A combined CFD-experimental method for developing an erosion equation for both gas-sand and liquid-sand flows

The surface degradation of equipment due to consecutive impacts of abrasive particles carried by fluid flow is called solid particle erosion. Solid particle erosion occurs in many industries including oil and gas. In order to prevent abrupt failures and costly repairs, it is essential to predict the erosion rate and identify the locations of the equipment that are mostly at risk. Computational Fluid Dynamics (CFD) is a powerful tool for predicting the erosion rate. Erosion prediction using CFD analysis includes three steps: (1) obtaining flow solution, (2) particle tracking and calculating the particle impact speed and angle, and (3) relating the particle impact information to mass loss of material through an erosion equation. Erosion equations are commonly generated using dry impingement jet tests (sand-air), since the particle impact speed and angle are assumed not to deviate from conditions in the jet. However, in slurry flows, a wide range of particle impact speeds and angles are produced in a single slurry jet test with liquid and sand particles. In this study, a novel and combined CFD/experimental method for developing an erosion equation in slurry flows is presented. In this method, a CFD analysis is used to characterize the particle impact speed, angle, and impact rate at specific locations on the test sample. Then, the particle impact data are related to the measured erosion depth to achieve an erosion equation from submerged testing. Traditionally, it was assumed that the erosion equation developed based on gas testing can be used for both gas-sand and liquid-sand flows. The erosion equations developed in this work were implemented in a CFD code, and CFD predictions were validated for various test conditions. It was shown that the erosion equation developed based on slurry tests can significantly improve the local thickness loss prediction in slurry flows. Finally, a generalized erosion equation is proposed which can be used to predict the erosion rate in gas-sand, water-sand and viscous liquid-sand flows with high accuracy.;Furthermore, in order to gain a better understanding of the erosion mechanism, a comprehensive experimental study was conducted to investigate the important factors influencing the erosion rate in gas-sand and slurry flows. The wear pattern and total erosion ratio were measured in a direct impingement jet geometry (for both dry impact and submerged impingement jets). The effects of fluid viscosity, abrasive particle size, particle impact speed, jet inclination angle, standoff distance, sand concentration, and exposure time were investigated. Also, the eroded samples were studied with Scanning Electron Microscopy (SEM) to understand the erosion micro-structure.;Also, the sand particle impact speed and angle were measured using a Particle Image Velocimetry (PIV) system. The measurements were conducted in two types of erosion testers (gas-solid and liquid-solid impinging jets). The Particle Tracking Velocimetry (PTV) technique was utilized which is capable of tracking individual small particles. Moreover, CFD modeling was performed to predict the particle impact data. Very good agreement between the CFD results and PTV measurements was observed.