Piping Systems Research Articles

Integrated finite element analysis and machine learning approach for propagation pressure prediction in hybrid Steel-CFRP subsea pipelines

Accurate prediction of the propagation pressure (PP) in hybrid steel-CFRP pipe systems presents a substantial challenge due to intricate interactions and complex collapse failure modes. An efficient FE-based algorithm is programmed using ANSYS to numerically estimate the PP of hybrid steel-CFRP pipe, subjected to external pressure. This study employs a machine learning (ML) framework, addressing the inherent complexity with a three-phase approach: Parameter Design, Buckle Propagation Analysis, and ML Model Development. The dataset, encompassing about two thousand observations with four key features, undergoes k-fold cross-validation and min-max normalization for robust ML performance. Five ML models—Random Forest (RF), K-Nearest Neighbors (KNN), Genetic Programming (GP), Multi-layer Perceptron (MLP), and Support Vector Machine (SVM)—are developed and evaluated. The results revealed a significant influence of Ds/ts, a three-phase relationship with ts/tc, and a substantial decrease in PPh/PPs with increasing σys/σuc, predominantly exhibiting U-shaped or dog-bone failure modes in different scenarios. Proven that GP, KNN, and RF are the superior performers, ranking ahead of SVM with Gaussian Kernel (SVM-GK), MLP, and SVM with Linear Kernel (SVM-LK). Statistical metrics, Taylor Diagram analysis, and comparisons with FE results emphasize the effectiveness of GP, KNN, and RF. Additionally, normality tests and feature importance analysis provide nuanced insights.

Optical analysis and design of a novel solar beam down concentrator for indoor cooking

This investigation provides the design and optical analysis of an innovative solar beam-down configuration, which can be a promising passive solution for indoor solar-based cooking, offering an eco-friendly and sustainable approach. The system uses a beam-down parabolic dish concentrator to concentrate the solar radiation onto a ground-mounted receiver module, which has a secondary optical module consisting of a secondary reflector-light pipe system. The receiver module is a well-insulated tank consisting of a receiver in contact with a primary heat transfer fluid. The thermal energy stored in the receiver module is transported via a secondary heat transfer fluid to and from the cooktop via a tube-in-tube arrangement, which induces a thermosyphon effect. A multi-variable optical analysis through an efficient ray tracing methodology has been adopted to identify optimal design values of optical components such as parabolic dish concentrators, secondary reflectors, and light pipe-receiver assemblies. The optimal optical design parameters and their corresponding ray trace analysis results are elaborated. It was found that the designed beam-down parabolic dish concentrator system provides an ideal thermal energy of 10.3 kWh per day at an average DNI of 650 W/m2. Further, this investigation provides a design for a beam-down parabolic dish concentrating system that may be used for efficient and sustainable solar energy solutions.

Acoustic emission source localization in complex pipe structure using multi-task deep learning models

Localizing defects in long-range pipelines is essential to reduce the inspection time and develop timely repair strategies. The acoustic emission (AE) method is employed to pinpoint the position of defects in pipelines. The conventional 1-D localization algorithm requires time of arrival differences between two sensors, which may not be accurately captured due to the dispersive nature of the pipe structures. The geometric variations such as elbows and welds can influence the propagating elastic waves and, consequently, arrival time. In this study, an AE source localization approach using a deep learning model is developed to tackle the influences of sensor-source distance and geometric variables. The multi-task learning model first identifies the impact of the elbow and subsequently integrates this information when predicting the source location. The proposed model is evaluated on a complex piping system, which features welded elbows in its connections. Incorporating the elbow effect into the model shows a notable improvement in overall accuracy, rising from 53% (conventional method) to 94% (proposed multi-task learning method).

