Experimental study on the air/water counter-current flow limitation in a model of the hot leg of a pressurized water reactor

An experimental investigation on the air/water counter-current two-phase flow in a horizontal rectangular channel connected to an inclined riser has been conducted. This test-section representing a model of the hot leg of a pressurized water reactor is mounted between two separators in a pressurized experimental vessel. The cross-section and length of the horizontal part of the test-section are (0.25 m × 0.05 m) and 2.59 m, respectively, whereas the inclination angle of the riser is 50°. The flow was captured by a high-speed camera in the bended region of the hot leg, delivering a detailed view of the stratified interface as well as of dispersed structures like bubbles and droplets. Countercurrent flow limitation (CCFL), or the onset of flooding, was found by analyzing the water levels measured in the separators. The counter-current flow limitation is defined as the maximum air mass flow rate at which the discharged water mass flow rate is equal to the inlet water mass flow rate.From the high-speed observations it was found that the initiation of flooding coincides with the formation of slug flow. Furthermore, a hysteresis was noticed between flooding and deflooding. The CCFL data was compared with similar experiments and empirical correlations available in the literature. Therefore, the Wallis-parameter was calculated for the rectangular cross-sections by using the channel height as length, instead of the diameter. The agreement of the CCFL curve is good, but the zero liquid penetration was found at lower values of the Wallis parameter than in most of the previous work. This deviation can be attributed to the special rectangular geometry of the hot leg model of FZD, since the other investigations were done for pipes.     

CFD studies on the phenomena around counter-current flow limitations of gas/liquid two-phase flow in a model of a PWR hot leg

In order to improve the understanding of counter-current two-phase flow and to validate new physical models, CFD simulations of a 1/3rd scale model of the hot leg of a German Konvoi pressurized water reactor (PWR) with rectangular cross section were performed. Selected counter-current flow limitation (CCFL) experiments conducted at Helmholtz-Zentrum Dresden-Rossendorf (HZDR) were calculated with ANSYS CFX using the multi-fluid Euler–Euler modelling approach. The transient calculations were carried out using a gas/liquid inhomogeneous multiphase flow model coupled with a shear stress transport (SST) turbulence model.In the simulation, the drag law was approached by a newly developed correlation of the drag coefficient (Höhne and Vallée, 2010) in the Algebraic Interfacial Area Density (AIAD) model. The model can distinguish the bubbles, droplets and the free surface using the local liquid phase volume fraction value. A comparison with the high-speed video observations shows a good qualitative agreement. The results indicate also a quantitative agreement between calculations and experimental data for the CCFL characteristics and the water level inside the hot leg channel.     

Study of countercurrent flow limitation in a horizontal pipe connected to an inclined one

Experiments with air and water in small hot leg reproductions were carried out aiming to acquire a better understanding of the countercurrent flow limitation (CCFL) in this geometry. The effects of various geometrical parameters of the test section and of the inlet water flow rate on the onset of flooding, on the partial delivery of water and on the zero liquid penetration were investigated. It was observed that while the onset of flooding is affected by the inlet water flow rate, the zero liquid penetration is independent of this flow rate. The results with partial delivery showed that, for a fixed air velocity, an increase in the horizontal length, or in the inclined length, of the flow channel leads to an increase of the water carried over by the air. On the other hand, in pipes with larger diameters the drag of the water is smaller. The experimental results showed small differences in the results for tests with inclination of the riser lower than 90°. For an inclination equal to 90°, the water carried by the air tends to be lower than in the others angles for a fixed air velocity. The study led also to a new correlation for the flooding.     

