Investigation of solid particle erosion‐related failures in once‐through steam generators (<scp>OTSGs</scp>) in oil sands in‐situ production: The limitations of the <scp>API RP 14E</scp> guideline in <scp>OTSG</scp> design or operational decision‐making

The required steam for steam-assisted gravity drainage (SAGD) oil sands operations is generated using a once-through generator (OTSG) that fed with relatively poor quality process water. Industries have reported possible solid particle erosion-related failure in the OTSG boiler tubes because of transport precipitated dense inorganic particles. However, presence other damage mechanisms, e.g. corrosion, flow accelerated corrosion (FAC), often masks evidence erosive wear. Also, industries set an upper limit operating velocity API RP 14E guideline, which provides no quantitative erosion rates to determine envelope. This study presents computational fluid dynamics (CFD) analysis SAGD tube. results revealed may not be effective decision-making tool system. For example, 10% increase velocity, even at conditions below threshold, showed decrease time by 40%–50%.