createTime=1752490458214, creator=13701087609, updateTime=1757398693384, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1172178336315985942, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1151591705854751239, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1172178336315985943, tenantId=1146029695717560320, journalId=1146031787341344770, issueId=1151591705854751239, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=52, endPage=60, ext={EN=ArticleExt(id=1151591712540471850, articleId=1151591712162984483, tenantId=1146029695717560320, journalId=1146031787341344770, language=EN, title=Study on erosion characteristics of valve sleeve blowdown valve of shale gas separator, columnId=1149733269173878863, journalTitle=China Safety Science Journal(CSSJ), columnName=Safety engineering technology, runingTitle=null, highlight=null, articleAbstract=

To solve the problem of severe erosion caused by sand particles passing through separators during shale gas extraction,a well in Changning Shale Gas Field was taken as an example. Based on FLUENT software,numerical simulation was used to simulate the erosion characteristics of sand particles on the drain valve under different speeds,sand content,particle size,shape coefficient and valve opening. The main factors affecting the erosion characteristics of the drain valve were evaluated to clarify the erosion situation of the drain valve. The results indicate that the erosion damage of the valve disc and throttle hole is the main reason for the failure of the sewage valve. As the valve opening decreases,the pressure difference inside the valve increases exponentially,and the flow velocity is the largest at the valve disc and throttle hole. With the decrease of shape coefficient of sand particles,the erosion of the valve is more severe. Based on sensitivity analysis,the degree of influence of various factors on valve erosion characteristics is: ξl (Speed)=0.73,ξm (Sand particle size)=0.71,ξn (Sand content)=0.70 and ξq (Shape coefficient)=0.67. Therefore,it is recommended to control the fluid flow rate to within 7 m/s by increasing the internal flow area of the valve,improving the sand removal ability of the desander,and preventing larger sand particles (sand particle size>60 μm) from entering the sewage valve. The sand particle size entering the sewage valve should be controlled within 60 μm,which provides an effective means for the evaluation and optimization of on-site equipment.

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为解决页岩气开采过程中砂粒经过分离器后对排污阀造成严重冲蚀的问题,以长宁页岩气田某井为例,基于FLUENT软件,采用数值模拟的方法模拟在不同速度、砂量、粒径、形状系数和阀门开度情况下砂粒对排污阀冲蚀特性,并评估影响排污阀冲蚀特性的主要因素,明确排污阀的冲蚀情况。结果表明:阀瓣与节流孔冲蚀破坏是造成排污阀失效的主要原因;随着阀门开度减小,阀内压差呈指数式增长,在阀瓣和节流孔处流速最大,砂粒形状系数减小,对阀门冲蚀越严重;基于敏感性分析,各因素对阀门冲蚀特性影响程度为:ξl(速度)=0.73,ξm(砂粒粒径)=0.71,ξn(砂量)=0.70,ξq(形状系数)=0.67。因此,建议通过增大阀门内部流通面积将流体流速控制在7m/s以内,提高除砂器除砂能力,避免粒径较大的砂粒(砂粒粒径>60 μm)进入排污阀,将进入排污阀的砂粒粒径控制在60 μm内,为现场设备评价优化提供有效手段。

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刘恩斌 (1980—),男,四川遂宁人,博士,教授,主要从事油气管网仿真/优化技术、瞬变流和计算流体力学等方面的研究。E-mail:

姜军 工程师

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刘恩斌 (1980—),男,四川遂宁人,博士,教授,主要从事油气管网仿真/优化技术、瞬变流和计算流体力学等方面的研究。E-mail:

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刘恩斌 (1980—),男,四川遂宁人,博士,教授,主要从事油气管网仿真/优化技术、瞬变流和计算流体力学等方面的研究。E-mail:

