Investigation of Erosion Mitigation Using 3D Printed Twisted Tape Insert

Abstract

The aim of this research is to assess the applicability of the 3D printed twisted tape inserts for reducing erosion in pipe system under liquid-solid and liquid-solid-gas flows, a major problem in industrial environment particularly in oil, gas, and chemical processing industries where suspended abrasives effectively diminishing the material quality and lifespan of pipes. To achieve this, three twisted tape configurations: single-twist tape, four-twist tape, and another four-twist tape with perforations configurations were designed and used in experiments involving the flow of a watersilica sand mixture at 1%, 3%, and 5% by volume of sand in the PVC pipes. Mass loss and paint erosion tests showed that all the twisted tapes decrease erosion with regards to plain pipes; with the highest level of erodent reduction attained by the perforated four-twist tape. Simulations based on CFD/DPM were conducted to support the experiments; these data confirmed that the inserts generate vortex flow that eliminates the abrasive particles and minimizes the pipe wall erosion. The proximity of the experimental and simulation data proves the effectiveness of the twisted tape inserts for the improvement of pipe toughness in abrasion dominant operations.