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Investigating of Erosion Corrosion in Horizontal Steel Pipes With Slurry Seawater Flow

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Investigating of Erosion Corrosion in Horizontal Steel Pipes with Slurry Seawater


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ISSN 2035-1755
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May 2014

International Review of
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On the Initial Stage in Potato Immersion Frying


by Luis T. Villa, Angélica C. Boucíguez, Ricardo F. Lozano IN
Investigating of Erosion Corrosion in Horizontal Steel Pipes with Slurry Seawater Flow 117

122
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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
by A. Aboura, A. Seddak, A. Hebbar
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Concentration Dependency of the Rheological Behaviour of Oil-Water Emulsions 137


by L. Benali
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International Review of Chemical Engineering (I.RE.CH.E.), Vol. 6, N. 3
ISSN 2035-1755 May 2014

Investigating of Erosion Corrosion in Horizontal Steel Pipes


with Slurry Seawater Flow

M. El-Zebda, M. Shehadeh, I. Hassan

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.

Keywords: Erosion-Corrosion, Turbulent, Pipeline Corrosion, Slurry, Seawater

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

Experimental apparatus is shown in Fig. 1 and Spectrophotometer (i.e. microprocessor-controlled,


procedures are described in following sections. Two single-beam instrument for colorimetric testing) was
series of experiments are carried out; the first series of used to measure the quantity of iron loss from the steel
experiments for studying the E-C rate in the pipes by pipe in each sample of seawater. Also commercial iron
using plain seawater and the second series experiments reagent was used to determine the quantity of iron in
expose the tested pipes to a flow of seawater with solid seawater.
particles (sand). The E-C analyses in these experiments were carried
out for the determinations of its rate in each pipe in the
four different mediums and at certain velocity of the flow
every three hours. A water sample of the out flowing
water was collected every 1800 seconds in a clean test
tube which was initially washed with distilled water.
Eight pipes were tested in four different mediums (i.e.
seawater and three sand concentrations).

III. Results and Discussions


The erosion-corrosion rate was estimated from the

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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.

Fig. 1. Schematic experimental system

Many steps had been considered before starting


experiments, firstly: choosing the material of the tested
IN Erosion-corrosion rate is commonly given by the
following expression:

where:
Erosion-corrosion rate 
WL
AT
(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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diameter, 4 mm wall thickness and 1 m length. Hence,


The results of calculated E-C are estimated for all
Pipe of class B (A106) is widely used in fields of
cases. As an example for the results, only two results of
offshore platforms which proposed as more exposed
uncontaminated and contaminated seawater of 9 g/l sand
material for erosion-corrosion phenomena.
are chosen for presenting the behaviour of E-C with time,
The E-C rates were determined for flow regimes
show in Figs. 2, 3, 4 and 5. Figs. 2 and 3 show a direct
ranging from laminar, i.e. Re < 2300, up to turbulent
relationship between the E-C rate and the time for the
flow regimes of seawater at different levels of sand
laminar flow case with constant increment time of 1800
contamination. The Reynolds number calculations were
second in each velocity.
based on the pipe inner diameter.
Figs. 4 and 5 show the same relation for the turbulent
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The seawater density and dynamic viscosity were


flow case. From the observation of the trends at all
taken as 1025 kg/m3 and 0.0011 kg/ms, respectively [9].
mediums, it is clear that the increase of erosion-corrosion
Seawater was prepared at the laboratory by dissolving 35
rate is observed here due to the change in the flow
grams of salt in each liter of water [10]. However, direct
regime from laminar to turbulent, especially for seawater
usage of seawater is not recommended as it can contain
with concentration of sand 9 g/l at turbulent flow.
uncontrollable concentrations of solid particles, which
Moreover, the increase in weight losses due to sand
can also have harmful effects to the system.
contamination arises due to erosion effects as described
Total weight loss of iron was measured every 1800
by [11].
second for a period of 10800 second of whole system
However, for uncontaminated seawater, the increase
operation.
of erosion-corrosion rate at laminar flow is lower than all
The weight loss was measured for plain seawater and
other cases. Accordingly, it can be concluded that the
sand-contaminated seawater with sand concentrations of
main two parameters that effect directly the E-C rate is
3 g/l, 6 g/l and 9 g/l for eight different flow velocities
the flow velocity and sand concentrations which is agree
(i.e. Reynolds number), see Table I. Sand of average
with many researchers [12],[13].
grain size of 300 m was added to the prepared seawater From Figs. 2, 3, 4 and 5, the E-C is slightly decreased
at different concentrations. from time of 1800 second to 7200 second; thereafter the

