Abstract
The aim of this study is to develop a combined mathematical and computational fluid dynamics based model for the prediction of erosion–corrosion rates in fluid transport pipelines which is one of the critical problems that every productive industry may encountered with. The effects of reattaching and detaching of flow lines, which are common in pipelines, are considered in this study. In order to validate the developed model, the predicted results are compared with experimental data in a practical geometry. Two-phase saline water containing 2 % by volume silica at 30 °C is considered as the studied fluid. High Reynolds number within the system ensured using a turbulence model for predicting the fluid pattern of the system. For obtaining the overall erosion–corrosion model parameters, simulation was done by using a finite element code. The predicted wear profile matched closely with the experimental data and the presented model provided high accuracy predictions for pipelines with straight and contracted geometries.
Similar content being viewed by others
References
Krupina E.M.: Corrosion-mechanical wear: nature, characteristics, and methods of prevention. Prot. Met. 19, 689–699 (1984)
Stack M.M., Zhou S., Newman R.C.: Effects of particle velocity and applied potential on the erosion of mild steel in a carbonate/bicarbonate slurry. Mater. Sci. Technol. 12, 261–268 (1996)
Bjordal, B.; Bardal, E.; Rogne, T.; Eggen, T.G.: Erosion and corrosion properties of WC coatings and duplex stainless steel in sand-containing synthetic sea water. Wear 186–187, 508–514 (1995)
Postlethwaite J., Nesic S., Adamopoulos G., Bergstrom D.J.: Predictive models for erosion–corrosion under disturbed flow conditions. Corrosion 35, 627–633 (1993)
Blatt W., Kohley T., Lotz U., Heitz E.: The influence of hydrodynamics on erosion–corrosion in a two-phase liquid–particle flow. Corrosion 45(10), 793–804 (1989)
Lotz, U.; Postlethwaite, J.: Erosion–corrosion in disturbed two phase liquid/particle flow, Corrosion 30, 95–106 (1990)
Sydberger T., Lotz U.: Relation between mass transfer and corrosion in a turbulent pipe flow. J. Electrochem. Soc. 129(2), 276 (1982)
Blatt, W.; Heitz, E.: Hydromechanical measurements for erosion–corrosion. NACE Corrosion 90 Paper no. 25, Houston, Texas (1990)
RajahramS.S. Harvey T.J., Wood R.J.K.: Erosion–corrosion resistance of engineering materials in various test conditions. Wear 267, 244–254 (2009)
Rajahram S.S., Harvey T.J., Wood R.J.K.: Full factorial investigation on the erosion–corrosion resistance of UNS S31603. Tribol. Int. 43, 2072–2083 (2010)
Rajahram S.S., Harvey T.J., Walker J.C., Wang S.C., Wood R.J.K., Lalev G.: A study on the evolution of surface and subsurface wear of UNS S31603 during erosion–corrosion. Wear 271, 1302–1313 (2011)
Rajahram S.S., Harvey T.J., Wood R.J.K.: Electrochemical investigation of erosion–corrosion using a slurry pot erosion tester. Tribol. Int. 44, 232–240 (2011)
Rajahram S.S., Harvey T.J., Walker J.C., Wang S.C., Wood R.J.K.: Investigation of erosion–corrosion mechanisms of UNS S31603 using FIB and TEM. Tribol. Int. 46, 161–173 (2012)
Pourahamadi F., Humphrey J.A.C.: Modeling solid–fluid turbulent flows with application to predicting erosive wear. Int. J. Physicochem. Hydrodyn. 4, 191–219 (1983)
Zeisel, H.; Durst, F.: Computations of erosion–corrosion processes in separated two-phase flows. NACE Corrosion Paper no. 29, Houston, Texas (1990)
Nesic, S.; Postlethwaite, J.: Relationship between the structure of the flow and erosion–corrosion. Corrosion 46, 874 (1990)
Nesic S., Postlethwaite J.: Hydrodynamics of disturbed flow and erosion–corrosion, part I single-phase flow study. Can. J. Chem. Eng. 69, 698–703 (1991)
Nesic S., Postlethwaite J.: Hydrodynamics of disturbed Flow and erosion–corrosion, part II two-phase flow study. Can. J. Chem. Eng. 69, 704–710 (1991)
Nesic S., Postlethwaite J.: A predictive model of localised erosion–corrosion. Corrosion 47, 582–589 (1991)
Nesic, S.: Computation of localized erosion–corrosion in disturbed two-phase flow. PhD Thesis, University of Saskatchewan, Saskatoon (1991)
Nesic, S.; Postlethwaite, J.; Bergstrom, D.J.: Calculation of wall-mass transfer rates in separated aqueous flow using a low-Reynolds number k–ɛ model. Int. J. Heat Mass Transfer 35, 1977–1985 (1992)
Davis C., Frawley P.: Modelling of erosion–corrosion in practical geometries. Corrosion 5, 769–775 (2009)
Stack M.M., Corlett N., Turgoose S.: Some thoughts on modeling the effects of oxygen and particle concentration on the erosion–corrosion of steels in aqueous slurries. Wear 255, 225–236 (2003)