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姜军 工程师

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姜军 工程师

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authorNames=周守为, 朱军龙, 单彤文, journalName=中国海上油气, refType=null, unstructuredReference=周守为, 朱军龙, 单彤文, 等. 中国天然气及LNG产业的发展现状及展望[J]. 中国海上油气, 2022, 34(1):1-8., articleTitle=中国天然气及LNG产业的发展现状及展望, refAbstract=null), Reference(id=1172491024304845327, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1151591712162984483, doi=null, pmid=null, pmcid=null, year=2022, volume=34, issue=1, pageStart=1, pageEnd=8, url=null, language=null, rfNumber=[1], rfOrder=1, authorNames=ZHOU Shouwei, ZHU Junlong, SHAN Tongwen, journalName=China Offshore Oil and Gas, refType=null, unstructuredReference=ZHOU Shouwei, ZHU Junlong, SHAN Tongwen, et al. 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articleId=1151591712162984483, language=EN, label=Table 1, caption=

Orthogonal experimental data

, figureFileSmall=null, figureFileBig=null, tableContent=
方案 速度/
(m·s-1)
砂粒质
量流量/
(kg·d-1)
颗粒
粒径/
μm
形状
系数
平均冲蚀
速率/
(10-3kg·
s-1·m-2)
1 4 2 20 0.56 0.17
2 6 60 0.66 0.44
3 8 80 0.76 0.67
4 12 100 0.86 0.87
5 7 2 20 0.56 0.29
6 6 60 0.66 0.91
7 8 80 0.76 1.36
8 12 100 0.86 1.74
9 8 2 20 0.56 0.61
10 6 60 0.66 1.02
11 8 80 0.76 2.79
12 12 100 0.86 3.04
13 11 2 20 0.56 1.31
14 6 60 0.66 3.02
15 8 80 0.76 5.79
16 12 100 0.86 6.82
), ArticleFig(id=1172491023784751613, tenantId=1146029695717560320, journalId=1146031787341344770, articleId=1151591712162984483, language=CN, label=表1, caption=

正交试验数据

, figureFileSmall=null, figureFileBig=null, tableContent=
方案 速度/
(m·s-1)
砂粒质
量流量/
(kg·d-1)
颗粒
粒径/
μm
形状
系数
平均冲蚀
速率/
(10-3kg·
s-1·m-2)
1 4 2 20 0.56 0.17
2 6 60 0.66 0.44
3 8 80 0.76 0.67
4 12 100 0.86 0.87
5 7 2 20 0.56 0.29
6 6 60 0.66 0.91
7 8 80 0.76 1.36
8 12 100 0.86 1.74
9 8 2 20 0.56 0.61
10 6 60 0.66 1.02
11 8 80 0.76 2.79
12 12 100 0.86 3.04
13 11 2 20 0.56 1.31
14 6 60 0.66 3.02
15 8 80 0.76 5.79
16 12 100 0.86 6.82
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页岩气分离器阀套式排污阀冲蚀特性研究
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刘恩斌 1 , 李茜 1 , 寇博 2 , 姜军 3 , 李党建 4
中国安全科学学报 | 安全工程技术 2024,34(5): 52-60
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中国安全科学学报 | 安全工程技术 2024, 34(5): 52-60
页岩气分离器阀套式排污阀冲蚀特性研究
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刘恩斌1 , 李茜1, 寇博2, 姜军3, 李党建4
作者信息
  • 1 西南石油大学 石油与天然气工程学院,四川 成都 610500
  • 2 国家管网集团 云南公司,云南 昆明 650214
  • 3 西南油气田分公司 重庆气矿,重庆 400707
  • 4 中联煤层气有限责任公司,山西 吕梁 033200
  • 刘恩斌 (1980—),男,四川遂宁人,博士,教授,主要从事油气管网仿真/优化技术、瞬变流和计算流体力学等方面的研究。E-mail:

