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Sand erosion has been long recognized as a potential problem in Oil and Gas production systems sometimes causing equipment failures. There has always been a need to understand the erosion mechanism and if possible predict erosion rates to better manage erosion in surface and subsea systems. Computational predictions commonly employed in production systems (which typically deal with fluids with a low solid content) are less complex and better validated than those employed in fracking or well kill where the flow can contain up to 50% solid by volume. Special adjustments are needed to the existing erosion prediction methodology to better understand and emulate these extreme conditions.

A case study will be presented which utilizes flow simulation software (CFD) to analyze where the fluid has a relatively high solid content, such as during a fracking operation. The case study will include results from a dynamic analysis which takes into account real time changes in equipment wall position due to erosion. Additionally, CFD predictions from few production scenarios and some validation work conducted by Prospect will also be presented.