A Combined CFD-Mechanistic Approach for Predicting Solid Particle Erosion in Annular Flow in Pipe Fittings and Elbows

Abstract In internal flows, solid particles carried by the fluid could damage pipelines and fittings. Particles that are entrained in the fluid can cross streamlines and transfer a part of their momentum to the internal surface by impacts and cause local wall material degradation. Over the past decades, a wide range of models is introduced to predict particle erosion which includes empirical models, mechanistic models, and CFD which is currently the state-of-art numerical approach to simulate the erosion process. Multiphase flow under annular flow conditions adds to the complexity of the model. Although with the current computational capabilities transient CFD models are effectively applicable, this type of transient multiphase approach is not practical yet for engineering prediction of erosion especially for the large diameter applications with huge computational domains. Therefore, the presented combined approach could be utilized to obtain erosion rates for large diameter cases. Thus, an approach combining CFD and mechanistic multiphase models characterizing annular flow is developed to predict solid particle erosion. Different factors including film thickness in pipes and fittings which are affecting erosion under gas-dominated multiphase flow conditions are investigated. The results from the current approach are compared to experimental data and transient CFD simulations for annular flow in elbows showing a very good agreement with both.

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Effect of erosive parameters on solid particle erosion of cotton fiber–based nonwoven mat/wooden dust reinforced hybrid polymer composites

Journal of Industrial Textiles ◽

10.1177/15280837211064241 ◽

2021 ◽

pp. 152808372110642

Author(s):

Sachin Tejyan

Keyword(s):

Solid Particle ◽

Impact Velocity ◽

Cotton Fiber ◽

Polymeric Composites ◽

Solid Particle Erosion ◽

Erosion Wear ◽

Impingement Angle ◽

Particle Erosion ◽

Fiber Loading ◽

Wide Range

Abrasive particle-induced erosive wear of polymeric engineering components is a major industrial issue. The research of solid particle erosion characteristics of polymeric composites becomes essential due to operational needs in dusty conditions. Nonwovens are now employed in industrial applications for polymeric composites. Nonwoven products are made from a wide range of raw materials, ranging from synthetic to natural fibers. This work finding the effect of nonwoven cotton fiber (5, 10, and 15 wt.%) loading on the physical, mechanical, and erosion wear of fixed wooden dust (4 wt.%) filled hybrid epoxy composites. Experimental results reveal improved impact strength, hardness, and compressive and tensile strength with an increment of fiber loading from 5–15 wt.%. The density of the composites was found to increase, whereas void content decreases with an increase in cotton fiber. The erosion wear of the composites has been studied using an L27 orthogonal array to assess the effects of various parameters such as fiber loading, erodent size, impact velocity, impingement angle, and stand-off distance. The erosion wear increased with impact velocity and remained highest for 60° of impingement angle. The most significant parameter affecting the erosion wear was determined as impact velocity followed by impingement angle. Surface morphologies of eroded samples reveal the fiber pull-out, and fiber breakage was the prominent phenomenon for the erosion wear of the evaluated composites.

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Resistance of PVD Coatings to Erosive and Wear Processes: A Review

Coatings ◽

10.3390/coatings10100921 ◽

2020 ◽

Vol 10 (10) ◽

pp. 921

Author(s):

Alicja Krella

Keyword(s):

Wear Rate ◽

Solid Particle ◽

Coefficient Of Friction ◽

Cavitation Erosion ◽

Solid Particles ◽

Solid Particle Erosion ◽

Pvd Coatings ◽

Particle Erosion ◽

Tribological Tests ◽

Hydraulic Machines

Due to the increasing maintenance costs of hydraulic machines related to the damages caused by cavitation erosion and/or erosion of solid particles, as well as in tribological connections, surface protection of these components is very important. Up to now, numerous investigations of resistance of coatings, mainly nitride coatings, such as CrN, TiN, TiCN, (Ti,Cr)N coatings and multilayer TiN/Ti, ZrN/CrN and TN/(Ti,Al)N coatings, produced by physical vapor deposition (PVD) method using different techniques of deposition, such as magnetron sputtering, arc evaporation or ion plating, to cavitation erosion, solid particle erosion and wear have been made. The results of these investigations, degradation processes and main test devices used are presented in this paper. An effect of deposition of mono- and multi-layer PVD coatings on duration of incubation period, cumulative weight loss and erosion rate, as well as on wear rate and coefficient of friction in tribological tests is discussed. It is shown that PVD coating does not always provide extended incubation time and/or improved resistance to mentioned types of damage. The influence of structure, hardness, residence to plastic deformation and stresses in the coatings on erosion and wear resistance is discussed. In the case of cavitation erosion and solid particle erosion, a limit value of the ratio of hardness (H) to Young’s modulus (E) exists at which the best resistance is gained. In the case of tribological tests, the higher the H/E ratio and the lower the coefficient of friction, the lower the wear rate, but there are also many exceptions.