Experimental CFD grade data for stratified two-phase flows

Stratified two-phase flows were investigated at two test facilities with horizontal test-sections. For both, rectangular channel cross-sections were chosen to provide optimal observation possibilities for the application of optical measurement techniques. In order to show the local flow structure, high-speed video observation was applied, which delivers the high-resolution in space and time needed for CFD code validation.The first investigations were performed in the Horizontal Air/Water Channel (HAWAC), which is made of acrylic glass and allows the investigation of air/water co-current flows at atmospheric pressure and room temperature. At the channel inlet, a special device was designed for well-defined and adjustable inlet boundary conditions. For the quantitative analysis of the optical measurements performed at the HAWAC, an algorithm was developed to recognise the stratified interface in the camera frames. This allows to make statistical treatments for comparison with CFD calculation results. As an example, the unstable wave growth leading to slug flow is shown from the test-section inlet. Moreover, the hydraulic jump as the quasi-stationary discontinuous transition between super- and subcritical flow was investigated in this closed channel. The structure of the hydraulic jump over time is revealed by the calculation of the probability density of the water level. A series of experiments show that the hydraulic jump profile and its position from the inlet vary substantially with the inlet boundary conditions due to the momentum exchange between the phases.The second channel is built in the pressure chamber of the TOPFLOW test facility, which is used to perform air/water and steam/water experiments at pressures of up to 5.0 MPa and temperatures of up to 264 °C, but under pressure equilibrium with the vessel inside. In the present experiment, the test-section represents a flat model of the hot leg of the German Konvoi pressurised water reactor scaled at 1:3. The investigations focus on the flow regimes observed in the region of the elbow and of the steam generator inlet chamber, which are equipped with glass side walls. An overview of the experimental methodology and of the acquired data is given. These cover experiments without water circulation, which can be seen as test cases for CFD development, as well as counter-current flow limitation experiments, representing transient validation cases of a typical nuclear reactor safety issue.     

Assessment of RELAP5/MOD3.2.2γ against flooding database in horizontal-to-inclined pipes

A total of 356 experimental data for the onset of flooding are compiled for the data bank and used for the assessment of RELAP5/MOD3.2.2γ predictions of counter-current flow limitation (CCFL) in horizontal-to-inclined pipes simulating a PWR hot leg. RELAP5 calculations show that higher gas flow rates are required to initiate the flooding compared with the experimental data if the L/D is as low as that of the hot legs of typical PWRs. Based on the present data bank, the new CCFL correlation is derived, which shows the L/D effect. The present correlation agrees well with the database within the prediction error, 8.7% and it is implemented into the RELAP5 and validated against the data bank. The predictions of the flooding limit by the modified version lie well on the applied CCFL curve if the L/D is lower than 22, which is the case of the hot legs of typical PWRs.     

Air—water model studies of cocurrent flow into and along a PWR hot leg to the steam generator

An experimental study is made of the cocurrent flow of air and water at atmospheric pressure from a reactor vessel into and along an approximately ninth-scale replica of the Sizewell ‘B’ PWR hot leg to the steam generator. A flow regime map of conditions in the hot leg is presented.The water interface level in the reactor vessel as a function of the flowrates is in agreement with a recent theory developed by the author. The same theory predicts the level in the hot leg when discharging two phases through a horizontal break and is in agreement with the results of other workers on this subject for the discharge of air and water up to a pressure of 5 bar and of steam and water up to a pressure of 62 bar.Results on the water level in the hot leg are correlated empirically but, for lower flowrates, the results are in approximate agreement with a theory for the onset of flooding.     

Correlation for countercurrent flow limitation in a PWR hot leg

Numerical simulations were done to evaluate countercurrent flow limitation (CCFL) characteristics in a pressurized water reactor (PWR) hot leg with the diameter of 750 mm by using a volume of fluid (VOF) method implemented in the CFD software, FLUENT6.3.26. The calculated CCFL characteristics agreed well with known values including the UPTF data at 1.5 MPa. Sensitivity analyses for system pressures up to 8 MPa showed that the calculated CCFL characteristics in the Wallis diagram were slightly mitigated from 0.1 MPa to 1.5 MPa with increasing system pressure, but they did not change from 1.5 MPa to 8MPa. Using the CCFLs calculated in this study and values measured under air–water and steam–water conditions, a CCFL correlation and its uncertainty were derived.     

Counter-current flow limitations during hot leg injection in pressurized water reactors

A one-dimensional model is presented to predict counter-current flow limitations during hot leg injection in pressurized water reactors. Different from previous models, it may also be applied in case of high Froude numbers of the liquid flow, such as to be expected in the case of emergency coolant injection through the hot leg. The model has been verified with an extensive experimental program performed in the WENKA test facility at the Forschungszentrum Karlsruhe. Typical flow regimes were investigated for a wide range of flow conditions, simulated with air and water at ambient pressure and temperature, in a simplified Pressurized Water Reactor (PWR) hot leg geometry. Depending on the water and air flow rates, flow phenomena such as a hydraulic jump and flow reversal were experimentally observed. The theoretical model shows that not only the nondimensional superficial velocities of liquid and gas, but also the Froude number of the liquid at the injection point and the Reynolds number of the gas play an important role for the prediction of flow reversal. In case of a high liquid inlet Froude number, a flow reversal could only be observed if the liquid flow became locally subcritical, i.e. if a hydraulic jump occurred in the channel. The flow reversal is predicted by the presented model with good accuracy.     

