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Erosion, a mechanical process during which material is removed from the pipelines and other flow-containing equipment, can occur when solid particles such as sand are carried by the flow. Erosion is more critical when there is a change in the flow direction, such as particle-laden flows in elbows and tees.
While experimentation is a possible approach to obtain erosion rates, the conditions under which tests could be performed are limited in some respects.
Erosion prediction models are important tools for preventing costly failures that can happen due to solid particle erosion. Various models such as computational models, mechanistic models and correlations, and machine learning approaches have been developed and utilized by researchers for predicting the erosion rate. The mentioned models have been developed under certain conditions, therefore, there are limitations on the application of each model. In the present study, mechanistic models, a two-dimensional CFD-based model developed by the Erosion/Corrosion Research Center are compared to other models from the literature including DNV RP O501 correlation. Experimental erosion data for standard elbows obtained by ultrasonic measurements in literature are used to evaluate different models. Experiments cover a wide range of flow conditions with air, water, and sand, 50.8 mm, 76.2 mm, and 101.6 mm pipe sizes, and particle sizes from 20 μm to 300 μm. The accuracy of the models for various flow regimes is examined and their limitations are discussed. Moreover, to expand the examined flow conditions, CFD data for high-pressure gas-sand flows, high-viscosity liquid-solid flows, and large-diameter pipes are used to evaluate a modification to the mechanistic model.
High temperature sulfidation (or sulfidic) corrosion of steel by sulfur species in crude oil has long been known to damage refinery equipment. Corrosion engineers have been using prediction curves derived from field corrosion data to estimate rates of sulfidation corrosion. However, a significant inaccuracy is often encountered in these estimations because of the extensive diversity in molecular structures of sulfur compounds in crude oils.
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Delayed coking process is one of the major process technologies used for breaking down the heavy, long chain hydrocarbon molecules of the residual oil into shorter coker gas oil (and petroleum coke as by-product). Severe cyclic operating conditions are involved in these units. The main vessels, coke drums, are exposed to multiple damage mechanisms, as summarized in API 934G and J.
A life cycle costing analysis (LCCA) is the process of compiling cost estimates for each coating system option in combination with the expected life span of each of those options. In general terms, the lowest cost per year of service is the most economical choice. This LCCA process can be paired with an environmental impact analysis to evaluate the sustainability considerations of managing the water tank asset. One of the most commonly addressed factors in an environment life cycle assessment is a calculation of the greenhouse gas emissions associated with a process, presented in equivalent CO2 emissions.