Accurate corrosion depth mapping in inaccessible areas is a problem of major importance across a wide spectrum of industries. While several thickness gauging techniques are available, they are only applicable when the area to be inspected is directly accessible. In fact, standard gauging methods require a probing sensor to be scanned over the area where corrosion damage is expected. However, this is not always possible as access can be limited due to the presence of other structural members. As an example, determination of the depth of corrosion at supports of pipelines is a major issue in the petrochemical industry. At present the only reliable way to determine the corrosion depth accurately is to lift the pipe from the support and to use standard methods, thus resulting in a very costly and potentially hazardous inspection procedure. Here, we propose a tomographic approach similar to X-ray CT. However, instead of using ionizing radiation we employ guided ultrasonic waves that can be transmitted across the inspection area from a remote and accessible transducer location. While the interaction of photons with matter can be described by simple ray models in X-ray CT, scattering, diffraction and refraction phenomena characterise the encoding of mechanical property information in guided wave signals. These phenomena add much complexity to the problem of retrieving thickness maps in GWT and represent the main challenge of this proposal. Therefore, at a fundamental level this programme aims at developing a general approach to GWT that can address this complexity borrowing ideas developed in geophysical exploration and medical diagnostics. From a more applied perspective, we propose to develop a field deployable prototype for mapping corrosion at supports which will serve the twofold purpose of maintaining the research focussed on practical problems and of facilitating the translation of the proposed technology to industry. Moreover, the prototype will have a flexible design that will allow its application to corrosion mapping problems in inaccessible areas other than pipe supports to ensure that the proposed technology will have an impact across a wide spectrum of industries. This proposal is being submitted within the UK Research Centre in NDE to the targeted research programme, the funding for which is earmarked by EPSRC for industrially driven NDE research. It is supported by Shell and Petrobras who are contributing 90k cash as well as in-kind contributions to the project.

The prime aim of the Centre is to do world-class research in NDE and related fields. The Centre is a collaboration between six universities and 14 (in 07-08)large, end-user companies plus a number of smaller, associate members. The membership includes expertise in mechanical and electronic engineering, physics and materials, so recognising the interdisciplinary nature of NDE. The Centre will have a wide portfolio of activities from longer term, higher risk adventurous research, through medium term application research and development to short term practical projects and technology transfer activities with SMEs and other exploiters of new products. The EPSRC funds that are the main subject of this proposal will support longer term, adventurous research in three key priority areas: defect sizing to improve structural integrity assessments, permanently installed monitoring systems to reduce the down-time associated with inspection, and exploiting advances made in other areas to introduce innovative technology to improve the quality of NDE instrumentation. Over 50% of the cost of the research will be met by industrial contributions. The purpose of all the research, whether shorter or longer term, will be to benefit the nation in terms of quality of life, through improved safety, environmental protection and economic security. The Centre will do this by assisting UK companies to improve (a) their competitiveness and (b) their ability to meet the public's requirements for safe and secure operation.