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Electrical resistance probe measurements of solid particle erosion in multiphase annular flow

Wear ◽

10.1016/j.wear.2017.04.005 ◽

2017 ◽

Vol 382-383 ◽

pp. 15-28 ◽

Cited By ~ 16

Author(s):

Ronald E. Vieira ◽

Mazdak Parsi ◽

Peyman Zahedi ◽

Brenton S. McLaury ◽

Siamack A. Shirazi

Keyword(s):

Solid Particle ◽

Electrical Resistance ◽

Annular Flow ◽

Solid Particle Erosion ◽

Particle Erosion ◽

Probe Measurements

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Representative volume element-based simulation of multiple solid particles erosion of a compressor blade considering temperature effect

Proceedings of the Institution of Mechanical Engineers Part J Journal of Engineering Tribology ◽

10.1177/1350650119884825 ◽

2019 ◽

Vol 234 (8) ◽

pp. 1173-1184

Author(s):

Bijan Mohammadi ◽

AmirSajjad Khoddami

Keyword(s):

Finite Element ◽

Solid Particle ◽

Representative Volume Element ◽

Erosion Rate ◽

Compressor Blade ◽

Volume Element ◽

Solid Particles ◽

Solid Particle Erosion ◽

Particle Erosion ◽

Representative Volume

Solid particle erosion is one of the main failure mechanisms of a compressor blade. Thus, characterization of this damage mode is very important in life assessment of the compressor. Since experimental study of solid particle erosion needs special methods and equipment, it is necessary to develop erosion computer models. This study presents a coupled temperature–displacement finite element model to investigate damage of a compressor blade due to multiple solid particles erosion. To decrease the computational cost, a representative volume element technique is introduced to simulate simultaneous impact of multiple particles. Blade has been made of Ti-6Al-4V, a ductile titanium-based alloy, which is impacted by alumina particles. Erosion finite element modeling is assumed as a micro-scale impact problem and Johnson–Cook constitutive equations are used to describe Ti-6Al-4V erosive behavior. In regard to a wide variation range in thermal conditions all over the compressor, it is divided into three parts (first stages, middle stages, and last stages) in which each part has an average temperature. Effective parameters on erosive behavior of the blade alloy, such as impact angle, particles velocity, and particles size are studied in these three temperatures. Results show that middle stages are the most critical sites of the compressor in terms of erosion damage. An exponential relation is observed between erosion rate and particles velocity. The dependency of erosion rate on size of particles at high temperatures is indispensable.

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Particle-Based Numerical Simulation Study of Solid Particle Erosion of Ductile Materials Leading to an Erosion Model, Including the Particle Shape Effect

Materials ◽

10.3390/ma15010286 ◽

2021 ◽

Vol 15 (1) ◽

pp. 286

Author(s):

Shoya Mohseni-Mofidi ◽

Eric Drescher ◽

Harald Kruggel-Emden ◽

Matthias Teschner ◽

Claas Bierwisch

Keyword(s):

Solid Particle ◽

Particle Shape ◽

Solid Particles ◽

Solid Particle Erosion ◽

Shape Effect ◽

Particle Erosion ◽

Erosion Model ◽

Ductile Materials ◽

Erosion Behavior ◽

Numerical Predictions

Solid particle erosion inevitably occurs if a gas–solid or liquid–solid mixture is in contact with a surface, e.g., in pneumatic conveyors. Having a good understanding of this complex phenomenon enables one to reduce the maintenance costs in several industrial applications by designing components that have longer lifetimes. In this paper, we propose a methodology to numerically investigate erosion behavior of ductile materials. We employ smoothed particle hydrodynamics that can easily deal with large deformations and fractures as a truly meshless method. In addition, a new contact model was developed in order to robustly handle contacts around sharp corners of the solid particles. The numerical predictions of erosion are compared with experiments for stainless steel AISI 304, showing that we are able to properly predict the erosion behavior as a function of impact angle. We present a powerful tool to conveniently study the effect of important parameters, such as solid particle shapes, which are not simple to study in experiments. Using the methodology, we study the effect of a solid particle shape and conclude that, in addition to angularity, aspect ratio also plays an important role by increasing the probability of the solid particles to rotate after impact. Finally, we are able to extend a widely used erosion model by a term that considers a solid particle shape.

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A Statistical Approach for Modeling Stochastic Rebound Characteristics of Solid Particles

Volume 5: Multiphase Flow ◽

10.1115/ajkfluids2019-4655 ◽

2019 ◽

Cited By ~ 1

Author(s):

G. Haider ◽

A. Asgharpour ◽

J. Zhang ◽

S. A. Shirazi

Keyword(s):