An accurate and robust method for intensification of wastewater sludge pipe flow

Globally, environmental impacts and population growth are driving the process intensification of wastewater treatment plants (WWTPs) via transition from conventional (2–3 wt% solids) to highly concentrated (4–6 wt% solids) wastewater sludges (HCWS). This presents an industrial challenge as HCWS are complex, non-Newtonian materials whose viscosity increases nonlinearly with solids concentration. This viscosity increase is particularly relevant for sludge pipe flow as it leads to considerable pumping pressure that ultimately limits the feasibility of pipe flow transportation. Hence, process intensification demands accurate prediction of HCWS turbulent pipe flow to design and optimise pumping infrastructure and piping systems. Such prediction requires accurate rheological characterisation of HCWS and numerical prediction of HCWS turbulent pipe flow, neither of which has been achieved to date due to respective limitations associated with benchtop rheometry and numerical turbulence models. We address these challenges by first developing accurate methods for rheological characterisation of HCWS via laminar flow of digested sludge at various solids concentrations (2–5 %) in a fully instrumented pipe loop facility at a large-scale WWTP. These rheological parameters are used in direct numerical simulation (DNS) computations (that avoid turbulence models) of turbulent pipe flow of HCWS. These predictions are then validated against turbulent flow pipe loop data. This method yields accurate (2–15 % error) predictions of HCWS turbulent pipe flow, compared with up to ∼75 % error for conventional pipe flow correlations. This validation highlights the need for accurate rheological characterisation and numerical simulation to predict HCWS pipe flow and provides a sound basis for the intensification and optimisation of WWTP pipeline systems.

Impacts of thermally stratified medium on transient convective heat transfer between co‐axial horizontal fixed pipes: Applications of the thermal stratification

AbstractThermal stratification improves coaxial pipe systems’ efficiency and stability. Thermal stratification enables accurate temperature maintenance, reduces thermal stress, optimizes heat transmission performance, and minimizes usage of energy to guarantee the system's long‐term performance. The main aim of the current study is to investigate the impacts of thermal stratification on buoyancy force flow and thermal transmission between coaxial fixed pipes. In the present research, the applications of thermally stratified medium on transient convective heat transfer between two coaxial fixed pipes are studied. A two‐dimensional mathematical formulation in terms of mutually nonlinear partial differential equations is used to analyze the unsteady flow and temperature field between the co‐axial pipes, when the internal pipe is uniformly heated and the outer wall of the external pipe is placed at infinity from the surface of the inner fixed pipe. Flow is assumed along the axial direction of the internal pipe and stationary boundary condition is assumed at the surface of the inner pipe. The coupled equations of the simulated model are solved numerically by applying the Implicit Finite Difference Technique. The computed outcomes in the form of geometrical interpretation are highlighted by using the technically advanced software TECHPLOT‐360. Comprehensive detail of the obtained results for the non‐dimensional parameters included in the flow formulation is predicted for steady state velocity, temperature distribution, time‐dependent surface shearness and time‐dependent energy shearness in results and discussion section of the manuscript. The emphasis is placed on the thermal stratification parameter in the above mentioned chief quantities. From the obtained results, it is predicted that the fluid flow pattern and thermal distribution are both reduced for rising values of the thermal stratification parameter S = 0.001, 0.03, 0.05, and 0.07. Minimum flow and thermal profile are observed at S = 0.07. Further, the amplitude of the time‐dependent surface shearness is uniformly distributed throughout the medium and the amplitude of the time‐dependent energy shearness is reduced effectively for S = 1.0, 5.0, and 10.0.

CFD Modelling of Swirling Mechanism to Reduce Erosion of Pipe Bend in Pneumatic Conveying System

Dry powders mixed with air transportation had bend erosion issues. CFD analysis by Shear-Stress Transport (SST) k-ɯ Model within Ansys was used to conduct a comprehensive numerical analysis of particle erosion within a 90° mild steel pipe bend in Pneumatic Conveying System. Part of the conveying pipe rotation achieved with the external motor swirling device was used to create swirling of particle before bend. Different-sized sand particles at different rpm were tested with and without a swirling device. Reduction in erosion rate of pipe bend carries significant implications, notably an extension of the system's operational lifespan. Reduction in erosion rate reports an impressive increase of 50% bend lifespan at higher RPM levels of the swirling device. The results underscore the effectiveness of this device in mitigating erosion, with significant implications for enhancing the longevity and reliability of bend life in piping systems of Pneumatic Conveying applications.

