Experiments with a Wire-Mesh Sensor for stratified and dispersed oil-brine pipe flow

Two-phase oil–water flow was studied in a 15 m long horizontal steel pipe, with 8.28 cm internal diameter, using mineral oil (having 830 kg/m³ density and 7.5 mPa s viscosity) and brine (1073 kg/m³ density and of 0.8 mPa s viscosity). Measurements of the holdup and of the cross-sectional phase fraction distribution were obtained for stratified flow and for highly dispersed oil–water flows, applying a capacitive Wire-Mesh Sensor specially designed for that purpose. The applicability of this measurement technique, which uses a circuit for capacitive measurements that is adapted to conductive measurements, where one of the fluids is water with high salinity (mimicking sea water), was assessed. Values for the phase fraction values were derived from the raw data obtained by the Wire-Mesh Sensor using several mixture permittivity models. Two gamma-ray densitometers allowed the accurate measurement of the holdups, which was used to validate the data acquired with the capacitive Wire-Mesh Sensor. The measured time-averaged distribution of the phase fraction over the cross-sectional area was used to investigate the details of the observed two-phase flow patterns, including the interface shape and water height. The experiments were conducted in the multiphase-flow test facility of Shell Global International B.V. in the Netherlands.     

Void fraction and pressure drop during external upward two-phase crossflow in tube bundles – part I: Experimental investigation

The present paper is the part I of a broad study concerning void fraction and pressure drop for air-water upward external flow across tube bundles. Experimental results were obtained for liquid and gas superficial velocities ranging from 0.02 to 1.50 m/s and 0.20 to 10.00 m/s, respectively. Void fraction measurements were performed for bubbly flow using a capacitive probe. The test section consisted of a triangular tube bundle counting with 19 mm OD tube and transverse pitch of 24 mm. Initially, the paper describes the test facility and the data regression and experimental procedures. Then, the pressure drop and void fraction measurements are validated based on tests for single-phase flow and quiescent liquid conditions, respectively. Finally, the experimental data are presented and analyzed. In the second part of this study (Part II), a literature review on predictive methods for void fraction and pressure drop is presented. Additionally, these methods are compared with the database presented in Part I and new predictive methods for void fraction and frictional pressure drop are proposed.     

Development of a robust image processing technique for bubbly flow measurement in a narrow rectangular channel

This paper presents a robust image processing technique for bubbly flow measurement over a wide range of void fractions. The proposed algorithm combines geometrical, optical and topological information recorded with high speed cameras to separate and reconstruct the overlapping bubbles. The common difficulties such as overlapping, irregular bubble shape, surface deformation and large clustering in digital image processing are solved by combining different information based on a preset decision table and flow chart. Test with synthetic bubble images is performed to evaluate the reliability of the algorithm and quantify the uncertainty of the data. The result shows that the proposed algorithm can accurately measure bubbly flows with void fraction up to 18% for large bubbles. Four runs of bubbly flow images in a 30 mm  ×  10 mm rectangular channel are then recorded by three high speed cameras. The area-averaged void fraction of these test runs range from 2.4% to 9.1%. The axial and lateral distributions of bubble number density are obtained by the present algorithm for studying the characteristics of these flows.     

An investigation of a model of the flow pattern transition mechanism in relation to the identification of annular flow of R134a in a vertical tube using various void fraction models and flow regime maps

