Influence of the operation pressure on slug length in near horizontal gas–liquid pipe flow

Slug flow is commonly observed in gas production offshore fields. At high operation pressure only short hydrodynamic slugs are observed. However, as the offshore fields become older, the operation pressure becomes lower and long slugs may form. At near atmospheric pressures the long slugs may reach a size of 500 pipe diameters or more. Such slugs can cause serious operational failures due to the strong fluctuating pressure. Identifying the operation pressure conditions at which the long slugs appear, may reduce or prevent these negative effects.     

Prediction of the transition from stratified to slug flow or roll-waves in gas–liquid horizontal pipes

In stratified gas–liquid horizontal pipe flow, growing long wavelength waves may reach the top of the pipe and form a slug flow, or evolve into roll-waves. At certain flow conditions, slugs may grow to become extremely long, e.g. 500 pipe diameter. The existence of long slugs may cause operational upsets and a reduction in the flow efficiency. Therefore, predicting the flow conditions at which the long slugs appear contributes to a better design and management of the flow to maximize the flow efficiency.     

The flow pattern map of a two-phase non-Newtonian liquid–gas flow in the vertical pipe

A map for the determination of flow pattern for two-phase flow of gas and non-Newtonian liquid in the vertical pipe has been presented. Our own experimental data confirm applicability of such a map.     

On the accuracy of gas flow rate measurements in gas–liquid pipe flows by cross-correlating dual wire-mesh sensor signals

This article presents an assessment of the accuracy of gas flow rate measurement in gas–liquid pipe flows by cross-correlating dual wire-mesh sensor signals. The differences between the estimated and the actual gas superficial velocities in different flow regimes were analyzed. It was demonstrated that this gas flow rate measurement method is susceptible to significant systematic errors, some of which are inherent to the use of cross-correlation and others which are specific to wire-mesh sensors. It was concluded that this method would be accurate only for flow conditions within narrow ranges.     

Prediction of mono-disperse gas–liquid turbulent flow in a vertical pipe

A two-fluid model in the Eulerian–Eulerian framework has been implemented for the prediction of gas volume fraction, mean phasic velocities, and the liquid phase turbulence properties for gas–liquid upward flow in a vertical pipe. The governing two-fluid transport equations are discretized using the finite volume method and a low Reynolds number $k-\varepsilon$ model is used to predict the turbulence field for the continuous liquid phase. In the present analysis, a fully developed one-dimensional flow is considered where the gas volume fraction profile is predicted using the radial force balance for the bubble phase. The current study investigates: (1) the turbulence modulation terms which represent the effect of bubbles on the liquid phase turbulence in the k–ε transport equations; (2) the role of the bubble induced turbulent viscosity compared to turbulence generated by shear; and (3) the effect of bubble size on the radial forces which results in either a center-peak or a wall-peak in the gas volume fraction profiles. The results obtained from the current simulation are generally in good agreement with the experimental data, and somewhat improved over the predictions of some previous numerical studies.     

One-way coupled fluid–structure interaction of gas–liquid slug flow in a horizontal pipe: Experiments and simulations

Pipelines conveying a multiphase mixture must withstand the cyclic induced stresses that occur due to the alternating motion of gas pockets and liquid slugs. Few previous studies have considered gas–liquid slug flow and the associated fluid–structure interaction problems. In this study, experimental and numerical techniques were adopted to simulate and analyze the two-phase slug flow and the associated stresses in the pipe structure. In the numerical simulation, a one-way coupled fluid–structure framework was developed to explore the slug flow interaction with a horizontal pipe assembly under various superficial gas and liquid velocities. A modified Volume of Fluid and finite element methods were utilized to model the fluid and structure domains. The file-based coupling technique was adopted to execute the coupling mechanism. By contrast, slug characteristics were measured experimentally, while Bi-axial strain gauges were used to capture time-varying strain signals. Excellent agreements between the predicted and measured stress results were achieved with a maximum error of 10.2 %. It was found that at constant superficial liquid velocity, the maximum induced stresses on the pipe wall increased with increasing the slug length and slug velocity. While for the slug frequency, the maximum principal stresses decreased with increasing the slug frequency.     

The formation of hydrodynamic slugs by the interaction of waves in gas–liquid two-phase pipe flow

This paper examines the effects of wave interaction on the formation of hydrodynamic slugs in two-phase pipe flow at relatively low gas and liquid superficial velocities. The experiments were conducted using a horizontal 31 m long, D = 10 cm internal diameter transparent pipe at atmospheric pressure. High resolution photography allowed the location of the gas–liquid interface to be measured with a high degree of accuracy at 5 Hz. Image analysis allowed individual waves to be tracked over a 14D section of the pipe. Regular waves having similar properties such as speed, amplitude and length were seen far from the region of slug formation. However, near the transition region, where hydrodynamic slugs were formed, significant differences between wave properties were observed which resulted in wave interaction leading to a type of sub-harmonic resonance and slug formation. The formation of hydrodynamic slugs due to wave interaction differs from predictions for slug formation using long wavelength stability theory. The properties of the waves were quantified which gave detailed information on the resonance mechanism found near the transition to slugging.     