Experimental Data ◽

Solid Particle ◽

Oil And Gas ◽

Great Influence ◽

Solid Particles ◽

Process Equipment ◽

Particle Impact ◽

Solid Particle Erosion ◽

Contributing Factors ◽

Particle Erosion

Abstract During production of oil and gas from wells, solid particles such as removed scales or sand may accompany petroleum fluids. These particles present in this multiphase flow can impact inner walls of transportation infrastructure (straight pipelines, elbows, T-junctions, flow meters, and reducers) multiple times. These repeated impacts degrades the inner walls of piping and as a result, reduce wall thickness occur. This is known as solid particle erosion, which is a complex phenomenon involving multiple contributing factors. Prediction of erosion rates and location of maximum erosion are crucial from both operations and safety perspective. Various mechanistic and empirical solid particle erosion models are available in literature for this purpose. The majority of these models require particle impact speed and impact angle to model erosion. Furthermore, due to complex geometric shapes of process equipment, these solid particles can impact and rebound from walls in a random manner with varying speeds and angles. Hence, this rebound characteristic is an important factor in solid particle erosion modeling which cannot be done in a deterministic sense. This challenge has not been addressed in literature satisfactorily. This study uses experimental data to model particle rebound characteristics stochastically. Experimental setup consists of a nozzle and specimen, which are aligned at different angles so particles impact the specimen at various angles. Information regarding particle impact velocities before and after the impacts are obtained through Particle Tracking Velocimetry (PTV) technique. Distributions of normal and tangential components of particle velocities were determined experimentally. Furthermore, spread or dispersion in these velocity components due to randomness is quantified. Finally, based on these experimental observations, a stochastic rebound model based on normal and tangential coefficients of restitutions is developed and Computational Fluid Dynamics (CFD) studies were conducted to validate this model. The model predictions are compared with experimental data for elbows in series. It is found that the rebound model has a great influence on erosion prediction of both first and second elbows especially where subsequent particle impacts are expected.

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Experimental Investigation of Solid Particle Erosion in S-Bend

Journal of Fluids Engineering ◽

10.1115/1.4031685 ◽

2015 ◽

Vol 138 (4) ◽

Cited By ~ 4

Author(s):

Quamrul H. Mazumder ◽

Kawshik Ahmed ◽

Siwen Zhao

Keyword(s):

Experimental Investigation ◽

Solid Particle ◽

Solid Particle Erosion ◽

Surface Erosion ◽

Particle Sizes ◽

Air Velocity ◽

Particle Erosion ◽

Fluid Handling ◽

Wide Range ◽

Cause Of Failure

Solid particle erosion is a micromechanical process that removes material from the surface. Erosion is a leading cause of failure in fluid handling equipment such as pumps and pipes. An investigation was conducted using an S-bend geometry with 12.7 mm inside diameter, r/D ratio of 1.5 with three different air velocities and two different particle sizes. This paper presents the preliminary results of an investigation to determine the location of erosion for a wide range of conditions. The experimental results showed the location of maximum erosion at 29–42 deg from the inlet at 45.72 m/s air velocity with 300 μm particle sizes.

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Investigation of Particle Size Effects on Solid Particle Erosion of Elbows in Series for Liquid-Solid Flows

10.1115/fedsm2021-65875 ◽

2021 ◽

Author(s):

Yeshwanthraj Rajkumar ◽

Soroor Karimi ◽

Siamack A. Shirazi

Keyword(s):

Particle Size ◽

Solid Particle ◽

Size Effects ◽

Oil And Gas ◽

Solid Particles ◽

Solid Particle Erosion ◽

Particle Sizes ◽

Particle Erosion ◽

Particle Size Effects ◽

In Series

Abstract The entrainment of solid particles within the produced fluids can cause solid particle erosion by impacting the piping of production and transportation facilities. Liquid dominated flows are commonly encountered in deep water subsea pipelines while producing oil and gas fluids. It is of great importance to predict the erosion pattern and magnitude for elbows in series in liquid-solid flows as in the oil and gas productions, liquids tends to produce more solid particles compared to gas-solid flows. In the current work, erosion of elbows in series for different particle sizes are investigated by using computational fluid dynamics (CFD) and compare the erosion pattern results with the results of paint removal experiments using a 76.2 mm diameter acrylic elbows, qualitatively. CFD simulations have been performed to study the particle size effects on erosion using Reynolds stress turbulence model (RSM) and Low-Reynolds number K-ε model. Grid refinement studies have been performed and particles are rebounded at the particle radius to accurately examine the effects of particle sizes on solid particle erosion of these elbows. The CFD results shows that significant erosion is observed at the inner wall of the first elbow for larger particles, and the maximum erosion can be seen towards the end of the second elbow for 300 μm particle size.

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The Effect of Geometry of Outlet Channel of Nozzle Box on Solid Particle Erosion

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.773.19 ◽

2013 ◽

Vol 773 ◽

pp. 19-24

Author(s):

Li Zhang ◽

Yu Ting Zheng

Keyword(s):

Solid Particle ◽

Flow Characteristics ◽

Solid Particles ◽

Solid Particle Erosion ◽

Particle Erosion ◽

Lagrange Method ◽

Particle Trajectories ◽

Outlet Channel ◽

Control Stage

On the base of the original geometry of the outlet channel of nozzle box, four different geometry of the outlet channel were constructed. Using the Euler-Lagrange method, the flow characteristics of solid particles in the five different channels were numerical simulated. The particle trajectories and the erosion regions were discussed. The analysis showed that the different geometry of the outlet channel would effect the particle erosion in the channel and the stator of the control stage.

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