Improvement of Interval Control Valve (ICV) to Minimize Erosion in Intelligent Completion

This paper aims to improve erosion resistance of the high flow rate Electric Interval Control Valve (eICV) and validate predictive erosion models. The study includes direct impingement and full-scale testing, along with CFD based erosion prediction. The erosion model was initially developed using empirical data from direct impingement testing with particles entrained in gas. The erosion model is calibrated using the liquid testing to predict erosion in the valve. Valves were tested at various flow rates under accelerated erosion conditions, with increased particle concentration to simulate long-term sand throughput expected over the life of the well. Tests were conducted with viscofied water to ensure particles suspension. ANSYS Fluent was used for CFD simulations, conducted under different flow rates and conditions. The erosion model is validated by comparing the erosion profile on the coupon to the CFD predictions. Small particles used in these tests (50 μm) experienced significant drag in liquid, unlike larger particle (150 μm) used in the original model. Due to their smaller size, they were also less effective in causing erosion. So, a calibration factor is used to account for the particle size effect. After performing a numerical optimization of the valve design, the valve met the acceptance criteria, showing minor erosion traces and no function-compromising damage after the test for which the total sand rate is equivalent to 27 years of expected flow profile. The fully open position test revealed that the valve could handle the specified flow rate and sand without significant degradation. Simulations showed minimal measurable erosion, controlled on the top ridge of Metal to Metal (MTM) contact feature which is critical for high-pressure sealing. Comparing carbide erosion rates predicted by CFD with actual post-test inspection results showed CFD simulations were conservative. The findings confirmed the valve's durability and effectiveness in preventing erosion-related failures, with detailed CFD simulation supporting the empirical findings. This paper presents novel insights into the developing and validating of an erosion model for ICVs, supported by both empirical data and CFD simulations. The combination of empirical data and CFD-based erosion simulations offers valuable information for engineers on the long-term performance of flow control valves in harsh conditions, enhancing their reliability and longevity.