Performance Prediction of Erosive Wear of Steel for Two-Phase Flow in an Inverse U-Bend

Abstract

Erosion of the elbow due to non-Newtonian viscous slurry flows is often observed in hydrocarbon transportation pipelines. This paper intends to study the erosion behavior of double offset U-bends and 180° U-bends for two-phase (liquid-sand) flow. A numerical simulation was conducted using the Discrete Phase Model (DPM) on carbon steel pipe bends with a 40 mm diameter and an R/D ratio of 1.5. The validity of the erosion model has been established by comparing it with the results quantified in the literature by experiment. While the maximum erosive wear rates of all evaluated cases were found to be quite different, the maximum erosion locations have been identified between 150° and 180° downstream at the outer curvature. It was seen that with the increase in disperse phase diameter, the erosive wear rate and impact area increased. Moreover, with the change of configuration from a 180° U-bend to a double offset U-bend, the influence of turbulence on the transit of the disperse phase decreases as the flow approaches downstream and results in less erosive wear in a double offset U-bend. Furthermore, the simulation results manifest that the erosive wear increases with an increase in flow velocity, and the erosion rate of the double offset U-bend was nearly 8.58 times less than the 180° U-bend for a carrier fluid velocity of 2 m/s and 1.82 times less for 4 m/s carrier fluid velocity. The erosion rate of the double offset U-bend was reduced by 120% compared to the 180° U-bend for 6 m/s in liquid-solid flow.

Numerical Study of Gas-Sand Two-Phase Flow Erosion in a Standard 90° Elbow

“…Erosive wear takes place when a fluid-carrying erodent consistently impacts the target surface [1]. This consistent impact force applied by the erodent causes gradual material loss from the target material [2]. The angle of impaction between carrier fluid and target surface plays a crucial role in defining the erosion rate [3].…”