processes-12-01012
processes-12-01012
processes-12-01012
Article
Solid–Liquid Two-Phase Flowmeter Flow-Passage Wall Erosion
Evolution Characteristics and Calibration of
Measurement Accuracy
Wei Han 1,2 , Lumin Yan 1 , Rennian Li 1,3, *, Jing Zhang 1 , Xiang Yang 1 , Lei Ji 4 and Yan Qiang 1
1 School of Energy and Power Engineering, Lanzhou University of Technology, Lanzhou 730050, China
2 Key Laboratory of Advanced Pumps Valves and Fluid Control System of the Ministry of Education,
Lanzhou University of Technology, Lanzhou 730050, China
3 Key Laboratory of Fluid Machinery and Systems, Lanzhou 730050, China
4 Key Laboratory of Fluid Machinery and Engineering, Xihua University, Chengdu 610039, China
* Correspondence: 212080704026@lut.edu.cn
Abstract: Solid–liquid two-phase flowmeters are widely used in critical sectors, such as petrochem-
icals, energy, manufacturing, the environment, and various other fields. They are indispensable
devices for measuring flow. Currently, research has primarily focused on gas–liquid two-phase flow
within the flowmeter, giving limited attention to the impact of solid phases. In practical applications,
crude oil frequently contains solid particles and other impurities, leading to equipment deformation
and a subsequent reduction in measuring accuracy. This paper investigates how particle dynamic
parameters affect the erosion evolution characteristics of flowmeters operating in solid–liquid two-
phase conditions, employing the dynamic boundary erosion prediction method. The results indicate
that the erosion range and peak erosion position on the overcurrent wall of the solid–liquid two-phase
flowmeter vary with different particle dynamic parameters. Erosion mainly occurs at the contraction
section of the solid–liquid two-phase flowmeter. When the particle inflow velocity increases, the
erosion range shows no significant change, but the peak erosion position shifts to the right, primarily
due to the evolution of the erosion process. With an increase in particle diameter, the erosion range
expands along the inlet direction due to turbulent diffusion, as particles with lower kinetic energy
Citation: Han, W.; Yan, L.; Li, R.;
exhibit better followability. There is no significant change in the erosion range and peak erosion
Zhang, J.; Yang, X.; Ji, L.; Qiang, Y.
position with an increase in particle volume fraction and particle sphericity. With a particle inflow
Solid–Liquid Two-Phase Flowmeter
velocity of 8.4 m/s, the maximum erosion depth reaches 750 µm. In contrast, at a particle sphericity
Flow-Passage Wall Erosion Evolution
of 0.58, the minimum erosion depth is 251 µm. Furthermore, a particle volume fraction of 0.5 results
Characteristics and Calibration of
Measurement Accuracy. Processes
in a maximum flow coefficient increase of 1.99 × 10−3 .
2024, 12, 1012. https://doi.org/
10.3390/pr12051012 Keywords: particle dynamics parameters; erosion characteristics; measurement accuracy
this decline in measurement performance and accuracy can lead to disputes and losses
in the process of crude oil extraction and transport. Therefore, additional research on the
erosion characteristics of solid–liquid two-phase flowmeters holds significant engineering
importance [12–15]. It aims to safeguard solid–liquid two-phase flowmeters from erosion
and enhance measurement accuracy in practical engineering applications.
Scholars from domestic and international institutions have researched erosion damage
to the flow-passage walls in multiphase flowmeters with fixed boundaries. These factors
encompass the material and shape of the flow-passage walls, particle properties, particle
impact velocity, particle impact angle, and fluid properties [16–21]. Their interactions
collectively contribute to the individual impact on the equipment. Li [22] designed an
experimental setup to measure the impact of single particles and explored the influence of
impact parameters on particle behaviour and material deformation. Their findings revealed
that impact velocity significantly influences particle motion parameters, yet the shape of
the erosion crater remains consistent across various impact velocities. Moreover, He [12]
proposed a correlation equation for measuring the wet gas flow of the venturi flowmeter
based on the two-phase mass flow coefficient. They discussed the factors influencing
this coefficient and observed a linear increase with the Lockhart–Martinelli parameter,
along with a decrease as the gas–liquid density ratio increased. Furthermore, various
factors influence the erosion and damage to equipment operating in sandy conditions.
