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Journal of Chinese Society for Corrosion and protection  2026, Vol. 46 Issue (2): 611-619    DOI: 10.11902/1005.4537.2025.226
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Erosion-corrosion Failure Mechanism of 90° Elbow in 3.5%NaCl Solution Containing Sand
HU Zongwu1(), LIU Jianguo2, WANG Yu3, LI Kai1
1.College of Petrochemical Technology, Lanzhou University of Technology, Lanzhou 730050, China
2.College of Pipeline and Civil Engineering, China University of Petroleum, Qingdao 266580, China
3.China Petroleum Engineering Construction Corporation Qinghai Company, Dunhuang 736202, China
Cite this article: 

HU Zongwu, LIU Jianguo, WANG Yu, LI Kai. Erosion-corrosion Failure Mechanism of 90° Elbow in 3.5%NaCl Solution Containing Sand. Journal of Chinese Society for Corrosion and protection, 2026, 46(2): 611-619.

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Abstract  

In oil and gas fields, water pipelines often suffer from erosion-corrosion problems caused by liquid-solid two-phase flow, leading to frequent pipeline leakages and affecting normal production. Hence, the erosion-corrosion characteristics of 90° horizontal elbows of carbon steel in liquid-solid two-phase flow conditions (namely sand and 3.5%NaCl solution) was assessed via a home-made pipeline two phase flow experimental setup to simulate the actual service conditions of oil and gas field water pipelines. The aim is to reveal the erosion-corrosion damage mechanism of carbon steel elbows in these conditions and to provide guidance for corrosion protection. Meanwhile, the weight loss method was used to quantify the erosion-corrosion rates, and surface analysis techniques were used to characterize the erosion-corrosion morphologies. The results show that in corrosion conditions of merely 3.5%NaCl solution without sand, the elbow has good corrosion resistance; in erosion conditions of merely 3.5%NaCl solution without sand, it has good wear resistance. However, in liquid-solid two-phase flow conditions, the elbow suffers severe erosion-corrosion damage, particularly on the outward facing side, bottom and outlet of the elbow. The erosion-corrosion, where at the outer edge at the bottom area of the pipe with an axial angle of 30°-60° is relatively less. In general, the erosion-corrosion rate should include items such as pure corrosion, pure erosion, and the interaction between corrosion and erosion. In the present case, the item of erosion-corrosion interaction rate is rather higher, and the other two items is relatively lower. In fact, the erosion-corrosion interaction rates reached 41~56 times the pure corrosion rates and 45-112 times the pure erosion rates. In the interaction rates, the change in corrosion rate caused by erosion accounts for as much as 70% to 80%, which is significantly higher than the change in erosion rate caused by corrosion, and both are positive values. Therefore, the interaction between erosion and corrosion is the main cause for the sharp increase in erosion-corrosion of the elbow, as the two factors promote each other. In summary, erosion in the liquid-solid medium is the main factor leading to the failure of the carbon steel elbow. The results provide a scientific basis for pipeline protection in erosion-corrosion environments.

Key words:  carbon steel elbows      liquid-solid two-phase flow      erosion wear      erosion-corrosion      interaction     
Received:  15 July 2025      32134.14.1005.4537.2025.226
ZTFLH:  TG172.2  
Fund: Research Projects of PetroChina Innovation Foundation(2024DQ02-0101);Gansu Provincial Youth Science and Technology Fund(23JRRA774)

URL: 

https://www.jcscp.org/EN/10.11902/1005.4537.2025.226     OR     https://www.jcscp.org/EN/Y2026/V46/I2/611

Fig.1  Schematic diagram of erosion-corrosion testing device
Fig.2  Structural diagram of the test elbow: (a) top view, (b) left view
Fig.3  Particle size distribution of solid particles
Fig.4  Distribution of pure erosion rates on horizontal elbow (unit: mm/a) (a) and the cloud map of pure erosion rates (b)
Fig.5  Distribution of erosion-corrosion rates (unit: mm/a) (a, b), sand concentration (c) and shear stress (d) on horizontal elbow
Fig.6  Distribution of erosion-corrosion interaction rate (unit: mm/a) (a) and the cloud map of erosion-corrosion interaction rates on the elbow (b)
Fig.7  Comparison of various components in the erosion-corrosion rate at circumferential angle of 90°: (a) the magnitudes of the four components in the erosion-corrosion rate, (b) the ratio of the erosion-corrosion rate to the pure corrosion rate and the pure erosion rate
Fig.8  Percentage contributions of the two components to the interaction rate of the specimens at a 90° circumferential angle
Fig.9  Macroscopic erosion-corrosion morphologies of specimens at 90° (a1-g1) and 270° (a2-g2) circumferential angle of the location on the elbow after corrosion product removal
Fig.10  Three-dimensional morphology of pit (a) and groove (b)
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