Use of magnetic fluids in process system for pipe isolations

This paper investigates the use of magnetic fluids known as ferrofluids to act as ad hoc valves within pipe systems to create isolation points for stemming pipe leakages and to halt leakages before they become largescale disasters. The sealing abilities of ferrofluids were proven for microvalves (ID ≤ 1 mm) in hydrostatic experiments and extended to the macroscale applications (ID ≥ 6 mm). Theoretical prediction and magnetic finite element analysis (FEA) were also undertaken to predict the burst pressure, and a comparison of both results against the experimental measurement was made. The up-scale results (10–18 mm ID) indicated that it is feasible to develop a ferrofluid that can be extended to approximate the applicable magnet strength to achieve higher burst pressure. It was concluded that the ferrofluid isolation valves hold potential in macroscale environments for process engineering in favour of a positive isolation.

Prototipe Otomasi Pemantauan Suhu Dan Pemberian Tekanan Gas Pada Pemeraman Pisang Cavendish

In Indonesia, banana production is the highest compared to other fruits. One of the variations is the Cavendish Banana, which has high economic value and has the potential to support Indonesia's economic recovery. Due to the high demand for Cavendish Banana fruit, farmers use ethylene gas to accelerate fruit ripening. The ripening process is done by manually directing the ethylene gas taken from the container to the ripening room through a pipe system. The purpose of this research is to create a prototype of an automatic system for ethylene gas usage and temperature control, where compressor pressure is an alternative to ethylene gas pressure. This system operates automatically according to the schedule that has been set on the RTC Module. There is a Pressure Transmitter Sensor in charge of measuring pressure with an error rate of 3.5%, a Selenoid Valve that plays a role in flowing air pressure into a box equipped with a DC fan as a spreader, and a DHT22 Sensor used for temperature monitoring with an error rate of 2.8%. Information regarding time, temperature, and pressure values are displayed on a 20x4 LCD screen. System testing involves time scheduling where the device is turned on one minute after the system is activated. Subsequently, the device was switched on again after different times of 2 and 5 minutes. The pressure value was set at 30Psi. Based on the results of the system automation testing, the device was successful with a success rate of 80%, so this automation system is ready to be implemented directly on the Cavendish Banana fruit ripening device.

Experimental investigation on solidification cracking & intergranular corrosion of AISI 321 & AISI 316 L dissimilar weld on pulsed current gas tungsten arc welding (PCGTAW)

Dissimilar metal combinations are frequently employed in the power generation and nuclear industries. Where stainless steel piping systems are connected to pressure vessels made of low-alloy steel, the subsystems of liquid rocket engines also have different, dissimilar material combinations. Dissimilar welding plays a vital role in ensuring the integrity, performance, and reliability of components and structures operating in cryogenic environments, in this study, plates of AISI 316L and AISI 321, each 5 mm thick, were successfully joined using the pulsed current gas tungsten arc welding (PCGTAW) technique with optimized process parameters. These weld joints are mostly present in rocket engines subjected to a cryogenic environment. Due to the low temperature environment, the metallurgical properties of these joints change, which affects their mechanical properties. As it is a structural part, PCGTAW welding is most common method for joining this kind of material.In this work, Microstructural analysis of the weldment revealed a combination of vermicular, lacy, and acicular ferrite morphologies in the fusion zone at the root, mid, and crown locations.Furthermore, no solidification cracking was detected in the weldments based on the optical micrograph and SEM results. Intergranular corrosion (IGC) testing indicated the absence of a ditch structure, suggesting that the heat-affected zone (HAZ) on both sides of the weld joint was not being susceptible to sensitization. However, the HAZ of the AISI 316L side exhibited coarser grains compared to AISI 321. Analysis of tensile properties revealed a significant influence of the testing environment on the tensile strength of the dissimilar welded joints. At room temperature, the average ultimate tensile strength (UTS) was measured as 621 MPa. Remarkably, at cryogenic conditions, the average tensile properties significantly increased to 1319 MPa.Microhardness analysis showed the highest hardness associated with the AISI 321 side. The fusion zone exhibited a large deviation in the hardness profile (205 ± 10 HV), with the highest average hardness observed in the middle part of the weld. However, the hot cracking behavior of the weld was investigated by using a suutula diagram at various locations of the weld. The investigation revealed that the Creq/Nieq ratio exceeded the critical threshold value, effectively diminishing the propensity for hot cracking in the fusion zone. Overall, these findings underscore the effectiveness of the PCGTAW technique in joining dissimilar materials, as well as the importance of microstructural and mechanical property evaluations, especially under extreme operating conditions such as cryogenic temperatures.Paraphrase.

