Reduction of erosion rates for steam operations through nanocoatings

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AP Dynamics Inc. specializes in the fields of computational fluid dynamics (CFD), torsional vibrations, pipingstress, pulsation and erosion mitigation, and mechanical design. One of the current challenges is the erosion inOnce Through Heat Recovery Steam Generators (OTSGs) piping due to water droplets existing in the flow ofsteam. To mitigate the problem, a predictive approach is required to estimate the material loss in order to planpreventive maintenance and maximize steam productions in oil extractions. Furthermore, the reduction oferosion is needed to enhance longevity of steam pipes.The main goal of this project is the development of a model to predict the erosion rates in the steam pipes andpropose a nanocoating based on using nanoparticulates for enhancing erosion resistance. To investigate theerosion rate caused by the steam jet within the pipes, AP Dynamics and the University of Calgary have formeda collaborative relationship to design, manufacture, optimize, and test a setup to mimic the steam jet systemwith integrated sensors. In the proposed system, the unknown empirical parameters influencing the erosion rateof the internal surface of the pipes will be measured through dynamic analysis of the impacts on the internalsurface of the pipes. To mitigate the erosion, the nanocoating will be applied to steel pipe sections. The steamerosion tested metallic substrates will be characterized via a various microscopy techniques.The developed system will be used for performing a comprehensive experimental investigation on the effectsof different steam jet velocities, droplet sizes, fluids, etc. on bare and coated steel pipes. The outcomes of theproject will enable AP Dynamics to develop a model to predict and analyze the erosion in steam pipes andprevent catastrophic failures. The developed nano coatings can result in protective layers with higher erosionresistance values compared to the regular pipes. The outcomes of the research will enable training of HQP andprovide a competitive edge for AP Dynamics for analyzing and preventing erosion failures in steam pipes.