    姜军 工程师

Study on erosion characteristics of valve sleeve blowdown valve of shale gas separator
Enbin LIU1 , Xi LI1, Bo KOU2, Jun JIANG3, Dangjian LI4
Affiliations
  • 1 Petroleum Engineering School,Southwest Petroleum University,Chengdu Sichuan 610500,China
  • 2 PipeChina Yunnan Company,Kunming Yunnan 650214,China
  • 3 Chongqing Gas Mine,Southwest Oil and Gas Field Company,Chongqing 400707,China
  • 4 China United Coalbed Methane Co.,Ltd.,Lyuliang Shanxi 033200,China
出版时间: 2024-05-28 doi: 10.16265/j.cnki.issn1003-3033.2024.05.0364
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为解决页岩气开采过程中砂粒经过分离器后对排污阀造成严重冲蚀的问题,以长宁页岩气田某井为例,基于FLUENT软件,采用数值模拟的方法模拟在不同速度、砂量、粒径、形状系数和阀门开度情况下砂粒对排污阀冲蚀特性,并评估影响排污阀冲蚀特性的主要因素,明确排污阀的冲蚀情况。结果表明:阀瓣与节流孔冲蚀破坏是造成排污阀失效的主要原因;随着阀门开度减小,阀内压差呈指数式增长,在阀瓣和节流孔处流速最大,砂粒形状系数减小,对阀门冲蚀越严重;基于敏感性分析,各因素对阀门冲蚀特性影响程度为:ξl(速度)=0.73,ξm(砂粒粒径)=0.71,ξn(砂量)=0.70,ξq(形状系数)=0.67。因此,建议通过增大阀门内部流通面积将流体流速控制在7m/s以内,提高除砂器除砂能力,避免粒径较大的砂粒(砂粒粒径>60 μm)进入排污阀,将进入排污阀的砂粒粒径控制在60 μm内,为现场设备评价优化提供有效手段。

页岩气  /  分离器  /  阀套式排污阀  /  冲蚀特性  /  数值模拟

To solve the problem of severe erosion caused by sand particles passing through separators during shale gas extraction,a well in Changning Shale Gas Field was taken as an example. Based on FLUENT software,numerical simulation was used to simulate the erosion characteristics of sand particles on the drain valve under different speeds,sand content,particle size,shape coefficient and valve opening. The main factors affecting the erosion characteristics of the drain valve were evaluated to clarify the erosion situation of the drain valve. The results indicate that the erosion damage of the valve disc and throttle hole is the main reason for the failure of the sewage valve. As the valve opening decreases,the pressure difference inside the valve increases exponentially,and the flow velocity is the largest at the valve disc and throttle hole. With the decrease of shape coefficient of sand particles,the erosion of the valve is more severe. Based on sensitivity analysis,the degree of influence of various factors on valve erosion characteristics is: ξl (Speed)=0.73,ξm (Sand particle size)=0.71,ξn (Sand content)=0.70 and ξq (Shape coefficient)=0.67. Therefore,it is recommended to control the fluid flow rate to within 7 m/s by increasing the internal flow area of the valve,improving the sand removal ability of the desander,and preventing larger sand particles (sand particle size>60 μm) from entering the sewage valve. The sand particle size entering the sewage valve should be controlled within 60 μm,which provides an effective means for the evaluation and optimization of on-site equipment.

