A Direct-Measurement Method for Characterizing Wall Shear in Harsh Fluids

Abstract Wall shear stress is a key parameter in many oil and gas flow processes, including corrosion, erosion, and flow assurance challenges. However, it is typically inferred from indirect methods—such as pressure gradients or velocity profiles—which introduce uncertainty, especially in complex or multiphase systems. This study presents a feasibility demonstration of direct wall shear stress sensors in a controlled liquid flow environment using a Taylor-Couette apparatus. A total of four contoured shear sensors were embedded flush with the surface of the rotating inner cylinder to enable real-time, direct shear measurement. Experiments were conducted using Clearco 1000 cSt dimethylsiloxane oil (dynamic viscosity ≈ 0.97 Pa·s), a Newtonian fluid selected to provide stable, high-viscosity conditions. The system was operated over a range of inner cylinder speeds from 100 to 1500 RPM, producing analytically predicted shear stress values from approximately 7 to 200 Pa. Sensor outputs were compared against analytical predictions for laminar Taylor-Couette flow and validated with computational fluid dynamics (CFD) simulations. Across all conditions, the sensors exhibited strong linear response and stable performance, with an average deviation of 8.89% from theoretical values. These results confirm that direct shear sensors can reliably resolve wall shear stress in high-viscosity, single-phase liquid flows. Their accuracy, repeatability, and real-time capability position them as a valuable diagnostic tool for oil and gas applications—including corrosion rate estimation, erosion monitoring, and the improvement of flow assurance models in laboratory and field-scale systems.