Study on the occurrence and development mechanism of pipeline corrosion behind butterfly valve

doi:10.11949/0438-1157.20221209

Abstract

Abstract:

Aiming at the abnormal thinning of the pipeline behind the butterfly valve in a petrochemical plant, combined with corrosion analysis, corrosion test and numerical simulation, the causes of abnormal thinning of the pipeline were analyzed, and the occurrence and development mechanism of corrosion were studied. The structure and composition of the samples were characterized by scanning electron microscope (SEM), X-ray diffraction (XRD), energy spectrometer (EDS) and metallographic microscope. The influence of flow field parameters on corrosion process was calculated and analyzed based on computational fluid dynamics (CFD). The results show that the main failure reason is flow accelerated corrosion. In addition, the pipeline behind the butterfly valve is divided into three different areas based on the relationship between velocity boundary layer and wall roughness, and the occurrence and development mechanism of corrosion in different areas are explained by schematic diagrams.

Key words: pipeline, corrosion, computational fluid dynamics, electrochemistry, flow

摘要：

针对某石化厂蝶阀后管线异常减薄的问题，结合腐蚀分析、腐蚀实验和数值模拟，分析了管线异常减薄的原因，研究了腐蚀的发生与发展机制。样品的结构及成分通过扫描电镜（SEM）、X射线衍射（XRD）和能谱仪（EDS）及金相显微镜进行表征，并结合计算流体动力学（CFD）分析了流场参数对腐蚀过程的影响。结果表明，管线主要的失效原因是流动加速腐蚀。此外，基于速度边界层与壁面粗糙度之间的关系，将蝶阀后管线划分为三个不同的区域，并用示意图对不同区域腐蚀的发生与发展机制进行了解释。

关键词: 管线, 腐蚀, 计算流体力学, 电化学, 流动

CLC Number:

TE 969

Guoqing SU, Jianwen ZHANG, Yan LI. Study on the occurrence and development mechanism of pipeline corrosion behind butterfly valve[J]. CIESC Journal, 2022, 73(12): 5504-5516.

苏国庆, 张建文, 李彦. 蝶阀后管线腐蚀发生与发展机制研究[J]. 化工学报, 2022, 73(12): 5504-5516.

Figures/Tables 22

Fig.1 Butterfly valve structure and pipe wall division

Table 2 Composition of conveying medium

组成	含量/%(mass)
H₂O	18
C₃	0.06
C₄	0.31
C₅	1.25
C₆	6.85
C₇	15.05
C₈	25.34
C₉	24.23
C₁₀	8.23
C₁₁	0.64
H₂S	0.0272
Cl^-	0.006

Fig.2 Physical map of samples

Fig.3 Thickness distribution

Fig.4 SEM images of samples

Fig.5 EDS spectrums of samples

Fig.6 XRD patterns of samples

Table 3 Chemical composition of 304 stainless steel coupons

元素	含量/%(mass)
C	0.03
Mn	1.22
P	0.02
S	0.02
Si	0.31
Cr	18.90
Ni	9.10
Fe	70.4

Fig.7 Schematic diagram of experimental device

Fig.8 Morphology structure of specimen

Fig.9 Micromorphology of specimen

Fig.10 Computational domain and mesh division of butterfly valve

Table 4 Simulated boundary conditions

参数	数值
入口流速/(m/s)	1.5
介质密度/(kg/m³)	790
介质黏度/cP	0.43
压力/MPa	0.15

Fig.11 Wall shear distribution of left wall at different number of meshes

Fig.12 Schematic diagram of section position

Fig.13 Velocity nephogram of different sections

Fig.14 Streamline distribution of different sections

Fig.15 Wall shear distribution at different opening degrees

Fig.16 Wall shear distribution at different wall roughness

Table 5 Flow types at different roughness

e/mm	流动类型
0≤e≤0.08	水力光滑管
0.08<e<0.85	过渡区圆管
e≥0.85	完全粗糙管

Fig.17 Schematic diagram of occurrence and development mechanism of pipeline corrosion behind butterfly valve

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