shale gas  /  separator  /  valve sleeve type drain valve  /  erosion characteristics  /  numerical simulation
刘恩斌, 李茜, 寇博, 姜军, 李党建. 页岩气分离器阀套式排污阀冲蚀特性研究. 中国安全科学学报, 2024 , 34 (5) : 52 -60 . DOI: 10.16265/j.cnki.issn1003-3033.2024.05.0364
Enbin LIU, Xi LI, Bo KOU, Jun JIANG, Dangjian LI. Study on erosion characteristics of valve sleeve blowdown valve of shale gas separator[J]. China Safety Science Journal(CSSJ), 2024 , 34 (5) : 52 -60 . DOI: 10.16265/j.cnki.issn1003-3033.2024.05.0364
为实现双碳目标,天然气作为清洁能源的地位逐渐提高,页岩气作为天然气的重要组成部分,也成为能源领域发展的新趋势[1]。但与常规天然气开发不同,页岩气及其开发特性决定了其必须依赖水力压裂技术[2]。而水力压裂技术会致使页岩气中携带大量的颗粒和岩屑,且出砂较多持续时间较长,砂砾和岩屑对地面集输设备和管线造成严重的冲蚀磨损,导致页岩气田地面集输系统出现较多的安全运行问题[3]。因此,需要对开采出的页岩气进行除砂,并实现气液分离。但目前的除砂器无法实现对小粒径砂粒的完全分离,小粒径砂粒通过除砂器之后在立式分离器中进一步的分离,经排污管线排出[4-5]。在排污过程中,分离器内部与排液管线末端压差可使液固介质瞬时流速达到6~10m/s,对排污阀、“三通”和弯头等产生冲蚀,生产流程投运0.5~3.0年后,会出现部分冲蚀失效,缩短现场设备的使用寿命。为保障管线设备安全稳定运行,针对排污阀的冲蚀研究是非常有必要的。
目前,关于冲蚀的大部分研究都集中于固体颗粒对于三通管、弯管和管箱的冲蚀磨损,因为这些部件都是最容易受到冲蚀的。阀门冲蚀方面,LIU Xingqiang等[6]采用FLUENT软件中离散相模型(Discrete Phase Model,DPM)分析液压滑阀的固体冲蚀行为以及影响因素,得到液压滑阀冲蚀以及颗粒轨迹分布,发现在阀中靠近阀芯的上游区域和面向来流的套筒位置冲蚀较严重;ZHU Hongjun等[7]利用有限元结构交互模型及狄利克雷过程混合模型耦合算法三维模拟了针阀的冲蚀速率,着重讨论了入口流速、阀门开度、入口流道尺寸、颗粒浓度、颗粒直径、颗粒物相组成对冲蚀结果的影响;钟林等[8]采用FLUENT软件模拟了排污阀因颗粒冲蚀造成内漏问题,在不同影响因素下,如速度、颗粒大小、形状以及含砂量对排污阀冲蚀的影响,提出在排污时减缓冲蚀的措施。研究重点主要包括阀门开度、流速等因素对阀门冲蚀影响以及阀门中冲蚀较严重的位置,但针对页岩气分离器阀套式排污阀的冲蚀研究相对较少,且基于试验或现场测试研究页岩气集输设备的冲蚀情况,在试验手段和研究成本上均有较大难度。
鉴于此,笔者拟综合考虑排污阀冲蚀因素,以长宁页岩气田某井为例,使用FLUENT软件,采用数值模拟的方法分析排污阀冲蚀特性的敏感性,找到对排污阀冲蚀影响较大的因素,以期为阀门减缓冲蚀提供依据。
剪切应力输运k-ω湍流模型(Shear Stress Transport k-ω turbulence model,SST)考虑到阀套式排污阀结构的复杂性与启闭过程中多相流的流型变化,故选用该模型作为湍流模型,其表达式如下[9]:
( ρ k ) t + ( ρ k u i ) x i = Γ k k x i x j + G k - Y k + S k
( ρ ω ) t + ( ρ ω u i ) x i = Γ ω ω x i x i + G ω - Y ω + S ω
式中:ΓkΓω分别为流动能k和湍流能量耗散率ω的扩散率;Gkk增长或衰减过程中由外部施加的额外能量;Gωω增长和减少受外部影响的能量;YkYω分别为kω的发散项;SkSω为自定义数据。
在DPM中,忽略两相流中离散相颗粒之间的相互作用和颗粒的温度变化,其表达式为[10-11]:
d u p d t = F D ( u - u p ) + g x ( ρ p - ρ ) ρ p + F x
F D = 18 μ ρ p d 2 p C D R e 24
式中:FD(u-up)为颗粒相的单位质量曳力,N;u为流速,m/s;up为颗粒相速度,m/s;gx为重力在x方向上的分量,m2/s;ρp为颗粒密度,kg/m3;dp为颗粒直径,m。
MESSA[12]、OKA[[13]等提出冲蚀模型,冲蚀率 E q被定义为:
E q = E 90 | V w p | V r k 2 d d r k 3 f ( γ )
式中: E 90为90°下的参考冲蚀率,kg/(m3·s);V为颗粒冲击速度,m/s;Vr为相对速度,m/s;ddr分别为颗粒直径和颗粒参考直径,m;f(γ)为冲击角函数。
使用动网格方法以实现阀套式排污阀真实启闭过程的数值模拟,但需要通过用户自定义函数(User Defined Function,UDF)进行2次开发,从而实现阀门的复杂运动[14-15]。对于动态网格,边界移动的任意控制体V上的通用标量ϕ的守恒方程的积分形式为[16]:
d d t V ρ ϕ d V + V ρ ϕ u - u g · d A = V Γ ϕ · d A + V S ϕ d V
式中:u为矢量速度; u g为网格移动速度;Γ为扩散系数;Sϕ为源项;∂V为控制体积的边界V
FLUENT软件提供基于C语言的UDF,在UDF中编写相应的宏函数便能使阀瓣进行运动,从而实现排污阀的动态变化[17]。常见的动网格宏有DEFINE_CG_MOTION,其作用是定义每一个时间步刚体运动的线速度和角速度[18]
基于灰色关联分析法(Grey Relational Analysis,GRA)分析影响阀套式排污阀冲蚀特性的主要因素并进行改进,以提升排污阀的抗冲蚀性能[19]。首先,确定分析目标为排污阀的平均冲蚀速率,以Y=[y(1),y(2),…,y(m)]表示,影响因素如下:

x = ( x 11 x 21 x n 1 ) T = x 11 1 x 12 2 x 1 n m x 21 1 x 22 2 x 2 n ( m )   x n 1 1 x n 2 2 x n n ( m )

式中:n为影响平均冲蚀速率的因素数量,取4;m为各因素考虑参数个数,取4。
速度与粒径等因素的量纲存在区别,故先归一化处理所有因素:
x ' i ( k ) = x i ( k ) 1 m k = 1 m x i ( k ) ( i = 1,2 n )
y ' ( k ) = y ( k ) 1 m k = 1 m y ( k )
通过归一化后的结果得出各因素序列与平均冲蚀速率序列元素的绝对差值,即Δik=|y'(k)-x'(k)|(i=1,2,…,n;k=1,2,…,m),将其代入式(8)与式(9),即可计算出各影响因素的灰色关联度。

ξ i ( k ) =

m i n i m i n k | y ' ( k ) - x ' i k | + β m a x i m a x k | y ' ( k ) - x ' i k | | y ' ( k ) - x ' i ( k ) | + β m a x i m a x k | y ' ( k ) - x ' i k |

( i = 1,2 n ; k = 1,2 m )
r i = 1 m k = 1 m ξ i ( k ) ( i = 1,2 n )
式中: ξ i ( k )为灰色关联系数;β为分辨系数,β取0.5。
基于长宁页岩气田分离器阀套式排污阀的结构特点,建立阀套式排污阀的几何模型,为防止回流,延伸阀门出入口,其中,上游管长为6倍管径,下游管长为3倍管径,其几何模型及网格划分如图1图2所示。
以最大速度与最大冲蚀速率为指标,对产液量为0.500m3/h,含砂量为0.417kg/h,砂粒尺寸为25μm的工况进行无关性验证,如图3所示。
图3可以看出,最大冲蚀速率和最大速度变化趋势一致,当网格数从2 594 071增加到4 103 574时,所得的最大流速和最大冲蚀速率变化不大,则在考虑计算准确性和计算负荷条件下,认为2 594 071网格数已经达到无关性要求。
在建立排污阀几何模型后,基于FLUENT软件模拟固液两相流排污阀,考虑到动网格分析中,阀门打开-闭合需要1s,若时间步长会导致网格单元出现负面积,一般根据最小网格尺度和边界运动最大速度确定最大时间步长:
Δ t = Δ s V = 0.000   3   m 0.050   26   m / s = 0.005   97   s
由此可知:最大时间步长为0.005 97s,为使计算易收敛,设置时间步长为0.004s,需250个时间步进行数值模拟计算。因此,计算可得冲刷时间为1s。
以速度7m/s,砂量0.001 444kg/s工况为例,分析阀门内流体流动状态。其中,阀瓣启闭过程中不同开度下流体域对称截面压力与速度分布云图如图4所示。
图4a图4d可知:携砂污水压力随着流程增加逐渐减小,特别在阀瓣与节流孔处;随着开度减小,下阀体内部压力逐渐增大。当开度为10%时,其最大压力达1.1×107Pa,是100%开度时阀腔内压力峰值的55倍。由此可见:在阀门即将关闭时管内压力会瞬间增大,从而产生震动和水击等现象。
图4e图4h可知:当污水经过阀瓣并从节流孔流出时,流体速度不断增大,在节流孔处达到峰值。在阀门关闭的过程中,流体速度变化尤为明显,特别是阀瓣与节流孔2个位置。当开度为10%时,节流孔处的过流面积非常小,致使速度急剧增大,其速度峰值是100%开度下最大速度的12倍。提取4~11m/s内阀门不同开度的进出口压力差,压力差随阀门开度和入口速度的变化曲线,如图5所示。