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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Fig. 6 clearly indicates that rabidly increase in


erosion-corrosion rate by increasing the quantity of solid
particles in seawater as well as increasing the flow
velocity. The E-C obeyed a linear relationship with the
flow velocity, as shown in Fig. 4. Accordingly,
regression equations for E-C rates are proposed from the
linear trends of Fig. 4: Fig. 4. Erosion corrosion rate vs time for seawater
at different turbulent flow
For laminar regime:
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LnE  C  0.001 Re 013Sc  21.97 (2)

and for turbulent regime:

LnE  C  5.53  105 Re 0.08Sc  19.73 (3)

where the Sc is sand concentration in g/l. The Eqs. (2)


and (3) can help in prediction of the constant E-C rates
based on the flow velocity and solid particle
concentrations at certain time of system operations [14].
Finally, a high resolution camera was used to
investigate the internal surface of all pipes after three
hours of operation for each Reynolds number. The
erosion of the pipe is depicted in Figs. 7 and 8 [15].
The E-C experiments and found that less standard Fig. 5. Erosion corrosion rate vs time for slurry seawater (9 g/l sand)
error at 10800 second. at different turbulent flow

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).

(a) Reynolds 664 (b) Reynolds 900


IN [2]

[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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resistance of engineering materials in various test conditions,


Wear, 267 (2009), 244–254.
[8] M. Shehadeh, I. Hassan, H. Mourad, H.EL-Gamal, Monitoring
Erosion Corrosion in Carbon Steel Elbow Using Acoustic
Emission Technique, 30th European Conference on Acoustic
(c) Reynolds 1408 (d) Reynolds 1737
Emission Testing /7th International Conference on Acoustic
Emission, Granada, Spain, June (2012).
Figs. 7. Internal surface of pipes for slurry seawater
[9] C.Q. Guo, C.H. Zhang, M.P. Paidoussis, Modification of equation
at different laminar flow regime
of motion of fluid-conveying pipe for laminar and turbulent flow
profiles, Journal of Fluids and Structures, 26 (2010), 793-803.
[10] F. Culkin, The Major Constituents of Seawater, Chemical
Oceanography, l (1965), 121-161.
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[11] T. Boran, 2007: Mechanistic Understanding and Effective


Prevention of Erosion-corrosion of Hydrotransport Pipes in Oil
Sand Slurry, MSc. Thesis, University OF Calgary, Canada
(2007).
[12] M .R.Ansari, S. Mohammadi And M.K. Oskouei, 2012: Two-
phase Gas/Liquid-Solid Flow Modeling in 90° Bends and Its
(a) Reynolds 3056 (b) Reynolds 8558 Effect on Erosion, Global Journal of researches in engineering,
12(1)(2012), 35-44.
[13] M. Shehadeh, A.I. Shahata, M. El-Shaib and A. Osman,
Numerical and Experimental Investigations of Erosion-corrosion
in Carbon-steel Pipelines, International Journal of Applied
Engineering Research, 8 (11) (2013), 1217-1231.
[14] Rajat Gupta, S.N. Singh, V. Sehadri, Prediction of uneven wear in
a slurry pipeline on the basis of measurements in a pot tester,
Wear, 184 (1995), 169-178.
[15] Md .AminulIslam, Zoheir.N.Farhat, The synergistic effect
(c) Reynolds 13252 (d) Reynolds 25002 between erosion and corrosion of API pipeline in CO2 and saline
medium, Tribology International 68 (2013), 26-34.
Figs. 8. Internal surface pipes for slurry seawater at different
turbulent flow regime

Copyright © 2014 Praise Worthy Prize S.r.l. - All rights reserved International Review of Chemical Engineering, Vol. 6, N. 3

120
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.

Dr. Mohamed Shehadeh is currently Associate


Professor at Marine Engineering Dept., Arab
Academy for Science and Technology. He
obtained BSc and MSc from Marine
Engineering Dpt., AASTMT, Alexandria, Egypt
and PhD from mechanical Engineering, Heriot
Watt University, UK. He had participated in
many European funds as well as works for
seventeen years in design and research of mechanical and marine
engineering fields.

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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.
IN
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