In the present study, new experimental data are presented for literature on the prediction of film thickness and identification of flow regime during the co-current downward condensation in a vertical smooth copper tube having an inner diameter of 8.1 mm and a length of 500 mm. R134a and water are used as working fluids in the tube side and annular side of a double tube heat exchanger, respectively. Condensation experiments are done at mass fluxes of 300 and 515 kg m^?2 s^?1. The condensing temperatures are between 40 and 50 °C; heat fluxes are between 12.65 and 66.61 kW m^?2. The average experimental heat transfer coefficient of the refrigerant HFC-134a is calculated by applying an energy balance based on the energy transferred from the test section. A mathematical model by Barnea et al. based on the momentum balance of liquid and vapor phases is used to determine the condensation film thickness of R134a. The comparative film thickness values are determined indirectly using relevant measured data together with various void fraction models and correlations reported in the open literature. The effects of heat flux, mass flux, and condensation temperature on the film thickness and condensation heat transfer coefficient are also discussed for the laminar and turbulent flow conditions. There is a good agreement between the film thickness results obtained from the theoretical model and those obtained from six of 35 void fraction models in the high mass flux region of R134a. In spite of their different valid conditions, six well-known flow regime maps from the literature are found to be predictive for the annular flow conditions in the test tube in spite of their different operating conditions.     

Experimental investigation of horizontal forced-vibration effect on air-water two-phase flow

In order to investigate the potential seismic vibrations effect on two-phase flow in an annular channel, experimental tests with air-water two-phase flow under horizontal vibrations were carried out. A low-speed eccentric-cam vibration module capable of operating at motor speed of 45–1200 rpm (f = 0.75–20 Hz) was attached to an annular channel, which was scaled down from a prototypic BWR fuel sub-channel with inner and outer diameters of 19.1 mm and 38.1 mm, respectively. The two-phase flow was operated in the ranges of 〈j_f〉 = 0.25–1.00 m/s and 〈j_g〉 = 0.03–1.46 m/s with 27 flow conditions, and the vibration amplitudes controlled by cam eccentricity (E) were designed for the range of 0.8–22.2 mm. Ring-type impedance void meters were utilized to detect the area-averaged time-averaged void fraction under stationary and vibration conditions. A systematic experimental database was built and analyzed with effective maps in terms of flow conditions (〈j_g〉-〈j_f〉) and vibration conditions (E-f and f-a), and the potential effects were expressed by regions on the maps. In the 〈j_g〉-〈j_f〉 maps, the void fraction was found to potentially decrease under vibrations in bubbly flow regime and relatively lower liquid flow conditions, which may be explained by the increase of distribution parameter. Whereas and the void fraction may increase at the region closed to bubbly-to-slug transition boundary under vibrations, which may be explained by the changes of drift velocity due to flow regime change from bubbly to slug flows. No significant change in void fraction was found in slug flow regime under the present test conditions.     

Experimental investigation of a developing two-phase bubbly flow in horizontal pipe

Experimental results for various water and air superficial velocities in developing adiabatic horizontal two-phase pipe flow are presented. Flow pattern maps derived from videos exhibit a new boundary line in intermittent regime. This transition from water dominant to water–gas coordinated regimes corresponds to a new transition criterion C_T = 2, derived from a generalized representation with the dimensionless coordinates of Taitel and Dukler.Velocity, turbulent kinetic energy and dissipation rate, void fraction and bubble size radial profiles measured at 40 pipe diameters for J_L = 4.42 m/s by hot film velocimetry and optical probes confirm this transition: the gas influence is not continuous but strongly increases beyond J_G = 0.06 m/s. The maximum dissipation rate, derived from spectra, is increased in two-phase flow by a factor 5 with respect to the single phase case.The axial evolution of the bubble intercept length histograms also reveal the flow organization in horizontal layers, driven by buoyancy effects. Bubble coalescence is attested by a maximum bubble intercept evolving from 2.5 to 4.5 mm along the pipe. Turbulence generated by the bubbles is also manifest by the 4-fold increase of the maximum turbulent dissipation rate along the pipe.     