图5a中,排污阀开度变化对阀内压差影响较为明显。当速度为4m/s,阀门开度由20%变为80%,压差变化74.95%。从图5b可以看出,当开度80%减少到40%,阀内压差变化较小;开度从40%减少到20%,压差变化幅度较大,说明阀门开度对阀内压差影响更明显;当阀门开度为10%,速度为7m/s时,压差达到5.575MPa,其高于排污阀的最高工作压力5.5MPa,故速度取值应为7m/s以下。
分离器运行压力会直接影响排污管线内介质的速度,而速度是影响排污阀冲蚀磨损的重要因素。根据运行数据,当排污系统在1.5~5.5MPa内,管线内的介质速度为4~11m/s。在该范围内,模拟分析不同速度对排污阀动态运动过程中冲击侵蚀的影响。80%开度时不同速度下各部件的冲蚀情况,如图6所示。从图6可以看出,阀瓣与节流孔冲蚀程度最严重,主要表现在阀瓣下端面的冲蚀磨损呈“八角形”分布,且节流孔连接位置处冲蚀速率最大;下阀套主要冲蚀区域呈现“扇形”分布,随着速度增加,“扇面”分布更大;携砂污水从节流孔流出后冲击阀体壁面并向四周扩散,致使上阀体受冲蚀区域呈“圆环状”分布,且冲蚀区域均位于节流孔正对位置。此外,在上阀体出口下部的棱角处,砂粒的冲蚀情况较为严重。
为研究不同部位冲蚀情况,研究80%开度时不同速度下各部件的冲蚀情况的数值,其结果如图7所示。从图7可以看出,当入口速度增加时,各部件冲蚀速率不断增大,阀瓣的冲蚀情况最为严重。同时,根据冲蚀速率的变化将速度区间划分为3个区域。在区域①中(4~6m/s),各部件冲蚀速率的上升较为平缓;在区域②中(6~8m/s),冲蚀速率的增长率逐渐增大;在区域③中(8~11m/s),增长幅度达到了峰值。
污水中的含砂量是影响阀套式排污阀冲击侵蚀的重要因素,因此,结合页岩气井场生产数据,分析7m/s下不同含砂量对阀门冲蚀影响的情况,如图8所示。从图8中可以看出,阀门不同部位均受到冲击侵蚀,但主要冲蚀区域不发生改变。通过研究不同砂量下阀瓣等部件冲蚀速率变化,发现随着砂粒浓度增加,冲蚀分布区域会更密集。为分析含砂量与冲蚀速率的增长率之间的关系,进行不同含砂量下排污阀冲击侵蚀数值研究,具体如图9所示。
图9可以中看出,当开度为80%和60%时,最大冲蚀速率增长趋势基本相同。当砂量从2kg/d增至8kg/d时,冲蚀速率增幅较大;超过8kg/d后,增长率会逐渐减小,这是由于颗粒浓度增大到一定程度时,颗粒之间相互碰撞次数增加,从而造成颗粒动能衰减,但颗粒浓度增大同样会增加与壁面碰撞的频率。当开度为40%时,冲蚀速率增长率在6kg/d时发生转变,即超过6kg/d,冲蚀速率增幅会减小,同样当开度为10%时,冲蚀速率再次出现转折点“前移”现象,增长率在4kg/d时发生转变,这是由于阀瓣是受冲蚀磨损最严重的部位,随着阀瓣开度的减小,阀瓣与节流孔的过流面积逐渐减小,从而颗粒在狭小的区域内与壁面碰撞次数逐渐增大,在低含砂量的情况下对阀瓣的冲蚀影响较大,从而出现转折点“前移”的现象。
现场集液包内砂粒的粒径大小不一,而不同砂粒粒径对阀套式排污阀造成的冲击侵蚀会发生变化,因此,评估阀瓣等部件在不同粒径下冲蚀情况。80%开度时不同粒径下阀瓣等部件的冲蚀情况,如图10所示。不同粒径下排污阀的冲蚀速率变化,如图11所示。
图10可知:排污阀的冲蚀磨损随着砂粒尺寸的增大而不断加剧。
图11中可以看出,当粒径在10~60μm时,最大冲蚀速率与年冲蚀厚度上升较为缓慢,粒径超过60μm后,冲蚀速率会呈现线性增长趋势。基于不同开度下的冲蚀情况,当开度在40%以上时,阀门开度对冲蚀特性的影响较小,而开度低于40%时,砂粒对阀门的冲击侵蚀会显著增强。
