Simulation and experimental investigation on gas-liquid two-phase flow separation behaviors in multitube T-Junction separator

A specially designed separator for gas-liquid two-phase flow separation and measurement is proposed. The flow characteristics and working scope are studied under different gas/liquid superficial velocities and different flow patterns through FLUENT numerical simulation and experimental research. The working scope of the separator is related to both the gas and liquid superficial velocity. The separator work well under the when the gas superficial velocity ranges from 0.65 to 21 m/s, and the liquid superficial velocity ranges from 0.01 to 0.31 m/s. When the actual working condition is beyond this range, the performance is not so outstanding in case of partial slug flow and annular. Under the working range of the separator, the measurement error of gas and liquid mass flow rates is less than ±2.5%. The special structure provides a buffer space for liquid slug, which shows good shock resistance capacity under high liquid superficial velocity. The investigation offers a valuable guidance for multiphase flow rates measurement.     

Refined reconstruction of liquid–gas interface structures for stratified two-phase flow using wire-mesh sensor

Wire-mesh sensors (WMS), developed at HZDR [4], [13], are widely used to visualize two-phase flows and measure flow parameters, such as phase fraction distributions or gas phase velocities quantitatively and with a very high temporal resolution. They have been extensively applied to a wide range of two-phase gas–liquid flow problems with conducting and non-conducting liquids. However, for very low liquid loadings, the state of the art data analysis algorithms for WMS data suffer from the comparably low spatial resolution of measurements and from boundary effects, caused by e.g. flange rings – especially in the case of capacitance type WMS. In the recent past, diverse studies have been performed on two-phase liquid–gas stratified flow with low liquid loading conditions in horizontal pipes at the University of Tulsa. These tests cover oil–air flow in a 6-inch ID pipe and water–air flow in a 3-inch ID pipe employing dual WMS with 32×32 and 16×16 wires, respectively. For oil–air flow experiments, the superficial liquid and gas velocities vary between 9.2 m/s≤ν_SG≤15 m/s and 0.01 m/s≤ν_SL≤0.02 m/s, respectively [2]. In water–air experiments, the superficial liquid and gas velocities vary between 9.1 m/s≤ν_SG≤33.5 m/s and 0.03 m/s≤ν_SL≤0.2 m/s, respectively [17], [18]. In order to understand the stratified wavy structure of the flow, the reconstruction of the liquid–gas interface is essential. Due to the relatively low spatial resolution in the WMS measurements of approximately 5 mm, the liquid–gas interface recognition has always an unknown uncertainty level. In this work, a novel algorithm for refined liquid–gas interface reconstruction is introduced for flow conditions where entrainment is negligible.     

Research on signal amplitude of the Kármán vortex street in gas–liquid two-phase flow with high void fraction

Based on Biot–Savart law and single-phase flow Kármán vortex characteristics, flow field has been analyzed when gas–liquid flow past a fixed bluff body with high void fraction. Vortex signal characteristics have been studied for stratified two-phase flow on atmospheric conditions in a horizontal pipe. To discuss the relation between void fraction and vortex signal amplitude spectrum, this paper sets up the vortex-induced pressure field model for gas–liquid two-phase flow and gives the relationship between void fraction and relative amplitude spectrum of two-phase flow to single-phase flow. An algorithm is proposed for predicting the two-phase flow parameters. Experiments were performed using air–water as working fluid along with a test tube diameter of 50 mm, at gas volume flow rate of 20–68 m³/h, and void fraction of 0.9–1. The results indicate that calculations by the vortex-induced pressure field model on the amplitude spectrum of vortex signal are in good agreement with the experimental data, and relative errors of the algorithm predictions on gas volume flow rate and liquid volume flow rate are 0.08 and 0.56, respectively.     

Experimental investigation of gas-liquid flow in a vertical venturi installed downstream of a horizontal blind tee flow conditioner and the flow regime transition

A venturi device is commonly used as an integral part of a multiphase flowmeter (MPFM) in real-time oil-gas production monitoring. Partial flow mixing is required by installing the venturi device vertically downstream of a blind tee pipework that conditions the incoming horizontal gas-liquid flow (for an accurate determination of individual phase fraction and flow rate). To study the flow-mixing effect of the blind tee, high-speed video flow visualization of gas-liquid flows has been performed at blind tee and venturi sections by using a purpose-built transparent test rig over a wide range of superficial liquid velocities (0.3–2.4 m/s) and gas volume fractions (10–95%). There is little ‘homogenization’ effect of the blind tee on the incoming intermittent horizontal flow regimes across the tested flow conditions, with the flow remaining intermittent but becoming more axis-symmetric and predictable in the venturi measurement section. A horizontal (blind tee) to vertical (venturi) flow-pattern transition map is proposed based on gas and liquid mass fluxes (weighted by the Baker parameters). Flow patterns can be identified from the mean and variance of a fast electrical capacitance holdup measured at the venturi throat.     