Prediction of counter-current flow limitation at hot leg pipe during a small-break LOCA

The possibility of hot leg flooding during reflux condensation cooling after a small-break loss-of-coolant accident in a nuclear power plant is evaluated. The vapor and liquid velocities in hot leg and steam generator tubes are calculated during reflux condensation cooling with the accident scenarios of three typical break sizes, 0.13, 1.02 and 10.19% cold leg break. The effect of initial water level to counter-current flow limitation is taken into account. It is predicted that the hot leg flooding is precluded when all steam generators are available for heat removal. It is also shown that both hot leg flooding and SG flooding are possible under the operation of one steam generator. Therefore, it can be said that the occurrence of hot leg flooding under reflux condensation cooling is possible when the number of steam generators available for heat removal is limited.     

One-dimensional three-field model of condensation in horizontal countercurrent flow with supercritical liquid velocity

A one-dimensional three-field model was developed to predict the flow of liquid and vapor that results from countercurrent flow of water injected into the hot leg of a PWR and the oncoming steam flowing from the upper plenum. The model solves the conservation equations for mass, momentum, and energy in a continuous-vapor field, a continuous-liquid field, and a dispersed-liquid (entrained-droplet) field. Single-effect experiments performed in the upper plenum test facility (UPTF) of the former SIEMENS KWU (now AREVA) at Mannheim, Germany, were used to validate the countercurrent flow limitation (CCFL) model in case of emergency core cooling water injection into the hot legs. Subcooled water and saturated steam flowed countercurrent in a horizontal pipe with an inside diameter of 0.75 m. The flow of injected water was varied from 150 kg/s to 400 kg/s, and the flow of steam varied from 13 kg/s to 178 kg/s. The subcooling of the liquid ranged from 0 K to 104 K. The velocity of the water at the injection point was supercritical (greater than the celerity of a gravity wave) for all the experiments. The three-field model was successfully used to predict the experimental data, and the results from the model provide insight into the mechanisms that influence the flows of liquid and vapor during countercurrent flow in a hot leg. When the injected water was saturated and the flow of steam was small, all or most of the injected water flowed to the upper plenum. Because the velocity of the liquid remained supercritical, entrainment of droplets was suppressed. When the injected water was saturated and the flow of steam was large, the interfacial shear stress on the continuous liquid caused the velocity in the liquid to become subcritical, resulting in a hydraulic jump. Entrainment ensued, and the flow of liquid to the end of the hot leg was greatly reduced.The influence of condensation on the transition from supercritical to subcritical flow as observed in the experimental data is also predicted with the three-field model. When the injected water was subcooled, condensation on the flow of continuous liquid caused a reduction in the flow of vapor and, consequently, a reduction in the interfacial shear stress. Therefore, the flow of liquid remained supercritical to the end of the hot leg at the upper plenum. The entire flow of injected water flowed to the end of the hot leg at higher flows of steam when the injected water was subcooled than when it was saturated. When the flow of vapor was large enough to cause a hydraulic jump in the subcooled liquid, the rate of entrained droplets was greatly increased. The interfacial surface area of the droplets was several orders of magnitude greater than for the continuous-liquid field, and condensation rate on the droplet field was also several orders of magnitude greater. When the flow of vapor from the upper plenum was at its greatest, most of the flow in the continuous liquid was entrained before reaching the upper plenum. The large flow of subcooled droplets caused three-quarters of the steam to condense.     

Experimental investigation and CFD validation of countercurrent flow limitation (CCFL) in a large-diameter PWR hot-leg geometry

ABSTRACT

Countercurrent flow limitation (CCFL) is a phenomenon that consists of several flow patterns occurring simultaneously which produces a complex gas/liquid interface and interfacial momentum transfer, thus making it one of the most challenging two-phase flow configurations for computational fluid dynamics (CFD) validation. Numerous experimental investigations have been carried out in recent years regarding this, but most of those investigations were performed in small-diameter pipes or in non-pipe geometries (rectangular cross sections). A review of these experimental investigations has shown that the scale and geometry of the test section has a large impact upon the onset and characteristics of the CCFL. In order to provide a better understanding of this phenomenon in an actual pressurized water reactor (PWR) hot-leg geometry at a relatively large-diameter and scale, a test facility with a ～1/3.9 scale and a 190 mm inner diameter was constructed. Experiments were carried out at atmospheric pressure using water and air. High-speed recording was used to acquire high-quality images of the air/water interface. CCFL mechanisms, flow patterns, and the limits of the onset of CCFL and deflooding were experimentally identified. CFD simulations of two representative cases were carried out and assessed against experimental results. The analysis of the CFD simulations has provided insights into the improvements necessary for the accurate simulation of CCFL in large-scale geometries.     