Structures in gas–liquid churn flow in a large diameter vertical pipe

Gas–Liquid two phase co-current flow in a vertical riser with an internal diameter of 127 mm was investigated in the churn flow pattern. This paper presents detailed experimental data obtained using a Wire Mesh Sensor. It shows that the most obvious features of the flow are huge waves travelling on the liquid film. Wisps, large tendrils of liquid and the product of incomplete atomisation, which had previously detected in smaller diameter pipes, have also been found in the larger diameter pipe employed here. The output of the Wire Mesh Sensor has been used to determine the overall void fraction. When examined within a drift flux framework, it shows a distribution coefficient of ∼1, in contrast to data for lower gas flow rates. Film thickness time series extracted from the Wire Mesh Sensor output have been examined and the trends of mean film thickness, that of the base film and the wave peaks are presented and discussed. The occurrence of wisps and their frequencies have been quantified.     

An appraisal of liquid–liquid slug flow in different pipe orientations

Gas–liquid slug flow occurs over a wide range of phase flow rates and in a variety of practical applications during gas–liquid two-phase flows. The range of slug flow increases further in narrow pipes (<0.0254 m), undulated pipelines, riser tube, etc. On the other hand, the past literature shows that slug flow is rarely observed for liquid–liquid cases. In the present study, an interest was felt to investigate whether liquid–liquid slug flow occurs in situations known for excessive slugging in gas–liquid cases. For this, experiments have been performed in narrow (0.012 m ID) vertical and horizontal pipes and an undulated pipeline of 0.0254 m internal diameter where the V-shaped undulation comprises of an uphill and a downhill section between two horizontal pipes. The studies have been performed for both peak and valley orientation of the undulation. Kerosene and water have been selected as the test fluids and the optical probe technique has been used to supplement visual observations especially at higher flow rates. The studies have revealed the existence of the slug flow pattern over a wide range of phase flow rates in all the three geometries. Interestingly, it has been noted that the introduction of an undulation induces flow patterns which bear a closer resemblance to gas–liquid flows as compared to liquid–liquid flows through a horizontal pipe of 0.0254 m diameter.     

Prediction of the entrained liquid fraction in vertical annular gas–liquid two-phase flow

The study considers the prediction of the entrained liquid fraction in adiabatic gas–liquid annular two-phase flow in vertical pipes. Nine empirical correlations have been tested against an experimental data bank drawn together in this study containing 1504 points for 8 different gas–liquid combinations and 19 different tube diameters from 5.00 mm to 57.1 mm. The correlation of Sawant, Ishii and Mishima and the one of Oliemans, Pots and Trompé were found to best reproduce the available data. A new correlating approach, derived from both physical intuition and dimensional analysis and capable of providing further physical insight into the liquid film atomization process, was proposed and worked better than any of the existing methods. This new correlation is based on the core flow Weber number that is also a controlling dimensionless group in determining the wall shear stress and associated frictional pressure gradient of annular flows.     

Multi-scale particle dynamics of low air velocity in a horizontal self-excited gas–solid two-phase pipe flow

The particle fluctuation velocities of a horizontal self-excited gas–solid two-phase pipe flow with soft fins near MPD (minimum pressure drop) air velocity are first measured by high-speed PIV in the acceleration and fully-developed regimes. Then orthogonal wavelet multi-resolution analysis and power spectrum are used to reveal multi-scale characteristics of particle fluctuation velocity. It is observed that the pronounced peaks of the spectra of axial and vertical fluctuation velocities appear in the range of low frequency near the bottom of pipe. These peaks of spectra become larger and their frequencies decrease by using fins. In the range of low frequencies (3–25 Hz), the wavelet components of the fluctuating energy of axial particle velocity make the main contribution accounting for 87% and 93% respectively for non-fin and using fins near the bottom of pipe. In the range of relatively high frequency (50–400 Hz), however, the wavelet components of using fins, accounting for about 49%, become smaller than that of non-fin, accounting for about 72%, in the suspension flow regime near the top of pipe. The skewness factor of axial particle fluctuation velocity indicates that the wavelet components follow the Gaussian probability distribution as the central frequency decreases.     

A growth model for dynamic slugs in gas–liquid horizontal pipes

Long liquid slugs, with sizes reaching 500 pipe diameters or more, may form in gas–liquid horizontal pipe flow at intermediate liquid loadings. Such slugs cause serious operational upsets due to the strong fluctuations in flow supply and pressure. Therefore, predicting the transition from short (hydrodynamic) to long slug flow regimes may play a significant role in preventing or reducing the negative effects caused by the long slugs.     

Friction factor correlations for gas–liquid/liquid–liquid flows with drag-reducing polymers in horizontal pipes

In the present paper, two correlations have been developed to predict the effect of DRP on friction factor of two-phase flow for any pipe diameter. The correlations have been verified using published experimental results of DRP added to air–liquid annular flow and for oil–water flows with any flow pattern at the asymptotic state (maximum drag reduction). Such correlations are not available in literature and considered to be very useful in predicting the drag reduction using DRP and in understanding the most significant parameters that affecting the mechanism of drag reduction by polymers in multiphase flow.     