Local flow structure beyond bubbly flow in large diameter channels

A thorough review of the available literature has revealed a significant lack of usable data regarding the transport of interfacial area in large diameter channels. This represents a concern for various industrial systems, but especially for predicting the performance of safety systems in nuclear reactor systems. In order to remedy this gap in the current experimental database a series of experiments has been performed. These experiments included the measurement of the local interfacial area concentration and other parameters using local electrical conductivity probes in pipes with diameters of 0.152 m [6 in.], 0.203 m [8 in.] and 0.304 m [12 in.]. Volumetric fluxes ranged up to 2 m/s [6.56 ft/s] for the liquid phase and 10 m/s [32.8 ft/s] for the gas phase, and two nominal pressure conditions of 180 kPa [26.1 psia] and 280 kPa [40.6 psia] were included. Gas was injected as large cap bubbles in order to provide a basis for evaluating models for cap-bubbly flow at low void fractions. Measurements were performed simultaneously at three axial locations to allow the evaluation of interfacial area transport. The resulting data provides valuable insight into the flow structure and behavior in all flow regimes other than annular flow and will serve as a valuable database for the evaluation of models for predicting the transport of interfacial area across a wide variety of flow conditions and pipe sizes.     

Bubbly-to-cap bubbly flow transition in a long-26 m vertical large diameter pipe at low liquid flow rate

The concurrent upward two-phase flow of air and water in a long vertical large diameter pipe with an inner diameter (D) of 200 mm and a height (z) of 26 m (z/D = 130) was investigated experimentally at low superficial liquid velocities from 0.05009 to 0.3121 m/s and the superficial gas velocities from 0.01779 to 0.5069 m/s. The resultant void fractions range from 0.03579 to 0.4059. According to the observations using a high speed video camera, the flow regimes of bubbly, developing cap bubbly and fully-developed cap bubbly flows prevailed in the flows. The developing cap bubbly flow appeared as a flow regime transition from bubbly to fully-developed cap bubble flow in the vertical large diameter pipe. The developing cap bubbly flow changes gradually and lasts for a long time period and a wide axial region in the flow direction, in contrast to a sudden transition from bubbly to slug flows in a small diameter pipe. The analysis in this study showed that the flow regime transition depends not only on the void fraction but also on the axial distance in the flow and the pipe diameter. The axial flow development brings about the transition to happen in a lower void fraction flow and the increase of pipe diameter causes the transition to happen in a higher void fraction flow. The measured void fraction showed an N-shaped axial changing manner that the void fraction increases monotonously with axial position in the bubbly flow, decreases non-monotonously with axial position in the developing cap bubbly flow, and increases monotonously again with axial position in the fully-developed cap bubbly flow. The temporary void fraction decrease phenomenon in the transition region from bubbly to cap bubbly flow can be attributed to the formation of medium to large cap bubbles and their gradual growth into the maximum size of cap bubble and/or cluster of large cap bubbles in the developing cap bubbly flow. In order to predict the N-shaped axial void fraction changing behaviors in the flow regime transition from bubbly to cap bubbly flow, the existing 12 drift flux correlation sets for large diameter pipes are reviewed and their predictabilities are studied against the present experimental data. Although some drift flux correlation sets, such as those of Clark and Flemmer (1986) and Hibiki and Ishii (2003), can predict the present experimental data with reasonable average relative deviations, no drift flux correlation set for distribution parameter and drift velocity can give a reliable prediction for the observed N-shaped axial void fraction changing behaviors in the region from bubbly to cap bubbly flow in a vertical large diameter pipe.     

Effect of bubble size on void fraction fluctuations in dispersed bubble flows

It is known that bubble size affects seriously the average void fraction in bubbly flows where buoyant velocities vary considerably with bubble size. On the contrary, there is no systematic literature report about bubble size effects on the intensity and frequency of void fraction fluctuations around the average void fraction. This work aims to provide such information. An electrical impedance technique is employed along with non-intrusive ring electrodes to register void fraction fluctuations down to 10⁻⁵. Bubble size fluctuations are estimated from high resolution optical images. Experiments are conducted in co-current upward dispersed bubble flow inside a 21 mm tube with average bubble size between ∼50 and ∼700 μm. Water and blood simulant are used as test liquids with velocity from ∼3 to ∼30 cm s⁻¹. The above resemble conditions of Decompression Sickness (DCS) in the bloodstream of human vena cava. It is found that the intensity and frequency of void fraction fluctuations vary appreciably with bubble size at constant gas and liquid flow rates. Moreover, these variations are not random but scale with bubble size. As a first step to quantify this effect, an empirical expression is derived that relates average bubble size to the ratio standard deviation/average value of void fraction.     