Analytical model for CHF in narrow gaps with surface orientation effects

The CHF in rectangular narrow gaps has been investigated to develop a reasonable predictive model for CHF, accounting for the surface orientation effects. The model was based on Wallis formulation of the counter current flow limitation (CCFL) for flooding of the flow entrance gap. The results by the predictive model were compared with the experimental data by Kim and Suh (2003), and a good agreement was obtained for gap sizes of 1 mm and 2 mm with surface inclination angles ranging from 15° to 90°. However, when the surface inclination angle was less than 15° (nearly downward-facing position), the predictive model underestimated the CHF. A modified Katto–Kosho correlation based on Kutateladze approach was further proposed and it could predict the CHF well for inclination angles less than 15°, due to the surface tension effects. For the gap sizes of 5 mm and 10 mm, the predictive results were far larger than experimental data by Kim and Suh. And the large differences between the predictive results and experimental data were attributed to the fact that the mechanism of CHF in large gap is quite different from a narrow gap. It indicated that the validity of the model based on CCFL was limited to gaps of less than 5 mm. The present work is instructive for the safety analysis of the lower head of PWR in case of core meltdown during severe accident.     

Experimental investigations of the flow patterns in the hot leg of a pressurized water reactor

For the simulation of loss of coolant accidents in nuclear power plants, the flow patterns are predicted by using experimental results from small sized plants which usually have been achieved for fully developed flows. Experimental investigations in a large sized plant have indicated that these flow pattern maps are not fully applicable to the specific geometric properties of nuclear power plants. Therefore, we have conducted experimental investigations for cocurrent two-phase flow in the hot leg. For the experimental investigations a large sized experimental set-up has been constructed, which represents the hot leg of a pressurized water reactor at the scale of 1:1.7. To distinguish between the influence of the size of the plant and the influence of the elbow and the steam generator simulator on the flow pattern, the experimental investigations have been conducted in two steps. First, the flow in the horizontal part of the hot leg has been investigated without connecting the elbow to the plant. The flow regimes have been detected by visual observation. The experimental results are compared to those obtained for smaller pipe diameters and longer pipe lengths. Second, the 50° upwards inclined elbow and the steam generator simulator are added to the horizontal pipe and their influence on the flow patterns is investigated.     

反应堆压力容器下降段水-蒸汽CCFL实验与模型研究

为探究反应堆压力容器下降段在喷放末期冷段安注过程中的水-蒸汽逆流特性,建立下降段逆向流动限制(CCFL)模型,开展了基于压力容器模化本体的下降段CCFL实验研究以及建模分析。通过实验研究获得了不同入口安注水流量、安注水过冷度、堆芯蒸汽流量等条件下的下降段环腔内的安注特性数据,并基于实验数据进行了CCFL建模分析。结果表明,开始发生CCFL的蒸汽无量纲流速与入口安注水无量纲流速呈现正相关,基于无量纲流速建立的模型斜率与入口安注水无量纲流速呈现高度指数关联。本文建立了适用于从不发生CCFL至不完全CCFL,再到完全CCFL的下降段水-蒸汽气液逆流全过程预测模型。     

Condensation experiments for counter-current flow limitation in an inverted U-tube

In this study, we measured counter-current flow limitation (CCFL) characteristics in an inverted U-tube (18.4 mm diameter and 1.0 m straight-part length) simulating steam generator (SG) U-tubes under conditions of steam condensation at pressures of 0.1–0.14 MPa. Differential pressure ΔP between the top of the inverted U-tube and the lower tank was measured, and the flow patterns wave estimated by comparing the waveforms of ΔP with those in air–water experiments. As a result, we classified the flow patterns under CCFL conditions into CCFL-P, CCFL-L and CCFL-T. The falling water flow rate under CCFL conditions slightly increased as the pressure increased and the cooling water temperature decreased (subcooling of cooling water increased). In the case of CCFL-L, CCFL characteristics in the inverted U-tube were between those in air–water and saturated steam–water experiments at 0.1 MPa. Furthermore, we derived a Wallis type CCFL correlation and its uncertainty from CCFL data, including previously measured data, i.e., J*^1/2_G + 0.88J_L*^1/2 = 0.76 ± 0.05.     

