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<p>To address the reason of valve leakage, laboratory experiments and Fluent simulations were used to study the failure mechanism. Chemical composition analysis, metallographic examination, and mechanical property tests have verified that the material of the gate valve complies with the API 6A standard specifications. The outcomes of Fluent finite element numerical simulations have disclosed that the airflow velocity in the gate area is positively correlated with the inlet airflow velocity. It increases exponentially as the degree of gate closure diminishes. As the closure degree decreases, the position where the gas impacts shifts toward the gate. The macroscopic appearance of the gate demonstrates that long<b>-</b>term operation in a semi<b>-</b>open state leads to a significant surge in gas flow velocity, resulting in the erosion of the valve body. This erosion has been identified as the root cause of the leakage incident. Additionally, the electrochemical corrosion induced by CO<sub>2</sub> has expedited the failure process. It is advisable to coat the valve surface with a highly wear<b>-</b>resistant and corrosion<b>-</b>resistant material and to regularly monitor the operational status of the valve during daily production. The findings of this research provide substantial guidance for improving the operational reliability and extending the service life of valves.</p>

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Comprehensive Failure Analysis of Christmas Tree Gate Valves in Erosion-Corrosion Coupling Condition

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年6月30日

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  • Da Cheng Feng,
  • Wei Hou,
  • Long Long Lu,
  • Zheng Yi Xu,
  • Zhuan Zhao Yang,
  • An Qing Fu,
  • Xiu Qing Xu,
  • Chao Ming Wang

摘要

To address the reason of valve leakage, laboratory experiments and Fluent simulations were used to study the failure mechanism. Chemical composition analysis, metallographic examination, and mechanical property tests have verified that the material of the gate valve complies with the API 6A standard specifications. The outcomes of Fluent finite element numerical simulations have disclosed that the airflow velocity in the gate area is positively correlated with the inlet airflow velocity. It increases exponentially as the degree of gate closure diminishes. As the closure degree decreases, the position where the gas impacts shifts toward the gate. The macroscopic appearance of the gate demonstrates that long-term operation in a semi-open state leads to a significant surge in gas flow velocity, resulting in the erosion of the valve body. This erosion has been identified as the root cause of the leakage incident. Additionally, the electrochemical corrosion induced by CO2 has expedited the failure process. It is advisable to coat the valve surface with a highly wear-resistant and corrosion-resistant material and to regularly monitor the operational status of the valve during daily production. The findings of this research provide substantial guidance for improving the operational reliability and extending the service life of valves.