Gajan [23] conducted high-pressure experiments on a venturi flowmeter in wet gas flow
conditions. They analyzed the impact of water content on flow behaviour, comparing
experimentally obtained flow coefficients with predictions derived from the flowmeter’s
internal dynamics. Similarly, Dehkordi [24] employed the volume of fluid (VOF) model
to investigate the two-phase flow of high-viscosity oil and water in a venturi flowmeter.
They acquired data on two-phase pressure drops, instantaneous radial velocity, holding
rate distributions, cross-section time-averaged holding rates, and slip rates. Lastly, Liu [25]
conducted numerical calculations on a low-temperature venturi flowmeter. They observed
a linear relationship between the flow coefficient and the root mean square of the reciprocal
of the Reynolds number of the throat. The flow coefficient decreased with an increase in
the diameter ratio of the throat and increased with a rise in the angle of constriction.
Currently, the primary focus in multiphase flowmeter research revolves around inter-
nal flow characteristics and cavitation. However, erosion factors have not been adequately
considered in these studies. Furthermore, erosion-related research often relies on fixed
boundaries, lacking a genuine representation of flow field conditions. This paper exam-
ines the impact of various particle dynamic parameters on the erosion characteristics and
measurement accuracy of the solid–liquid two-phase flowmeter. It employs the dynamic
boundary erosion prediction method along with the Oka erosion model to offer a theoretical
reference for enhancing the measurement accuracy of solid–liquid two-phase flowmeters.
2. Numerical Model
2.1. Computational Domain Model
To comply with confidentiality requirements, the pertinent structural parameters of the
solid–liquid two-phase flowmeter cannot be disclosed. The computational domain is estab-
lished by SolidWorks 2010 3D modeling software, which includes the inlet straight section,
tapered section, throat, expanding section, and the outlet straight section. Refer to Figure 1
for the profile of the solid–liquid two-phase flowmeter computational domain model.
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Processes 2024, 12, 1012 2.4. Erosion Depth Model Based on Dynamic Boundary 4 of 13
h = ∑ ∆x
T
h xface,t (5)
(5)
f ace,t
t 0
t =0
EE represents theDPM
represents the DPM erosion
erosion (m3 /kg);
raterate (m /kg);
3 Mp isMthe
p isparticle
the particle mass∆t(kg);
mass (kg); MM isΔtthe is the mesh
MMmesh
travelling time
travelling step;Aface
timestep; Afaceisisthe mesh
the area
mesh (m2(m
area ); T2);
is T
theis total erosion
the total time; and
erosion h isand
time; the htotal
is the total
erosion depth.
erosion depth.
Figure 3. Flowchart
Figure 3. Flowchartofofprogressive
progressive erosion
erosion prediction
prediction method.
method.
Processes 2024, 12, 1012 5 of 13
Gk denotes the production of turbulent kinetic energy due to the mean velocity gra-
dient. Gb is the turbulent kinetic energy generated by the buoyancy force. YM denotes
the contribution of fluctuating expansion to the total dissipation rate in compressible tur-
bulence. Ak and αε are the inverse of the effective Prandtl numbers k and ε, respectively.
G1ε = 1.42, G2ε = 1.68.
The control equations were discretized and solved using the SIMPLEC algorithm. The
sub-relaxation factors were set to the default values provided by the system. These values
were as follows: pressure (0.3), density (1), body forces (1), momentum (0.7), turbulent
kinetic energy (0.8), turbulent dissipation rate (0.8), turbulent viscosity (1), and discrete
phase sources (0.5). The pressure, momentum, turbulent kinetic energy, and other factors
were set to the second-order windward format. The criterion for residual convergence
is 1 × 10−8 . The outcomes obtained from the numerical steady state simulation of the
fluid-phase served as preliminary values for the erosion simulation of the multiphase flow.
Then, the discrete phase model (DPM) was applied for calculating the particle erosion.