This proposal addresses the vital issue of prediction of multiphase flows in large diameter risers in off-shore hydrocarbon recovery. The riser is essentially a vertical or near-vertical pipe connecting the sea-bed collection pipe network (the flowlines) to a sea-surface installation, typically a floating receiving and processing vessel. In the early years of oil and gas exploration and production, the oil and gas companies selected the largest and most accessible off-shore fields to develop first. In these systems, the risers were relatively short and had modest diameters. However, as these fields are being depleted, the oil and gas companies are being forced to look further afield for replacement reserves capable of being developed economically. This, then, has led to increased interest in deeper waters, and harsher and more remote environments, most notably in the Gulf of Mexico, the Brazilian Campos basin, West of Shetlands and the Angolan Aptian basin. Many of the major deepwater developments are located in water depths exceeding 1km (e.g. Elf's Girassol at 1300m or Petrobras' Roncador at 1500-2000m). To transport the produced fluids in such systems with the available pressure driving forces has led naturally to the specification of risers of much greater diameter (typically 300 mm) than those used previously (typically 75 mm). Investments in such systems have been, and will continue to be, huge (around $35 billion up to 2005) with the riser systems accounting for around 20% of the costs. Prediction of the performance of the multiphase flow riser systems is of vital importance but, very unfortunately, available methods for such prediction are of doubtful validity. The main reason for this is that the available data and methods have been based on measurements on smaller diameter tubes (typically 25-75 mm) and on the interpretation of these measurements in terms of the flow patterns occurring in such tubes. These flow patterns are typically bubble, slug, churn and annular flows. The limited amount of data available shows that the flow patterns in larger tubes may be quite different and that, within a given flow pattern, the detailed phenomena may also be different. For instance, there are reasons to believe that slug flow of the normal type (with liquid slugs separated by Taylor bubbles of classical shape) may not exist in large pipes. Methods to predict such flows with confidence will be improved significantly by means of an integrated programme of work at three universities (Nottingham, Cranfield and Imperial College) which will involve both larger scale investigations as well as investigations into specific phenomena at a more intimate scale together with modelling studies. Large facilities at Nottingham and Cranfield will be used for experiments in which the phase distribution about the pipe cross section will be measured using novel instrumentation which can handle a range of fluids. The Cranfield tests will be at a very large diameter (250 mm) but will be confined to vertical, air/water studies with special emphasis on large bubbles behaviour. In contrast those at Nottingham will employ a slightly smaller pipe diameter (125 mm) but will use newly built facilities in which a variety of fluids can be employed to vary physical properties systematically and can utilise vertical and slightly inclined test pipes. The work to be carried out at Imperial College will be experimental and numerical. The former will focus on examining the spatio-temporal evolution of waves in churn and annular flows in annulus geometries; the latter will use interface-tracking methods to perform simulations of bubbles in two-phase flow and will also focus on the development of a computer code capable of predicting reliably the flow behaviour in large diameter pipes. This code will use as input the information distilled from the other work-packages regarding the various flow regimes along the pipe.

This proposal addresses the vital issue of prediction of multiphase flows in large diameter risers in off-shore hydrocarbon recovery. The riser is essentially a vertical or near-vertical pipe connecting the sea-bed collection pipe network (the flowlines) to a sea-surface installation, typically a floating receiving and processing vessel. In the early years of oil and gas exploration and production, the oil and gas companies selected the largest and most accessible off-shore fields to develop first. In these systems, the risers were relatively short and had modest diameters. However, as these fields are being depleted, the oil and gas companies are being forced to look further afield for replacement reserves capable of being developed economically. This, then, has led to increased interest in deeper waters, and harsher and more remote environments, most notably in the Gulf of Mexico, the Brazilian Campos basin, West of Shetlands and the Angolan Aptian basin. Many of the major deepwater developments are located in water depths exceeding 1km (e.g. Elf's Girassol at 1300m or Petrobras' Roncador at 1500-2000m). To transport the produced fluids in such systems with the available pressure driving forces has led naturally to the specification of risers of much greater diameter (typically 300 mm) than those used previously (typically 75 mm). Investments in such systems have been, and will continue to be, huge (around $35 billion up to 2005) with the riser systems accounting for around 20% of the costs. Prediction of the performance of the multiphase flow riser systems is of vital importance but, very unfortunately, available methods for such prediction are of doubtful validity. The main reason for this is that the available data and methods have been based on measurements on smaller diameter tubes (typically 25-75 mm) and on the interpretation of these measurements in terms of the flow patterns occurring in such tubes. These flow patterns are typically bubble, slug, churn and annular flows. The limited amount of data available shows that the flow patterns in larger tubes may be quite different and that, within a given flow pattern, the detailed phenomena may also be different. For instance, there are reasons to believe that slug flow of the normal type (with liquid slugs separated by Taylor bubbles of classical shape) may not exist in large pipes. Methods to predict such flows with confidence will be improved significantly by means of an integrated programme of work at three universities (Nottingham, Cranfield and Imperial College) which will involve both larger scale investigations as well as investigations into specific phenomena at a more intimate scale together with modelling studies. Large facilities at Nottingham and Cranfield will be used for experiments in which the phase distribution about the pipe cross section will be measured using novel instrumentation which can handle a range of fluids. The Cranfield tests will be at a very large diameter (250 mm) but will be confined to vertical, air/water studies with special emphasis on large bubbles behaviour. In contrast those at Nottingham will employ a slightly smaller pipe diameter (125 mm) but will use newly built facilities in which a variety of fluids can be employed to vary physical properties systematically and can utilise vertical and slightly inclined test pipes. The work to be carried out at Imperial College will be experimental and numerical. The former will focus on examining the spatio-temporal evolution of waves in churn and annular flows in annulus geometries; the latter will use interface-tracking methods to perform simulations of bubbles in two-phase flow and will also focus on the development of a computer code capable of predicting reliably the flow behaviour in large diameter pipes. This code will use as input the information distilled from the other work-packages regarding the various flow regimes along the pipe.

