The main objective of this work is to establish an analytical model to evaluate the rate of corrosion in a horizontal pipe downstream of an orifice under flow-accelerated corrosion (FAC). FAC is a serious issue in nuclear and fossil power plants. In this work, an experimental setup was built to observe the effect of the flow on corrosion inside a tube. The experiments confirmed that the flow inside the tube caused more corrosion. However, accurate experimental data from literature has been selected and correlated by dimensional analysis, the modelling method of repeating variables and the Buckingham Pi theorem. It was found that the Sh number and the relative distance from the orifice are the main dimensionless parameters influencing FAC downstream of an orifice. The maximum value of the FAC rate could be well-predicted for the OR of 0.25, while the location of the maximum FAC rate could be well predicted for the OR of 0.5. The maximum FAC rate occurs between 2D to 4D downstream of the orifice and increases with a decreasing OR. This work could be useful for professionals in industry and researchers in the field and could be the starting point for a new way of evaluating the FAC rate downstream of a flow’s singularity. / Dissertation (MSc)--University of Pretoria, 2017. / Mechanical and Aeronautical Engineering / MSc / Unrestricted

Flow accelerated corrosion is a piping degradation mechanism that results in pipe wall thinning due to the dissolution of the magnetite oxide layer on carbon steel surfaces to the bulk flow. The rate limiting process of flow accelerated corrosion in piping system is the diffusion-controlled mass transfer. The surface roughness develops due to the mass transfer and can subsequently have a significant effect on the mass transfer. The naturally developing surface roughness in many dissolving surfaces, including carbon steel pipes, is a densely packed array of saucer shaped depression called scallops, which can have several length scales. Heretofore, the developing roughness on soluble walls has not been quantified, mainly due to the lack of a reliable measurement methodology. The overall objective of this research is to investigate the developing roughness and the corresponding mass transfer on soluble walls in different piping geometries. A wall dissolving method using gypsum test sections dissolving to water in a closed flow loop was used to mimic the mass transfer in carbon steel pipes due to a similar Schmidt number of 1200. A novel non-destructive measurement technique using X-ray CT scans was developed to measure the development of surface roughness and the corresponding mass transfer. The method was validated by performing experiments using straight pipe test sections and comparing against traditional measurements method using ultrasonic sensors, coordinate measurement machine and laser scans. The time evolution of surface roughness and the corresponding mass transfer were measured in pipe test sections at Reynolds number of 50,000, 100,000 and 200,000. The roughness scallops were observed to initiate locally and then develop until the surface is spatially saturated. The surface roughness was characterized by the RMS height, peak-to-valley height, integral length scale, density and spacing of the scallops. Two time periods of roughness development were identified: an initial period of slower growth in the roughness height followed by a relatively higher growth rate that corresponded to the period before and after the surface saturates with the scallops. The mass transfer enhancement due to the roughness in each of these time periods was also found to be different, with a higher increase in the first period followed by a slower increase once the streamwise spacing was approximately constant. Both the height and spacing of the roughness elements was found to affect the mass transfer enhancement. A new correlation is proposed for the mass transfer enhancement as a function of the height-to-spacing ratio of roughness, with a weak dependence on Reynolds number. The measurement methodology was extended to study the mass transfer and developing roughness in a complex S-shaped back to back bend at Reynolds number of 200,000. The mass transfer in bend geometry can be enhanced by both the local flow due to the geometry effect and the developing roughness. Two high mass transfer regions were identified: at the intrados of the first and second bends. The height-to-spacing ratio of the roughness was found to increase more rapidly in these high mass transfer regions. An additional one-time experiment was performed at a Reynolds number of 300,000. A higher surface roughness with smaller values of spacing-to-height ratio was found in the regions with high mass transfer. / Thesis / Doctor of Philosophy (PhD)

No description available.

<p>Flow accelerated corrosion(FAC) results in wall thinning of pipes, tubes or vessels from exposure to flow due to corrosion. If FAC is not detected, it can lead to sudden failure of piping components. Orifices are used in piping systems to monitor and control the flow. Flow separation and reattachment downstream of an orifice can enhance the mass transfer of the pipe wall. In this thesis, the effect of Reynolds numbers and surface roughness on the mass transfer rate downstream of an orifice was investigated. A dissolving wall method was used to measure the wall mass transfer. The test sections were cast from gypsum with water as the working fluid. Multiple destructive tests were performed for different test times in a 2.5 cm diameter flow loop, and the wear topology measured by a laser scanner to obtain the progression of wear with time over the pipe surface. None-destructive tests were performed in a 20 cm diameter flow loop using test section with an inner gypsum lining, and measured online at selected locations using an ultrasonic method. Experiments were performed at Reynolds numbers of 80000, 140000 and 200000 in the 2.5 cm diameter flow loop, and at 180,000 in the 20 cm diameter flow loop with an orifice to pipe diameter ratio of 0.5. The results show that different surface roughness patterns are developed at different Reynolds numbers from the initially smooth surfaces. The different surface roughness patterns have a significantly different effect on the mass transfer rate downstream of an orifice. A larger population of scallops developed from the smooth pipe surface, as the Reynolds number was increased, which enhanced the mass transfer rate. The mass transfer rate in the 20 cm diameter test section was much smaller than in the 2.5 cm diameter test section at a similar Reynolds number. The pattern of the roughness in the 20 cm diameter test section was formed as isolated roughness which is similar to the roughness pattern in 2.5 cm diameter test section at much lower Reynolds number.</p> / Master of Applied Science (MASc)