Developing structure of two-phase flow in a large diameter pipe at low liquid flow rate

In order to develop the interfacial area transport equation for the interfacial transfer terms in the two-fluid model, accurate data sets on axial development of local parameters such as void fraction, interfacial area concentration, interfacial gas velocity and Sauter mean diameter are indispensable to verify the modeled source and sink terms in the interfacial area transport equation. From this point of view, local measurements of both group 1 spherical/distorted bubbles and group 2 cap/slug bubbles in vertical upward air–water two-phase flow in a large diameter pipe with 200 mm in inner diameter and 26 m in height were performed at three axial locations of z/D = 41.5, 82.8 and 113 as well as 11 radial locations from r/R = 0–0.95 by using four-sensor probe method. Here, z, r, D and R are the axial distance from the inlet, radial distance from the pipe center, pipe diameter and pipe radius, respectively. The liquid flow rate and the void fraction ranged from 0.0505 m/s to 0.312 m/s and from 1.98% to 32.6%, respectively in the present experiment. The flow condition covered extensive region of bubbly flow, cap turbulent flow as well as their transition. The extensive analysis on the radial profiles of local flow parameters and their axial developments demonstrate the development of interfacial structures along the flow direction due to the bubble coalescence and breakup and the gas expansion. The significant decrease in void faction and interfacial area concentration and the increase in Sauter mean diameter and interfacial velocity were observed when the gradual flow regime transition occurred. Finally, the net change in the interfacial area concentration due to the bubble coalescence and breakup was quantitatively investigated in the present paper to reflect the true transfer mechanisms in observed two-phase flows.     

Measurement and modeling of two-phase flow parameters in scaled 8 × 8 BWR rod bundle

The behavior of reactor systems is predicted using advanced computational codes in order to determine the safety characteristics of the system during various accidents and to determine the performance characteristics of the reactor. These codes generally utilize the two-fluid model for predictions of two-phase flows, as this model is the most accurate and detailed model which is currently practical for predicting large-scale systems. One of the weaknesses of this approach however is the need to develop constitutive models for various quantities. Of specific interest are the models used in the prediction of void fraction and pressure drop across the rod bundle due to their importance in new Natural Circulation Boiling Water Reactor (NCBWR) designs, where these quantities determine the coolant flow rate through the core. To verify the performance of these models and expand the existing experimental database, data has been collected in an 8 × 8 rod bundle which is carefully scaled from actual BWR geometry and includes grid spacers to maintain rod spacing. While these spacer grids are ’generic’, their inclusion does provide valuable data for analysis of the effect of grid spacers on the flow. In addition to pressure drop measurements the area-averaged void fraction has been measured by impedance void meters and local conductivity probes have been used to measure the local void fraction and interfacial area concentration in the bundle subchannels. Experimental conditions covered a wide range of flow rates and void fractions up to 80%.     

Void fraction measurement of bubble and slug flow in a small channel using the multivision technique

Using the multivision technique, a new void fraction measurement method was developed for bubble and slug flow in a small channel. The multivision system was developed to obtain images of the two-phase flow in two perpendicular directions. The obtained images were processed—using image segmentation, image subtraction, Canny edge detection, binarization, and hole filling—to extract the phase boundaries and information about the bubble or slug parameters. With the extracted information, a new void fraction measurement model was developed and used to determine the void fraction of the two-phase flow. The proposed method was validated experimentally in horizontal and vertical channels with different inner diameters of 2.1, 2.9, and 4.0 mm. The proposed method of measuring the void fraction has better performance than the methods that use images acquired in only one direction, with a maximum absolute difference between the measured and reference values of less than 6%.     