砂粒形状系数也是造成阀套式排污阀冲蚀磨损的重要因素之一,FLUENT软件中无法直接定义砂粒形状,而是通过砂粒形状系数来描述颗粒的尖锐程度。形状系数(砂粒与同体积圆球的表面积之比)取值为0.1~1,数值越小表明颗粒越尖锐。结合现场砂粒形状和手册[20],取砂粒形状系数为0.56~0.96,讨论阀瓣等部件的冲蚀变化情况。80%开度时不同形状系数下阀瓣等部件的冲蚀情况,如图12所示。
图12可知:形状系数对冲蚀区域分布影响不明显。但随着形状系数逐渐减小,不规则砂粒造成的局部冲蚀更严重。不同砂粒形状系数下冲蚀速率变化如图13所示。由图13可知:排污阀冲蚀磨损与砂粒形状系数呈正相关,这进一步表明尖锐的砂粒会加剧冲蚀现象。当形状系数为0.56~0.76时,冲蚀速率显著下降,降幅最高可达64.47%;形状系数为0.76~0.96时,冲蚀情况变化较小。
此外,排污阀的冲蚀速率在40%开度以内时的增幅较大,故排污阀应避免在40%开度以下工作。对于形状系数较小的砂粒,应减小管线内污水速度,防止携砂污水形成高速射流,加剧阀门内部的冲击侵蚀情况。
基于影响阀门冲蚀的4种因素制定了四因素四水平的正交试验方案,以排污阀的平均冲蚀速率为评估指标,设定16组试验数据,见表1。其中,平均冲蚀速率为阀门各开度下最大冲蚀速率的平均值。基于表1中的正交试验数据,利用GRA分析污水速度与砂量等对阀门冲蚀特性的影响。
表1可知:各因素与排污阀冲蚀特性关联度为:ξl(速度)=0.73,ξm(砂量)=0.70,ξn(砂粒粒径)=0.71,ξq(形状系数)=0.67。为预防设备损坏,延长设备使用寿命,故现有排污阀在开启排污时尽量将流体速度与砂粒粒径控制在7m/s与60μm以内。
1) 文中验证了阀瓣与节流孔的冲蚀破坏严重,此区域是造成整个排污阀失效的主要原因。
2) 携砂污水速度、压力、阀门开度、砂粒尺寸和形状系数是造成排污阀失效的重要因素。随着开度减小,阀内压差呈指数形式增长,在阀瓣和节流孔处流速最大,砂粒形状系数减小,对阀门冲蚀就越严重。
3) 基于敏感性分析,各因素对阀门冲蚀特性影响程度依次为:速度>砂粒粒径>砂量>形状系数,因此,阀门开启时应重点关注介质速度与砂粒直径,为预防设备损坏,延长设备使用寿命,应尽量将其控制在7m/s与60μm范围以内。
  • 四川省自然科学基金资助(2023NSFSC0422)
  • 中石油重大科技项目(2021DJ2804)
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doi: 10.16265/j.cnki.issn1003-3033.2024.05.0364
  • 接收时间:2023-11-05
  • 首发时间:2025-07-14
  • 出版时间:2024-05-28
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  • 收稿日期:2023-11-05
  • 修回日期:2024-02-19
基金
四川省自然科学基金资助(2023NSFSC0422)
中石油重大科技项目(2021DJ2804)
作者信息
    1 西南石油大学 石油与天然气工程学院,四川 成都 610500
    2 国家管网集团 云南公司,云南 昆明 650214
    3 西南油气田分公司 重庆气矿,重庆 400707
    4 中联煤层气有限责任公司,山西 吕梁 033200
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2种不同金属材料的力学参数

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鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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