Spectral element-finite element modeling and dynamic analysis of a fluid-delivering cracked pipe subjected to both pulsation and base excitations

Previous studies on cracked pipes have predominantly focused on single excitation, but in practical engineering, pipe systems often experience a combined effect of fluid pulsation and base excitations, which can potentially trigger more complex dynamic behaviors. Moreover, the solid finite element (FE) models are generally adopted to simulate the breathing effect and stress singularity, but the solution efficiency is unacceptable. Therefore, this study presents a spectral element-finite element (SE-FE) method to construct the dynamic models of the fluid-delivering cracked pipes (FDCPs), which combines the efficiency of spectral element (SE) with the adaptability of FE. Furthermore, a fluid pulsation model is constructed using measured data. Specifically, dynamic models of intact and cracked pipe segments are constructed using SE and FE, respectively, and interface coupling is achieved by the penalty function method. Subsequently, an experimental system for fluid pulsation excitation is established, and then a fluid pulsation model is constructed. Finally, the dynamic behaviors of a FDCP under compound excitation are analyzed. The results show that the fluid pulsation in the FDCP is higher than that in the intact pipe due to the breathing effect. Moreover, the beat vibration will be triggered when the pulsation frequency approaches the base excitation frequency. This study can provide a better understanding for the dynamic behaviors of FDCP, thereby providing a reference for crack damage detection.

Numerical examination on seismic response behavior of a piping system considering the plastic deformation of supports

A previous study proposed a passive safety structure to mitigate severe damage to crucial components under the beyond design basis event (BDBE). To examine the applicability of this concept to the piping system, the effect of the elastic-plastic behavior of the piping support structure on the seismic response of the piping system was investigated through elastic-plastic time history response analyses on a piping system model with multiple support structures. The numerical analyses considered the elastic-plastic behavior of supports and/or the inelastic characteristics of pipe material. The analysis results confirmed that the response of the piping system can be suppressed by adequately introducing the inelastic behavior of support structures. The results show the possibility of realizing of passive safety structure in piping systems and addressing some issues, such as changing vibration modes due to the elastic-plastic deformation of the support or the order of generation of inelastic behavior of pipe material and supports.

Best-estimate water hammer simulations to avoid the calculation of unrealistically high loads or unphysical pressure and force peaks

For safety-related systems fluid loads due to fluid transients have to be quantified for subsequent structural analyses to ensure their integrity or function, as required. Usually transient fluid loads in pipe systems are determined with one-dimensional water hammer software. For single-phase liquid flow, the method of characteristics (MOC) is often used that gives in this case appropriate results. For the consideration of local vapor bubbles, the MOC is combined with the discrete vapor cavity model (DVC). The DVC model may generate unrealistic pressure spikes due to the calculation of the collapse of multi-cavities in scenarios, where only one vapor bubble should actually occur. The application of a two-phase code may improve the calculation results. One requirement for the latter codes is the ability to calculate the propagation of steep gradients without suffering from numerical diffusion to exclude the underestimation of fluid loads. This is commonly attained by applying higher-order numerical schemes. However, the application of a numerical method of pure 2nd order leads to the calculation of unphysical oscillations at steep gradients causing severe problems during the solution. To exclude this, numerical methods with flux limiters can be used. With their application, the calculation of unrealistically high loads due to numerical deficiencies can be minimized. In addition, the consideration of further physical effects, that lead to the reduction of loads during transient flow processes, allows for a more realistic calculation of the loads. These are unsteady friction, widening of the pipe caused by pressure increase, fluid-structure interaction at junctions and due to friction, degassing of gas that is initially dissolved physically in a liquid and thermodynamic non-equilibrium during vapor bubble collapse. The in-house code DYVRO applies a second-order accurate scheme with flux limiters based on the Godunov method and can account for the above-described physical phenomena. It is shown by comparison of calculation results obtained by DYVRO with experimental data from literature that with modeling of these physical effects the loads can be calculated more realistically. Generally, these loads are lower than the results calculated by simplified models, which do not account for these effects. Considering that these loads are applied in subsequent structural analyses, cost-intensive oversizing of pipes and their supports can be avoided, by ensuring the necessary safety.