An experimental investigation of two-phase air–water flow through a horizontal circular micro-channel

This paper is a continuation of the authors’ previous work. Two-phase air–water flow experiments are performed in a horizontal circular micro-channel. The test section is made of a fused silica tube with an inner diameter of 0.15 mm and a length of 104 mm. The flow phenomena, which are liquid/unstable annular alternating flow (LUAAF), liquid/annular alternating flow (LAAF), and annular flow, are observed and recorded by a high-speed camera mounted together with a stereozoom microscope. A flow pattern map is presented in terms of the phase superficial velocities and is compared with those of other researchers obtained from different working fluids. Image analysis is performed to determine the void fraction, which increases non-linearly with increasing volumetric quality. It is revealed that the two-phase frictional multiplier data show a dependence on flow pattern rather than mass flux. Based on the present data, a new pressure drop correlation is proposed for practical applications. According to the present study, in general the data for the two-phase air–water flow characteristics are found to comply with those of working fluids other than air–water mixtures.     

Stratified flow model for convective condensation in an inclined tube

Experimental data are reported for condensation of R134a in an 8.38 mm inner diameter smooth tube in inclined orientations with a mass flux of 200 kg/m² s. Under these conditions, the flow is stratified and there is an optimum inclination angle, which leads to the highest heat transfer coefficient. There is a need for a model to better understand and predict the flow behaviour. In this paper, the state of the art of existing models of stratified two-phase flows in inclined tubes is presented, whereafter a new mechanistic model is proposed. The liquid–vapour distribution in the tube is determined by taking into account the gravitational and the capillary forces. The comparison between the experimental data and the model prediction showed a good agreement in terms of heat transfer coefficients and pressure drops. The effect of the interface curvature on the heat transfer coefficient has been quantified and has been found to be significant. The optimum inclination angle is due to a balance between an increase of the void fraction and an increase in the falling liquid film thickness when the tube is inclined downwards. The effect of the mass flux and the vapour quality on the optimum inclination angle has also been studied.     

Interfacial measurements in stratified types of flow. Part II: Measurements for R-22 and R-410A

A new optical void fraction measurement system has been coupled to a flow boiling test facility to obtain dynamic and time-averaged void fractions in a horizontal tube. A series of evaporation tests have been run for two refrigerants. R-22 was tested under mass velocity conditions of 70, 100, 150 and 200 kg/m² s and R-410A for 70, 150, 200 and 300 kg/m² s in a 13.6 mm diameter glass tube. Using our newly developed image processing system, about 227 000 images have been analyzed in this study to provide the same number of dynamic void fraction measurements. From these images, 238 time-averaged void fraction values have been obtained for vapor qualities from 0.01 to 0.95. These experimental points show very good agreement with the horizontal version of the Rouhani–Axelsson drift flux void fraction model.     

Flow characteristics in hydraulically equilibrium two-phase flows in a vertical 2 × 3 rod bundle channel

In order to increase data on two-phase flow distribution in a multi-subchannel system, being similar to a rod bundle, experiments have been carried out using water and air at ambient pressure and temperature as the working fluids and a newly constructed 2 × 3 rod bundle channel as the test channel. The channel contained six rods in rectangular array and two-kinds of six subchannels, simulating a BWR fuel rod bundle. Experimental data on flow distribution and pressure drop along each subchannel axis were obtained in various single- and two-phase flows under a hydraulic equilibrium flow condition. From the measured pressure drop in the single-phase flow, friction factor data in each subchannel were obtained. The two-phase pressure drop data were compared with calculations by a simple, one-dimensional, one-pressure two-fluid model. In addition, Taylor bubble velocity in each subchannel in slug-churn flows was measured with a double needle contact probe. Using the bubble velocity data, we obtained a subchannel void fraction in each subchannel, and discussed a relationship of the subchannel void fractions between two different subchannels. Results of such experiments and discussions are presented in this paper.     