Stack, M.M.; Stott, F.H.; Wood, G.C.: A computer model to simulate the synergistic effects of erosion and corrosion. Key Eng. Mater. 72–74, 31–48 (1992)
Stack, M.M.; Song-Roehrle, Q.; Stott, F.H.; Wood, G.C.: Computer simulation of erosion–corrosion interactions at elevated temperatures. Wear (Switzerland) 181–183, 516–523 (1995)
Ferng Y.M., Ma Y.P., Ma K.T., Chung N.M.: A new approach for investigation of erosion–corrosion using local flow models. Corrosion 55, 332–342 (1999)
Keating A., Nesic S.: Numerical prediction of erosion–corrosion in bends. Corrosion 57, 621–633 (2001)
Zhang Z., Cheng X., Zheng Y., Ke W., Yao Z.: Numerical simulation of erosion–corrosion in liquid-solid two-phase flow. Corros. Sci. Prot. Tech. 13, 89–95 (2001)
Stack, M.M.; Jana, B.D.: Modelling particulate erosion–corrosion in aqueous slurries: some views on the construction of erosion–corrosion maps for a range of pure metals. Wear 256, 986–1004 (2004)
Davis, Cian; Frawley, P.: Modelling of erosion–corrosion in practical geometries. Corrosion Sci. 51, 769–775 (2009)
Keating, A.; Nesic, S.: Prediction of two-phase erosion–corrosion in bends. In: Second International Conference on CFD in the Minerals and Process Industries, Melbourne, pp. 229–236 (1999)
Chen Q., Li D.Y.: Computer simulation of erosion–corrosion of a non-passive alloy using a micro-scale dynamic model. Mater. Sci. Eng. A 369, 284–293 (2004)
Li L., Li D.Y.: Simulation of corrosion–erosion of passive metals using a micro-scale dynamical model. Wear 271, 1404–1410 (2011)
Harvey T.J., Wharton J.A., Wood R.J.K.: Development of a synergy model for erosion–corrosion of carbon steel in a slurry pot. Tribol. Mater. Surf. Interf. 1, 33–47 (2007)
Rajahram S.S., Harvey T.J., Wood R.J.K.: Evaluation of a semi-empirical model in predicting erosion–corrosion. Wear 267, 1883–1893 (2009)
El-Batsh H.M., Doheim M.A., Hassan A.F.: On the application of mixture model for two-phase flow induced corrosion in a complex pipeline configuration. Appl. Math. Model. 36, 5686–5699 (2012)
Chemical Engineering Module User’s Guide, COMSOLAB Version 3.5a (2008)
Launder, B.E.; Spalding, D.B.: Lectures in Mathematical Models of Turbulence. Academic Press London, England (1972)
Lotz, U.: Velocity effects in flow induced corrosion. NACE Corrosion Paper no. 27, Houston, Texas (1990)
Postlethwaite J., Dobbin M.H., Bergevin K.: The role of oxygen mass transfer in the erosion–corrosion of slurry pipelines. Corrosion 42(9), 514–521 (1986)
Huser, A.; Kvernvold, O.: Prediction of sand erosion in process and pipe components. In: 1st North American Conference on Multiphase Technology, Banff, Canada BHR group Conf. Series Publ. No., vol. 31, pp. 217–227 (1998)
Chen X., McLaury B.S., Shirazi S.A.: Application and experimental validation of a computational fluid dynamics (CFD)-based erosion prediction model in elbows and plugged tees. Comput. Fluids 33, 1251–1272 (2004)
Mamoun, M.: Analytical models for the erosive–corrosive wear process, Rep. ANL-75- XX-2, Appendix I, Argonne National Laboratory (1975)
Hutchings I.M.: A model for the erosion of metals by spherical particles at normal incidence. Wear 70, 269–281 (1981)
Hutchings I.M.: Prediction of the resistance of metals to erosion by solid particles. Wear 35, 371–374 (1975)
Sundararajan, G.; Shewmon, P.G.: A new model for the erosion of metals at normal incidence. Wear84, 237–258 (1983)
Lewis, M.E.: Dissolved oxygen. In: U.S. Geological Survey Techniques of Water-Resources Investigations Book 9, Chapter A6, Section 6.2 (2009). http://pubs.water.usgs.gov/twri9A6. Accessed 25th January 2006
Hayduk W., Minhas B.S.: Correlations for prediction of molecular diffusivities in liquids. Can. J. Chem. Eng. 60, 295–299 (1982)
Keating, A.: A model for the investigation of two-phase erosion–corrosion in complex geometries, Mesc, University of Queensland (1999)
Saghatoleslami, N.; Okhovat, A.: A numerical investigation of the turbulent flow through channel expansion system, using COMSOL MULTIPHYSICS simulator. In: 13th National Iranian Chemical Engineering Congress & 1st International Regional Chemical and Petroleum Engineering Conference, Kermanshah, Iran (2010)
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Okhovat, A., Heris, S.Z., Asgarkhani, M.A.H. et al. Modeling and Simulation of Erosion–Corrosion in Disturbed Two-Phase Flow Through Fluid Transport Pipelines. Arab J Sci Eng 39, 1497–1505 (2014). https://doi.org/10.1007/s13369-013-0771-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s13369-013-0771-2