A Forward Sensitivity Analysis and Design of U-Shaped Bellows Considering the Radial Compensation Capability Under Internal Pressure

Abstract Bellows serve as integral component within a piping system, which withstand radial displacement loads and internal pressure loads. This study investigates the sensitivity analysis of structure design parameters, such as convolution height, convolution pitch, ply thickness, and convolution number, on radial compensation capability of U-shaped bellows under internal pressure. The influences of the geometric parameters on the strength performance of U-shaped bellows under internal pressure and radial displacement loads are also investigated. A forward design process considering the sensitivity of the structural parameters of the bellows to the bending stiffness and strength is provided. In order to improve the radial displacement compensation ability and to obtain better pressure resistance performance, a mathematical model is established to describe the performance of bellows, and multi-object optimization of bellows is conducted. The results show that the ply thickness has the greatest impact on bending stiffness and strength, and the optimized model has lower stiffness and higher strength compared to the initial model.

Memetic Alligator Optimization Algorithm for Optimal Thermoregulatory Control in Piping Systems

Memetic Alligator Optimization Algorithm for Optimal Thermoregulatory Control in Piping Systems

Experiments and three-dimensional flow simulations on twin-screw pumps operated as control valves for energy recovery

This study explores the characteristics of twin-screw pumps when operated in turbine, i.e., reverse mode as an alternative to traditional control valves in piping systems for recovering energy. Experimental and flow simulation methods are employed. By an overset grid technique, unsteady three-dimensional (3D) flow simulations are conducted, ensuring high cell quality and high spatial resolution, particularly in wall proximity and within the gaps. To assess viscosity effects, pump and turbine mode characteristics are analyzed for water and oil. Compared to water, a pronounced reduction of the flow rate dependence on pressure difference is revealed for highly viscous oil. The gap flow in oil is significantly affected by the spindles’ rotational speed and direction, whereas water displays minimal influence. Analyzing the variation in gap sizes, a 50% reduction in the minimum flank gap width leads to a slight rise in volumetric efficiency with negligible overall efficiency effects. Our findings underscore that utilizing twin-screw pumps as turbines for high-viscosity fluids can potentially recover up to 50% of the energy instead of dissipating it by using conventional control valves.

Modeling the vertical transmission of bioaerosols in residential building drainage systems

The vertical transmission of bioaerosols in building drainage systems is an understudied route of disease spread. This research examines how the position of drainage floors, flush volume, pipe type, and building story number affect the dynamics and reach of bioaerosols in such systems. Our findings show that drainage points positioned lower in a building amplify the number of the affected floors above, with recorded pressure differences at various drainage points ranging from 900 to 3200 Pa, depending on flush volume and floor position. The transition to a double pipe system significantly reduced pressure differences (to as low as 330 Pa in vent pipes), thereby diluting bioaerosol concentrations but increasing their dispersion across more floors. Building story number further influenced bioaerosol spread, with higher buildings exhibiting negligible pressure differences across stories (1400–2300 Pa) but a pronounced increase in affected floors above the drainage site.

Root cause analysis of corrosion failure of a firefighting pipeline

This is a specific case of corrosion damage to underground pipelines in the Arabian Gulf region caused by stray current corrosion. The damage occurred in a fire protection piping system connected to a sprinkler system. The investigation revealed that the corrosion surface morphology was localized and had historically occurred in the same location of previously failed pipe sections. Despite previous attempts to correct the problem, the cause remained undetected and undetermined. It was determined that the failure was due to electromagnetic forces generated by the proximity of high AC and DC voltages. Specifically, the stray current corrosion was caused by interference from electrical cables, including a high-voltage cable and a ground discharge from electrical electrodes. To prevent future failures, it was strongly recommended that all existing conduit pipes in the affected section be insulated with double-layer insulating tape, which has high impedance and dielectric properties.