In the dynamic mesh setup for erosion prediction in solid–liquid two-phase flowme-
ters, the spring smoothing and mesh reconstruction techniques from the smoothing method
were employed to smooth and reconstruct the mesh in the presence of substantial wall
deformation, ensuring the quality of the mesh. After a trial calculation, the initial mesh
movement time step was established as 24 h. In the spring smoothing process, the spring
constant factor was set to 1, while the convergence accuracy and number of iterations
were both left at their default system values, which were 0.001 and 20, respectively. The
element method chose the Tri in Tri Zones. The mesh reconstruction method selected Local
Cell and Local Face, with a minimum mesh size set to 0.4 and mesh size set to 0.9. The
maximum mesh cell skewness was set at 0.8, and the maximum face skewness was set at
0.7. Additionally, the mesh reconstruction frequency was set to 5.
(a) (b)
(c)
Figure
Figure 4.
4. Flowmeter
Flowmeter experimental setup. (a)
experimental setup. (a) Water
Water reservoirs;
reservoirs; (b)
(b)flowmeter
flowmetertest
testbench;
bench;(c)
(c)Flowmeter.
Flowme-
ter.
Processes 2024, 12, 1012 7 of 13
Experiments were conducted on the flowmeter at an inlet flow velocity of 4.15 m/s
in accordance with the designed flow rate. The experiments had varying durations of
12 h, 24 h, 36 h, 48 h, and 60 h. After each experiment, the flowmeter was subjected to
ultrasonic cleaning and drying, followed by precise weighing using an electronic scale with
an accuracy of 0.1 g. In this paper, a dynamic boundary erosion prediction method was
employed in numerical simulations. The boundary mesh was reconfigured with erosion
time and erosion rate, resulting in a change in mesh volume. The original mesh body minus
the reconfigured mesh volume represents the lost volume. Finally, the volume multiplied
by the density yields the lost mass. Combining these measurements with the numerical
simulation results, a comparison was made, showing that the numerical results had an error
of less than 3%, as illustrated in Table 3, affirming the reliability of the results presented in
this study.
Erosion Time (h) Experimental Value (g) Numerical Result (g) Relative Error (%)
12 2.02 1.98 1.98
24 4.11 4.02 2.19
36 5.97 5.86 1.84
48 8.19 8.05 1.71
60 9.98 10.13 1.47
Figure 6. Flow coefficient for different particle inflow velocities over time.
(a)
(a) (b)
(b) (c)
(c) (d)
(d)
Figure
Figure7.
Figure 7.7.Erosion
Erosiondepth
Erosion depthfor
depth fordifferent
for differentparticle
different particlevolume
volumefractions
volume fractionsover
fractions over
overtime. (a)
time.
time. (a)ααvαv=v=0.1;
(a) (b(b)(b)
=0.1;
0.1; )ααv v=α=v0.2; (c)
(c)
= 0.2;
0.2;
ααv v=α=v0.3;
(c) (d)
= 0.3;
0.3; ααv v=α=v0.5.
(d)(d) = 0.5.
0.5.
InInFigure
Figure8,8,asaserosion
erosiontimetimeincreases,
increases,the
theflow
flow coefficient
flowcoefficient
coefficientexhibits
exhibitsaaconsistent
consistenttrend,
trend,
namely,
namely, an increase in the flow coefficient with the passage of erosion time.
namely, an increase in the flow coefficient with the passage of erosion time. With thepar-
an increase in the flow coefficient with the passage of erosion With
time. Withthe particle
the par-
volume
ticle fraction
ticlevolume
volume increased,
fraction
fraction there was
increased,
increased, a corresponding
there
therewas increase in
wasaacorresponding
corresponding the solid–liquid
increase
increase ininthe two-phase
thesolid–liquid
solid–liquid
flowmeter of 1.04 × 10 −3 , 1.31 ×−310−3 , 1.56 −3× 10−3 , and
two-phaseflow
two-phase flowmetercoefficient,
flow with increments
flowcoefficient, with
withincrements ofof
1.04
1.04××10
10−3, ,1.31
1.31××1010−3, ,1.56
1.56××10
10−3, ,
−3
flowmeter coefficient, increments
1.99 × 10 − 3 over the course of 10 years.
and
and1.99
1.99××10 10−3over
−3
overthe
thecourse
courseofof1010years.
years.