Experimental and computational thermal-hydraulic results of fluid and thermal mixing tests

Experimental and computational analyses of a mixing test of cold and hot water flows in a rectangular tee model of the cold leg downcomer geometry of pressurized water reactor were performed. Results obtained from COMMIX-1A computer code calculations showed reasonable agreement with the experimental findings. Counter-current flow and thermal stratification in the cold leg were observed in both the experimental and calculated results for certain ranges of test parameters.     

Comparison of measured and predicted thermal mixing tests using improved finite difference technique

Experimental and computational analyses of a mixing test of cold and hot water flows in a rectangular tee model of the cold leg downcomer geometry of pressurized water reactor were performed. Results obtained from COMMIX-1A computer code calculations showed reasonable agreement with the experimental findings. Counter-current flow and thermal stratification in the cold leg were observed in both the experimental and calculated results for certain ranges of test parameters.     

Flooding in a thin rectangular slit geometry representative of ATR fuel assembly side-plate flow channels

Air-water counter-current flow limit experiments were conducted in thin rectangular channels at atmospheric pressure. The parameters were: narrow channel width, either 1.1 mm or 2.2 mm; inlet water temperature, ranging from 294 K to 330 K; channel surface condition, either clean aluminum, aluminum oxide, or acrylic; location and geometry of the air inlet; method of forcing air through the channel; and liquid head above the channel. Experimental results for each set of parameters can be linearly correlated using the square root of the non-dimensional superficial velocities. Channel surface wetting and location and geometry of the air injection had the greatest effect. Narrow channel width, water temperature, method used to force air through the channel, and liquid head above the channel had little effect on the flooding characteristics.     

Effects of fluid properties on CCFL characteristics at a vertical pipe lower end

The purpose of this study is to derive a counter-current flow limitation (CCFL) correlation and evaluate its uncertainty for steam generator (SG) U-tubes in a pressurized water reactor (PWR). Experiments were conducted to evaluate effects of the liquid viscosity on CCFL characteristics using air–40 wt% or air–60 wt% glycerol water solution and saturated steam–water at atmospheric pressure with vertical pipes simulating the lower part of the SG U-tubes. The steam–water experiments confirmed that CCFL characteristics could be expressed in terms of the Wallis parameters (J_G* and J_L*) for the pipe diameters of D = 14, 20, and 27 mm. A CCFL correlation was derived using the ratio μ_G/μ_L of the viscosities of the gas and liquid phases, μ_G and μ_L, as a correction term representing effects of fluid properties, where J_G^*1/2(μ_G/μ_L)^?0.07 was expressed by a cubic function of J_L^*1/2(μ_G/μ_L)^0.1. In the correlation, the constant C indicating the value of J_G^*1/2(μ_G/μ_L)^?0.07 at J_L* = 0 was (1.04 ± 0.05), and this uncertainty of ±0.05 would cover most of the previous experimental data including the ROSA-IV/LSTF data at 1, 3, and 7 MPa.     

Investigation on two-phase critical flow for loss-of-coolant accident of pressurized water reactor

The previous investigations were mainly conducted under the condition of low pressure,however,the steam-water specific volume and the interphase evaporation rate in high pressure are much different from those in low pressure,Therefore,the new experimental and theoretical investigation are performed in Xi‘an Jiaotong University.The investigation results could be directly applied to the analysis of loss-of -coolant accident for pressurized water reacor.The system transition characteristics of cold leg and hot leg break loss-of -coolant tests are described for convective circulation test loop.Two types of loss-of-coolant accident are identified for :hot leg” break,while three types for “cold leg”break and the effect parameters on the break geometries.Tests indicate that the mass flow rate with convergent-divergent nozzle reaches the maximum value among the different break sections at the same inlet fluid condition because the fluid separation does not occur.A wall surface cavity nucleation model is developed for prediction of the critical mass flow rate with water flowing in convergentdivergent nozzles.