Correlation to predict thermal characteristics of pulsating heat pipes with long evaporator section

In terms of employing closed-loop pulsating heat pipes as heat transfer devices in solar water heaters, the evaporator should be extremely long according to the length of the solar collector. However, there is a noticeable shortage of Semi-Empirical Correlations for predicting the thermal performance of extra-long closed-loop pulsating heat pipes utilized for heat absorption within solar collectors. The primary objective of this study was to formulate a Semi-Empirical Correlation specifically designed for predicting the thermal efficiency in extra-long closed-loop pulsating heat pipe configurations. This study extensively examined the thermal efficiency of a comprehensive design of closed-loop pulsating heat pipe samples when implemented in an evacuated-tube solar water heater system strategically designed for individual households. The specified maximum length for the evaporator section of the closed-loop pulsating heat pipes is set at 1.50 m, in contrast to the conventional design, which typically features an evaporator section of approximately 0.15 m. Furthermore, the investigation encompasses a number of sets, varying as one, two, and four. Therefore, a Semi-Empirical Correlation derived from the experimental data concerning seven pertinent non-dimensional parameters is presented, demonstrating a standard deviation percentage of 4.4 %. Among these parameters, the number of sets emerged as the most influential, inducing a maximum percentage change in the heat rate of water of 20.47 %. Moreover, compared with other studies utilizing pulsating heat pipes in solar water heaters, the correlation exhibited a 1.52 % error. These findings suggest that the developed Semi-Empirical Correlation is a valuable tool for predicting the thermal performance of an extra-long closed-loop pulsating heat pipe. It is particularly well suited for estimating the thermal behavior of closed-loop pulsating heat pipes with extended configurations, showcasing its enhanced accuracy and relevance in capturing the distinction of heat transfer in extra-long closed-loop pulsating heat pipe systems.

Effects of different culture methods on growth, meat yield, and nutritional composition of Mediterranean mussels (Mytilus galloprovincialis), south side of Marmara Sea, Türkiye

This study, conducted between February 2016 and October 2017 on the coast of Erdek in the Marmara Sea, established two longline systems (buoy and pipe). Monthly growth rates of juvenile mussels placed in polyethylene and polyamide nets within these systems were monitored. The monthly chemical composition and meat yield of mussels that reached harvest size were analyzed in both systems. Environmental parameters were measured monthly to assess environmental conditions. The highest meat yield of harvested mussels was recorded in January, with values of 36.99 ± 0.72% for mussels cultured in the pipe system and 31.43 ± 1.82% for those cultured in the buoy system. The highest growth in mussels was achieved in the group cultured in the pipe system within polyamide nets. The December sample showed the highest moisture content of 83.98% and the highest ash content of 2.34%. The highest crude fat content was found in the September sample. The June sample had the highest protein content. The Black Sea, Sea of Marmara, and Aegean Sea offer suitable areas for mussel cultivation. Currently, mussel farming is conducted in these areas, producing tens of thousands of tons annually. This publication contributes to the expansion of the production process.

Integrating Model-Centric and Data-Centric Techniques for Pipe System Prognostics and Health Management

In today's industrial landscape, the proactive implementation of predictive maintenance techniques is imperative, especially in the context of pipe systems, as companies increasingly embrace cutting-edge technologies such as artificial intelligence and the Internet of Things (IoT). Orano/La Hague, like many other industry leaders, recognizes the vital importance of integrating these technological advancements into their operations. One of the critical challenges they face relates to recurrent pipe-clogging incidents, leading to energy inefficiencies and financial losses. Addressing maintenance needs proactively is essential to mitigate risks and ensure the safety of both personnel and valuable assets. This research addresses these challenges by introducing an innovative hybrid approach that combines data-centric and model-centric methodologies for the continuous prognostics and monitoring of pipeline systems. Leveraging experimental passive acceleration measurements, this approach offers a reliable means to predict and assess the severity of clogs as they occur. To enhance the accuracy of predictions, a sliding window technique is employed to minimize noise and extract pertinent features from the data. The results of this study highlight the exceptional effectiveness of the proposed approach in accurately predicting clogging incidents and quantifying their severity, even in scenarios involving varying airflow rates within the pipes. This research marks a significant step forward in the domain of prognostics and health monitoring, with the potential for widespread applications across various industries. The integration of data-centric and model-centric approaches represents a promising solution to the complex challenge of predicting and preventing pipe-clogging incidents, ultimately contributing to enhanced operational efficiency and asset protection