An experimental study of the first normal stress difference — shear stress relationship in simple shear flow for concentrated shear thickening suspensions

For many polymeric solutions in a simple shear flow a plot of the logarithm of the first normal stress difference N ₁ against the logarithm of the shear stress , for a range of temperatures results in a linear relationship. For such polymer solutions these plots yield a straight line of slope very close to 2 when measured at low shear rates. This relationship is tested against a polymer solution (polyacrylamide in a 50/50 mixture of glycerol/water), a polymer melt (polyethylene), and three concentrated suspensions. These are Superclay (supplied by English China Clays, Cornwall, U.K.) in water, polyvinylchloride in dioctylphthalate and polystyrene latex in water, at volume concentrations of 40% 48%, and 60%, respectively. It was found that the log N ₁ — log relationship is applicable to the polymer solution and melt over a significant range of shear rates and temperatures. In the cases of concentrated suspensions the relationship holds to the point of onset of the shear thickening behaviour. Beyond this point a different relationship exists, however, flow instabilities are apparent. A comment on the contribution of N ₁ and N ₂ to the flow instabilities is made.     

A coupled model for simulation of the gas–liquid two-phase flow with complex flow patterns

A new model coupling two basic models, the model based on interface tracking method and the two-fluid model, for simulating gas–liquid two-phase flow is presented. The new model can be used to simulate complex multiphase flow in which both large-length-scale interface and small-length-scale gas–liquid interface coexist. By the physical state and the length scale of interface, three phases are divided, including the liquid phase, the large-length-scale-interface phase (LSI phase) and the small-length-scale-interface phase (SSI phase). A unified solution framework shared by the two basic models is built, which makes it convenient to perform the solution process. Based on the unified solution framework, the modified MCBA–SIMPLE algorithm is employed to solve the Navier–Stokes equations for the proposed model. A special treatment called “volume fraction redistribution” is adopted for the special grids containing all three phases. Another treatment is proposed for the advection of large-length-scale interface when some portion of SSI phase coalesces into LSI phase. The movement of the large-length-scale interface is evaluated using VOF/PLIC method. The proposed model is equivalent to the two-fluid model in the zone where only the liquid phase and the SSI phase are present and to the model based on interface tracking method in the zone where only the liquid phase and the LSI phase are present. The characteristics of the proposed model are shown by four problems.     

Effect of drag reducing polymers on oil–water flow in a horizontal pipe

Measurements of drag-reduction are presented for oil–water flowing in a horizontal 0.0254 m pipe. Different oil–water configurations were observed. The injection of water soluble polymer solution (PDRA) in some cases produced drag reduction of about 65% with concentration of only 10–15 ppm. The results showed a significant reduction in pressure gradient due to PDRA especially at high mixture velocity which was accompanied by a clear change in the flow pattern. Phase inversion point in dispersed flow regime occurred at a water fraction range of (0.33–0.35) indicated by its pressure drop peak which was disappeared by injecting only 5 ppm (weight basis) of PDRA. Effect of PDRA concentration and molecular weight on flow patterns and pressure drops are presented in this study. Influence of salt content in the water phase on the performance of PDRA is also examined in this paper.     

Prediction of void fraction for gas–liquid flow in horizontal,upward and downward inclined pipes using artificial neural network

In this work, the ability of artificial neural networks (ANNs) to predict void fraction of gas–liquid two–phase flow in horizontal and inclined pipes was investigated. For this purpose, an ANN model was designed and trained using a total of 301 experimental data points reported in the literature for inclination angles between –20° and +20°. Pipe inclination angle as well as superficial Reynolds number of gas (Re_sg) and liquid (Re_sl) were chosen as input parameters of different structures of multilayer perceptron (MLP) neural networks, while the corresponding void fraction was selected as their output parameter. A hyperbolic tangent sigmoid and a linear function were employed as transfer functions of hidden and output layers, respectively, and Levenberg–Marquardt back propagation algorithm was used to train the networks. By trial–and–error method, a three–layer network with 10 neurons in the hidden layer was achieved as optimal structure of the ANN which made it possible to predict the void fraction with a high accuracy. Mean absolute percent error (MAPE) of 1.81% and coefficient of determination (R²) of 0.9976 for training data and MAPE of 1.52% and R² value of 0.9948 for testing data were obtained. Also for all data, MAPE of 1.95% and R² value of 0.9972 were calculated, and 96% data were within ±5% error band. In addition, the accuracy of the proposed ANN model was compared with the predictions from 17 void fraction correlations available in the literature for different flow patterns and horizontal and inclined flows. For all cases, the proposed ANN model gave better performance than all of the studied correlations. The results confirm the very good capability of the ANNs to predict the void fractions of gas–liquid flow in inclined pipes, regardless of flow pattern. Finally, by performing interpolation using the trained network, the void fraction values for some other conditions were predicted.