Figure 8.8.Flow
Figure8. coefficient
Flowcoefficient for
coefficientfor different
fordifferent particle
differentparticle volume
particlevolume fractions
volumefractions over
fractionsover time.
overtime.
time.
Figure Flow
Figure10.
Figure 10.Flow
Flowcoefficient
coefficientfor
fordifferent
differentparticle
particlediameters
diametersover
overtime.
time.
4.4.
4.4.Influence
InfluenceofofParticle
ParticleSphericity
SphericityononErosion
ErosionEvolution
EvolutionCharacteristics
Characteristicsand
and Measurement
Measurement
Accuracy Accuracy
In
In practice, particlesare
practice, particles areseldom
seldomperfectly
perfectly spherical.
spherical. Therefore,
Therefore, investigating
investigating the
the sphe-
sphericity of particles with varying shapes holds significant value for engineering
ricity of particles with varying shapes holds significant value for engineering applications. applica-
tions.
In thisInsubsection,
this subsection, particle
particle sphericity
sphericity is employed
is employed as aasvariable
a variable to elucidate
to elucidate its its impact
impact on
on the erosion damage characteristics and flow coefficient of the solid–liquid
the erosion damage characteristics and flow coefficient of the solid–liquid two-phase flow- two-phase
flowmeter. Particle
meter. Particle sphericity
sphericity is defined
is defined as ratio
as the the ratio of surface
of the the surface
areaarea
of aof a sphere
sphere withwith a
a vol-
volume equal to that of the particle in question to the surface area of the particle itself, as
ume equal to that of the particle in question to the surface area of the particle itself, as
shown in Equation (9):
shown in Equation (9): s
φ= (9)
Ss
In Equation (9), s is the surface area of a sphere of equal volume, and S is the sur- (9)
S
face area of the particle itself. In this paper, three particle sphericities, as proposed by
In Equation
Epstein (9), employed,
[28], are s is the surface area of 0.66,
specifically a sphere
0.76,ofand
equal volume, and S is the surface area
0.86.
of the particle itself. In this paper, three particle sphericities, as proposed by Epstein [28],
are employed, specifically 0.66, 0.76, and 0.86.
In Figure 11, as particle sphericity increases, the depth of erosion pits on the flow-
passage wall of the solid–liquid two-phase flowmeter also increases. The most profound
erosion was noted at 10 years of erosion time, with a particle sphericity of 1, resulting in a
Processes 2024, 12, 1012 11 of 13
In Figure 11, as particle sphericity increases, the depth of erosion pits on the flow-
passage wall of the solid–liquid two-phase flowmeter also increases. The most profound
erosion was noted at 10 years of erosion time, with a particle sphericity of 1, resulting in
a maximum erosion depth of 582 µm. In comparison to the maximum erosion depth at a
particle sphericity of 0.58, this represents an approximately 2.3-fold increase. Nonetheless,
the extent of erosion remains largely consistent, with the peak maximum erosion depth
located at approximately 342 mm from the inlet. With increasing erosion time, the erosion
depth of the solid–liquid two-phase flowmeter’s flow-passage wall consistently rises,
indicating a cumulative effect on erosion depth over time. As erosion depth increases,
particle velocity decreases initially due to the small resistance coefficient of large spherical
particles; however, the gained kinetic energy results in a slight increase in particle velocity.
Processes 2024, 12, x FOR PEER REVIEW 12 of 14
Beyond the erosion peak position, approximately 348 mm from the inlet, as erosion time
increases and the follow-passage wall decreases, fluid velocity rises. This prompts
Processes 2024, 12, x FOR PEER REVIEW 12 of particles
14
to follow the fluid flow, leading to an overall increase in particle velocity.
Figure 12. Flow coefficient for different particle sphericity over time.