Mass flow rate measurements in gas–liquid flows by means of a venturi or orifice plate coupled to a void fraction sensor

Two-phase flow measurements were carried out using a resistive void fraction meter coupled to a venturi or orifice plate. The measurement system used to estimate the liquid and gas mass flow rates was evaluated using an air–water experimental facility. Experiments included upward vertical and horizontal flow, annular, bubbly, churn and slug patterns, void fraction ranging from 2% to 85%, water flow rate up to 4000 kg/h, air flow rate up to 50 kg/h, and quality up to almost 10%. The fractional root mean square (RMS) deviation of the two-phase mass flow rate in upward vertical flow through a venturi plate is 6.8% using the correlation of Chisholm (D. Chisholm, Pressure gradients during the flow of incompressible two-phase mixtures through pipes, venturis and orifice plates, British Chemical Engineering 12 (9) (1967) 454–457). For the orifice plate, the RMS deviation of the vertical flow is 5.5% using the correlation of Zhang et al. (H.J. Zhang, W.T. Yue, Z.Y. Huang, Investigation of oil–air two-phase mass flow rate measurement using venturi and void fraction sensor, Journal of Zhejiang University Science 6A (6) (2005) 601–606). The results show that the flow direction has no significant influence on the meters in relation to the pressure drop in the experimental operation range. Quality and slip ratio analyses were also performed. The results show a mean slip ratio lower than 1.1, when bubbly and slug flow patterns are encountered for mean void fractions lower than 70%.     

Irreversible thermodynamics of triple junctions during the intergranular void motion under the electromigration forces

A rigorous reformulation of internal entropy production and the rate of entropy flow is developed for multi-component systems consisting of heterophases, interfaces and/or surfaces. The result is a well-posed moving boundary value problem describing the dynamics of curved interfaces and surfaces associated with voids and/or cracks that are intersected by grain boundaries. Extensive computer simulations are performed for void configuration evolution during intergranular motion. In particular we simulate evolution resulting from the action of capillary and electromigration forces in thin film metallic interconnects having a “bamboo” structure, characterized by grain boundaries aligned perpendicular to the free surface of the metallic film interconnects. Analysis of experimental data utilizing previously derived mean time to failure formulas gives consistent values for interface diffusion coefficients and enthalpies of voids. 3.0 × 10⁻⁶ exp(−0.62 eV/kT) m² s⁻¹ is the value obtained for voids that form in the interior of the aluminum interconnects without surface contamination. 6.5 × 10⁻⁶ exp(−0.84 eV/kT) m² s⁻¹ is obtained for those voids that nucleate either at triple junctions or at the grain boundary-technical surface intersections, where the chemical impurities may act as trap centers for hopping vacancies.     

Void fraction and pressure waves in a transient horizontal slug flow

The void fraction and the pressure waves in an air–water mixture flowing in the slug regime are experimentally investigated in a horizontal line. The test section is made of a transparent Plexiglas pipe with 26 mm ID and 26.24 m long, operating at ambient temperature and pressure. The flow induced transients are made by quickly changing the air or the water inlet velocity. The test grid has four operational points. This choice allows one to create expansion and compression waves due to the changes to the gas or to the liquid. Each experimental run is repeated 100 times to extract an ensemble average capable of filtering out the intrinsic flow intermittence and disclosing the void fraction and pressure waves’ features. The slug flow properties such as the bubble nose translational velocity, the lengths of liquid film underneath the bubble and the liquid slug are also measured. The objective of the work is two-fold: access the main characteristics of the void fraction and pressure waves and disclose the mechanics of the transient slug flow as described through the changes of the slug flow properties.