Investigating of Erosion Corrosion in Horizontal Steel Pipes With Slurry Seawater Flow
Investigating of Erosion Corrosion in Horizontal Steel Pipes With Slurry Seawater Flow
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Performance Improvement of Adsorption Desalination Plant: Experimental Investigation 127
by I. I. El-Sharkawy, K. Thu, K. C. Ng, B. B. Saha, A. Chakraborty, S. Koyama
The Influence of Hydrogen and Chromium on Behavior Mechanic of the Welded Joints 133
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International Review of Chemical Engineering (I.RE.CH.E.), Vol. 6, N. 3
ISSN 2035-1755 May 2014
Abstract – Erosion corrosion is main problem in marine structures, such as offshore pipelines
and a ship's propeller churning in the ocean. Understanding the failure mechanism due to erosion
helps in the review of pipeline design. This paper concerns with studying the behavior of A106
carbon-steel pipes working in two different erosive environments (i.e. plain and slurry seawater).
Series of laboratory experiments are carried out to investigate the rates of iron losses due to both
flow rate variations and sand concentration variations. The flow rate is controlled to cover both
the laminar and turbulent flow regimes. The sand concentration varies from null to 9 g/l. The
relationship between the rate of corrosion rate and flow rate at different levels of contamination is
investigated. A regression equation is developed to describe the relationship of different erosion-
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corrosion rate at laminar and turbulent flow regimes along with different sand contamination
levels. Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved.
I. Introduction
The National Energy Board [1] estimated that the
ultimate volume of crude bitumen in place is to be some
IN Understanding of E-C of metals is complex, and
considerable work is required to determine the
interaction of affecting parameters and, furthermore, the
synergism of corrosion and erosion [7]. One of the most
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400 billion cubic meters. With the continuously growing challenging pipelines system operations is early detect
demand in oil consumption, conventional energy sources for any abnormal behaviors that may lead to catastrophic
are suffering from depletion. accidents.
The dependency on the oil sands, as a new source of The most crucial factor in pipeline operating system is
energy, will be increasing rapidly to compensate the the control of the pipe's corrosion. During the operation
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difference in the future global oil production. Hydro of the pipeline system, the system process may contain a
transport of Oil sand is a method of transporting oil sand corrosive flow (e.g. seawater) or operates in various
and preparing it for upstream processing all at the same velocities (e.g. laminar or turbulent). So all of this can
time. The hydro transport process, oil sands and water generate a suitable zone for the birth of erosion-corrosion
are mixed together to make a slurry. This slurry is and many huge consecutive problems can be occurred. In
transported via pipeline from the mine to a bitumen addition, a fault can be very costly in terms of production
extraction facility. There is no doubt that oil sand hydro loss. Online monitoring for pipeline erosion-corrosion is
transport is a much less expensive and more flexible way an important task for early detection for abnormal
to move oil sand than the old method. However, erosion- situation that may lead to catastrophic accident [8].
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corrosion and their synergism, erosion corrosion (E-C) The overall objective of this paper studies the
have constituted an essential threat to the integrity of the fundamentals of E-C of water pipe steel under different
oil sand slurry hydro transport system [2], [3]. Erosion conditions that might be relevant to oil sand slurry
corrosion is acceleration in the rate of corrosion attack in transportation. The parametric effects, including different
metal due to the Relative motion of the environment and slurry seawater flow velocities (i.e. Reynolds numbers)
the metal surface [4]. For example, in oil sand slurry, the and sand concentrations on E-C of pipe steel are
presence of water and oxygen, combined with the salts, investigated by weight loss technique.
causes corrosion to the carbon steel pipes, which is
accelerated by the flowing slurry and the solid sand
particles. II. Experimental and Procedures
The synergistic effects of corrosion and erosion can
generate material loss much greater than that caused by Identifying the damage behavior by E-C in the tested
individually [5], [6]. Development of the effective pipe is the main objective of this study. Reaching this
technique for prevention of Hydro transport pipe E-C has target is achieved by identifying the tested pipes
been identified as one of the highest profitable research specifications and behavior in different mediums at
priorities in oil sand industry [2]. various velocities.