5. Conclusions
Figure
Figure 12.12.Flow
At Flowcoefficient
coefficient
present, forsimulation
for
numerical differentparticle
different particle sphericity
sphericity
is employed overtime.
over
primarily time.
to investigate the erosion of
fixed boundary conditions or in conjunction with the PIV system, electron microscope
5. scanner,
Conclusions
and so forth to examine the multiphase flow and erosion morphology. However,
these approaches are unablesimulation
At present, numerical to accuratelyis portray
employedthe evolution
primarilyoftoerosion in multiphase
investigate the erosion of
flowmeter flow-passage walls. This paper presents a further study
fixed boundary conditions or in conjunction with the PIV system, electron of the erosion charac-
microscope
scanner, and so forth to examine the multiphase flow and erosion morphology. The
teristics of multiphase flowmeters through the dynamic boundary prediction method. However,
influence of erosion depth change on the average erosion rate and metering accuracy is
these approaches are unable to accurately portray the evolution of erosion in multiphase
analysed, with the results having significant implications for the protection of multiphase
flowmeter flow-passage walls. This paper presents a further study of the erosion charac-
Processes 2024, 12, 1012 12 of 13
5. Conclusions
At present, numerical simulation is employed primarily to investigate the erosion of
fixed boundary conditions or in conjunction with the PIV system, electron microscope scan-
ner, and so forth to examine the multiphase flow and erosion morphology. However, these
approaches are unable to accurately portray the evolution of erosion in multiphase flowme-
ter flow-passage walls. This paper presents a further study of the erosion characteristics of
multiphase flowmeters through the dynamic boundary prediction method. The influence
of erosion depth change on the average erosion rate and metering accuracy is analysed,
with the results having significant implications for the protection of multiphase flowmeter
erosion and improvement of the metering accuracy in practical engineering applications.
(1) Erosion ranges and peak locations on the solid–liquid two-phase flowmeter flow-
passage wall vary with distinct particle dynamic parameters. As the particle flow rate
increases, the erosion range remains largely unchanged. Nevertheless, the erosion
peak shifts to the right, mainly linked to the erosion evolution process. With an
increase in particle diameter, the erosion range extends towards the inlet due to
turbulent diffusion. Particles with lower kinetic energy closely follow the flow. The
erosion range and peak position remained relatively stable despite increases in particle
volume fraction and sphericity.
(2) Erosion depth increases progressively with higher particle dynamic parameters. At a
particle inflow velocity of 8.4 m/s, the maximum erosion depth is 750 µm. Conversely,
at a particle sphericity of 0.58, the minimum erosion depth is 251 µm. Moreover,
a particle volume fraction of 0.5 results in a maximum flow coefficient increase of
1.99 × 10−3 .
This paper explores the influence of dynamic parameters on the multiphase flowmeter
erosion characteristics and measurement accuracy in common working conditions. It is
acknowledged that other conditions and different dynamic parameters may influence
the multiphase flowmeter erosion characteristics and measurement accuracy. Therefore,
further research is required to investigate these factors. In practical engineering, multiphase
flowmeters may encounter two-phase cavitation and cavitation damage in gas–liquid
conditions as well as three-phase abrasion damage in gas–solid–liquid scenarios. Currently,
there is a paucity of research on these issues in multiphase flowmeters. Consequently,
further investigation into the causes and effects of cavitation and erosion damage in
multiphase flowmeters can be conducted at a later stage. Specifically, we will discuss the
potential for future studies to extend our research to include bubbly flow [29] scenarios
with water and solid particles, addressing slipping boundary issues [30] to enhance the
applicability and relevance of our findings in practical settings.
Author Contributions: Conceptualization, W.H. supervised and guided this work. L.Y. developed
the numerical model, ran the simulation, wrote the manuscript, and prepared all the data. Finally, R.L.
and J.Z. reviewed and revised the manuscript before submitting it. X.Y., L.J. and Y.Q. proofread and
typeset the manuscript. All authors have read and agreed to the published version of the manuscript.
Funding: This study was supported by the National Natural Science Foundation of China (Grant
No. 52179086), Central Government Guides Local Science and Technology Development Fund
Projects (Grant No. 23ZYQA0320), Open Research Subject of Key Laboratory of Fluid Machinery and
Engineering (Xihua University), Sichuan Province (Grant No. LTJX-2023003), and Natural Science
Foundation of Gansu Province (Grant No. 23JRRA788). Thanks to the staff of Haimo Technology
Group for the help.
Data Availability Statement: All data in this manuscript are available from the corresponding author
by e-mail.
Conflicts of Interest: The authors declare no conflict of interest.
Processes 2024, 12, 1012 13 of 13
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