This proposal addresses the vital issue of prediction of multiphase flows in large diameter risers in off-shore hydrocarbon recovery. The riser is essentially a vertical or near-vertical pipe connecting the sea-bed collection pipe network (the flowlines) to a sea-surface installation, typically a floating receiving and processing vessel. In the early years of oil and gas exploration and production, the oil and gas companies selected the largest and most accessible off-shore fields to develop first. In these systems, the risers were relatively short and had modest diameters. However, as these fields are being depleted, the oil and gas companies are being forced to look further afield for replacement reserves capable of being developed economically. This, then, has led to increased interest in deeper waters, and harsher and more remote environments, most notably in the Gulf of Mexico, the Brazilian Campos basin, West of Shetlands and the Angolan Aptian basin. Many of the major deepwater developments are located in water depths exceeding 1km (e.g. Elf's Girassol at 1300m or Petrobras' Roncador at 1500-2000m). To transport the produced fluids in such systems with the available pressure driving forces has led naturally to the specification of risers of much greater diameter (typically 300 mm) than those used previously (typically 75 mm). Investments in such systems have been, and will continue to be, huge (around $35 billion up to 2005) with the riser systems accounting for around 20% of the costs. Prediction of the performance of the multiphase flow riser systems is of vital importance but, very unfortunately, available methods for such prediction are of doubtful validity. The main reason for this is that the available data and methods have been based on measurements on smaller diameter tubes (typically 25-75 mm) and on the interpretation of these measurements in terms of the flow patterns occurring in such tubes. These flow patterns are typically bubble, slug, churn and annular flows. The limited amount of data available shows that the flow patterns in larger tubes may be quite different and that, within a given flow pattern, the detailed phenomena may also be different. For instance, there are reasons to believe that slug flow of the normal type (with liquid slugs separated by Taylor bubbles of classical shape) may not exist in large pipes. Methods to predict such flows with confidence will be improved significantly by means of an integrated programme of work at three universities (Nottingham, Cranfield and Imperial College) which will involve both larger scale investigations as well as investigations into specific phenomena at a more intimate scale together with modelling studies. Large facilities at Nottingham and Cranfield will be used for experiments in which the phase distribution about the pipe cross section will be measured using novel instrumentation which can handle a range of fluids. The Cranfield tests will be at a very large diameter (250 mm) but will be confined to vertical, air/water studies with special emphasis on large bubbles behaviour. In contrast those at Nottingham will employ a slightly smaller pipe diameter (125 mm) but will use newly built facilities in which a variety of fluids can be employed to vary physical properties systematically and can utilise vertical and slightly inclined test pipes. The work to be carried out at Imperial College will be experimental and numerical. The former will focus on examining the spatio-temporal evolution of waves in churn and annular flows in annulus geometries; the latter will use interface-tracking methods to perform simulations of bubbles in two-phase flow and will also focus on the development of a computer code capable of predicting reliably the flow behaviour in large diameter pipes. This code will use as input the information distilled from the other work-packages regarding the various flow regimes along the pipe.