Manuscript received and revised April 2014, accepted May 2014 Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved
117
M. El-Zebda, M. Shehadeh, I. Hassan
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quantity of iron loss from the carbon steel of the pipeline
system. Hence, the erosion corrosion rate was calculated
using Eq. (1) at all mediums for eight different velocities
(i.e. Reynolds number) with 30 minute increments.
where:
Erosion-corrosion rate
WL
AT
(1)
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specimen, secondly: assembling the experimental system
apparatus, thirdly determining the system velocities. All
WL iron loss weigh (mg)
experiments were carried out at room temperature using
A inner pipe surface area (cm²)
eight seamless pipes of steel class B (A106). The
T time (s)
seamless pipe has dimensions of 52 mm internal
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Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved International Review of Chemical Engineering, Vol. 6, N. 3
118
M. El-Zebda, M. Shehadeh, I. Hassan
E-C rate is almost constant. Accordingly, it can be From Figs. 2-5 and Table I, the E-C rate has been
developed regression equations for different found approximately stable starting from 10800 second
contaminations seawater in both laminar and turbulent which also considered as a less standard error.
regimes at time of 10800 second. Fig. 6 shows the E-C rate of iron losses and individual
The regression equation is developed here by using contributors as a function of the sand concentration and
commercial software. For choosing the most suitable Reynolds number at certain time of 10800 second.
equations for laminar and turbulent cases a regression
analysis to be attempted for fitting a linear model. The
modeler should be first determined whether or not there
is a relationship between the variables of interest.
This does not necessarily imply that one variable
causes the other, but that there is some significant
association between the two variables. Depending on
these results, Reynolds numbers and sand concentration
have been chosen.
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IN Fig. 3. Erosion corrosion rate vs time for slurry seawater(9 g/l sand)
at different laminar flow
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Fig. 2. Erosion corrosion rate vs time for seawater
at different laminar flow
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Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved International Review of Chemical Engineering, Vol. 6, N. 3
119
M. El-Zebda, M. Shehadeh, I. Hassan
IV. Conclusion
The effect of seawater flow rate with different sand
contamination levels on erosion-corrosion rates in this
work is investigated. The erosion corrosion rate increases
linearly with increasing the flow velocities and sand
concentrations.
Two regression equations were derived to determine
the erosion-corrosion rate in laminar and turbulent
regimes.
Fig. 6. Erosion Corrosion rate Vs Reynolds at 10800 second. Chemical analyses can be used only as a quantitative
technique to monitor and predict the E-C effects in
TABLE I pipeline systems.
STANDARD ERROR OF REGRESSION EQUATIONS FOR LAMINAR
AND TURBULENT FLOW However, further numerical and experiments
Time(s) Standard error investigations required on other geometries, such as large
Laminar Turbulent scale of pipelines, in different corrosive environments to
3600 0.23 0.228 study the qualitative as well as quantitative effect of
5400 0.2 0.217 erosion-corrosion rate and location along pipelines.
7200 0.191 0.227
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9000 0.185 0.176
10800 0.218 0.138
References
[1] National Energy Board, Canada’s Oil Sands, A Supply and
Market (2000).
[3]
[4]
[5]
Petroleum Technology Alliance Canada, Research Priorities
(Upstream Conventional Oil & Gas), Canada (2001).
Robert J.K. Wood, Erosion–corrosion interactions and their effect
on marine and offshore materials, Wear, 261 (2006), 1012–1023.
D.D. Macdonald, G.A. Cragnolino, Corrosion of Steam Cycle
Materials (ASME Handbook 1989).
Y. Li, G.T. Burstein, I.M. Hutchings, 1995: Influence of
environmental composition and electrochemical potential on the
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slurry erosion-corrosion of aluminum, Wear, 181(1995), 70-79.
[6] M.M. Stack, N. Pungwiwat, Particulate erosion–corrosion of Al
in aqueous conditions: some perspectives on pH effects on the
erosion–corrosion map, Tribology International, 35(2002), 651–
660.
[7] S.S. Rajahram, T.J. Harvey, R.J.K.Wood, Erosion–corrosion
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Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved International Review of Chemical Engineering, Vol. 6, N. 3
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M. El-Zebda, M. Shehadeh, I. Hassan
Authors’ information
Eng. Mohamed El-Zebda is currently Master
student at Marine Engineering Dpt., Arab
Academy for Science, Technology and Maritime
Transport (AASTMT), Alexandria, Egypt. He
was graduated from AAST He had several years
of experience in marine engineering field.
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Dr. Ibrahim Hassan is currently Associate
Professor at Department of Basic and Applied
Sciences, AASTMT, Alexandria, Egypt. He
obtained BSc, MSc and PhD in Chemical
Engineering, Faculty of Engineering, Alexandria
University, Egypt. The author’s major research
interest is in the field of corrosion and mass-
transfer processes. The author has a number of
publications in this field. The author was a Post Doctoral Researcher
during the period from February to September 2007and visitor
professor during June to September 2010 and 2012 with The Chemical
Engineering Department at Lakehead University, Thunder Bay,
Canada.
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