Preferential weld corrosion (PWC) remains a major operational challenge that jeopardizes the integrity of oil and gas production facilities. It is the selective dissolution of metal associated with welds, such that the weld metal (WM) and / or the adjacent heat-affected zone (HAZ) corrode rather than the parent metal (PM). Corrosion inhibition is conventionally used to mitigate this problem however several indications suggest that some corrosion inhibitors may increase PWC. Furthermore, it is not possible to detect systems that are susceptible to PWC and or to understand the apparent ineffectiveness of some corrosion inhibitors at high flow rates. Consequently, the aim of this research is to assess the suitability of submerged jet impingement method to study flow accelerated preferential weld corrosion, which is critical to safe and economic operations of offshore oil and gas facilities. In this research, a submerged jet-impingement flow loop was used to investigate corrosion control of X65 steel weldment in flowing brine, saturated with carbon dioxide at 1 bar, and containing a typical oilfield corrosion inhibitor. A novel jet-impingement target was constructed from samples of parent material, heat affected zone and weld metal, and subjected to flowing brine at velocities up to 10 ms- 1 , to give a range of hydrodynamic conditions from stagnation to high turbulence. The galvanic currents between the electrodes in each hydrodynamic zone were recorded using zero-resistance ammeters and their self-corrosion rates were measured using the linear polarisation technique. At low flow rates, the galvanic currents were small and in some cases the weld metal and heat affected zone were partially protected by the sacrificial corrosion of the parent material. However, at higher flow rates the galvanic currents increased but some current reversals were observed, leading to accelerated corrosion of the weld region. The most severe corrosion occurred when oxygen was deliberately admitted into the flow loop to simulate typical oilfield conditions. The results are explained in terms of the selective removal of the inhibitor film from different regions of the weldment at high flow rates and the corrosion mechanism in the presence of oxygen is discussed.

This project uses CFD analysis to make design choices for a facility to test flow accelerated lead corrosion erosion of steel samples. Two conceptual designs are considered and compared through mechanical and physical criteria. The first design uses steel samples on stationary plates next to rotating discs. The second design has the steel samples on the rotating disc. The first design is considered unfeasible due to high pressure gradients in the system and a high power requirement from the motor. The second design removes the issue of high pressure gradients and can decrease the motor requirements. This design is selected for further analysis and discussion of manufacturing. / Detta projekt använder CFD-analys för att göra designval för en anläggning för att testa flödesaccelererad blykorrosionserosion av stålprover. Två konceptuella konstruktioner beaktas och jämförs genom mekaniska och fysiska kriterier. Den första designen använder stålprover på stationära plattor bredvid roterande skivor. Den andra designen har stålproverna på den roterande skivan. Den första konstruktionen anses vara ogenomförbar på grund av höga tryckgradienter i systemet och ett högt effektbehov från motorn. Den andra designen tar bort problemet med höga tryckgradienter och kan minska motorkraven. Denna design är vald för vidare analys och diskussion om tillverkning.

<p>Flow-Accelerated Corrosion (FAC) is a pipe wall thinning mechanism affecting carbon steel piping systems in power generation plants. Mass transfer is the rate limiting factor, even though chemistry and materials determine the overall potential for FAC. Different localized thinning rates in back to back elbow configurations between the first and second elbow have been noted at nuclear power plants, and this difference depends on the length of pipe between the elbows, flow conditions, and the configuration of the back to back elbows (e.g. S, C, or out of plane). In this thesis, mass transfer measurements in back to back elbows arranged in an out of plane configuration under single and annular two-phase flow conditions are presented.</p> <p>The mass transfer measurements were performed using a wall dissolving technique with bend sections cast from gypsum. The diffusivity of gypsum in water is similar to the diffusivity of iron from the magnetite layer of carbon steel pipe in water, thus providing analogous mass transfer conditions to FAC in power generation plants. The wall dissolution of gypsum allows the surface roughness to develop due to the flow. The mass transfer is determined by passing water through the gypsum test sections in a flow loop system. The test sections are then sectioned into two halves to expose the worn surface. The surface topology is measured using a three dimensional laser scanner. The wear progression of the surface with time provides local mass transfer rates, locations of high mass transfer and local surface roughness.</p> <p>The single-phase flow experiments were performed at a Reynolds number of 70,000 for different lengths of pipe (0, 1, 2 and 5 pipe diameters) between the elbows. The mass transfer results show regions of higher mass transfer in the second elbow in comparison to the first el­­bow. The maximum mass transfer rate in the second elbow decreases when the length of the pipe between the elbows was increased from 0 to 5 pipe diameters. Surface features corresponding to flow streaks on the second elbow surface indicated swirling flow, and its strength decreases with increasing separation distance between the elbows. The surface roughness was found to be higher in the regions of high mass transfer and decreases with increasing elbow separation distance.</p> <p>The effect of air and water superficial velocities on the mass transfer for the bends with a separation distance of 0 pipe diameters was measured under two-phase air-water annular flow. In addition, the effect of separation distance of 0, 1 and 5 pipe diameters in length between the elbows was studied for one annular flow condition. The highest mass transfer was found on the outer wall of the first elbow for all cases. The maximum mass transfer in the second elbow was found to be approximately 60 percent of the maximum value in the first elbow, and was not affected significantly when the elbow separation distance was increased from 0 to 1 and 5 pipe diameters. The separation distance between the elbows did not affect the maximum mass transfer on the outer wall of the first elbow. The mass transfer increased with an increase in either the water or air superficial velocity, with the air velocity having a greater effect. The mass transfer enhancement factor relative to that in a straight pipe only increases significantly with increasing air superficial velocity. The roughness development in the pipe was modest, but increases significantly in the high mass transfer region of the first and second elbow.</p> / Master of Applied Science (MASc)