Intermittent flow parameters from void fraction analysis

Two-phase horizontal intermittent flow in straight pipes is experimentally investigated. A new procedure is proposed to characterize the flow through the statistical analysis of the instantaneous cross-sectional averaged void fraction obtained by means of ring impedance probes. The algorithm, based on the statistical analysis of the void fraction records, allows the main intermittent flow parameters, such as slug frequency and length, time average void fraction, minimum and average liquid film height to be evaluated. The procedure is validated through flow visualizations, as obtained from a fast digital video camera.Experiments on air-water horizontal flows in 40 and 60 mm inner diameter pipes are performed. The operating conditions cover the 0.3–4.0 and 0.6-3.0 m/s gas and liquid superficial velocity ranges, respectively.An extensive comparison with literature data shows a general agreement with present measurement. The reliability of both the instrumentation and the signal analysis procedures allows new correlations for minimum and average liquid film height in stratified regions to be proposed. Finally proper dimensionless numbers were applied to correlate frequency data in a wide range of superficial velocity values.     

A study on the relationship between upstream and downstream conditions in swirling two-phase flow

Inline fluid separation is a concept, which is used in the oil and gas industry. Inline fluid separators typically have a static design and hence changing inlet conditions lead to less efficient phase separation. For introducing flow control into such a device, additional information is needed about the relationship of upstream and downstream conditions. This paper introduces a study on this relationship for gas/liquid two-phase flow. The downstream gas core development was analyzed for horizontal device installation in dependence of the inlet gas and liquid flow rates. A wire-mesh sensor was used for determining two-phase flow parameters upstream and a high-speed video camera to obtain core parameters downstream the swirling device. For higher accuracy of the calculated void fraction, a novel method for wire-mesh sensor data analysis has been implemented. Experimental results have shown that void fraction data of the wire-mesh sensor can be used to predict the downstream behavior for a majority of the investigated cases. Additionally, the upstream flow pattern has an impact on the stability of the gas core downstream which was determined by means of experimental data analysis.     

Comparison between wire-mesh sensor and ultra-fast X-ray tomograph for an air–water flow in a vertical pipe

A comparison between ultra-fast X-ray CT and a wire-mesh sensor is presented. The measurements were carried out in a vertical pipe of 42 mm inner diameter, which was supplied with an air–water mixture. Both gas and liquid superficial velocities were varied. The X-ray CT delivered 263 frames per second, while the wire-mesh sensor was operated at a frequency four times higher. Two different gas injectors were used: four orifices of 5 mm diameter for creating large bubbles and gas plugs and a sintered plate with a pore size of 100 μm for generating a bubbly flow. It was found that the wire-mesh sensor has a significantly higher resolution than the X-ray CT. Small bubbles, which are clearly shown by the wire-mesh sensor, cannot be found in the CT images, because they cross the measuring plane before a complete scan can be performed. This causes artifacts in the reconstructed images, instead. Furthermore, there are large deviations between the quantitative information contained in the reconstructed tomographic 2D distributions and the gas fractions measured by the sensor, while the agreement is very good when the gas fraction is obtained by a direct evaluation of the X-ray attenuation along the available through-transmission chords of the tomography set-up. This shows that there is still potential for an improvement of the image reconstruction method. Concerning the wire-mesh sensor it was found that the gas fraction inside large bubbles is slightly underestimated. Furthermore, a significant distortion of large Taylor bubbles by the sensor was found for small liquid velocities up to 0.24 m/s. This effect vanished with growing superficial water velocity.     

Velocity distribution of liquid phase at gas-liquid two-phase stratified flow based on particle image velocimetry

Horizontal gas-liquid flows are commonly encountered in the production section of the oil and gas industry. To further understand all parameters of the pipe cross-section, this paper use particle image velocimetry to study the circular pipe cross-section liquid velocity distribution rule. Firstly the focus is on the software and hardware combination of image correction system, to solve the influence of different refractive indexes of medium and pipeline curvature caused by image distortion. Secondly, the velocity distribution law of the corrected stratified flow (the range of liquid flow of 0.09-0.18 m³/h, and gas flow range of 0.3-0.7 m³/h) cross-section at different flow points of the pipeline cross-section at x=0 and in the Y direction at the maximum liquid velocity is studied. It is found that these distribution laws are caused by the influence of the interphase force of the gas-liquid interface and the resistance of the pipe wall. The current measurements also produce a valuable data set that can be used to further improve the stratified flow model for gas-liquid flow.     

Separated two-phase flow regime parameter measurement by a high speed ultrasonic pulse-echo system

In this work, a high speed ultrasonic multitransducer pulse-echo system using a four transducer method was used for the dynamic characterization of gas-liquid two-phase separated flow regimes. The ultrasonic system consists of an ultrasonic pulse signal generator, multiplexer, 10 MHz (0.64 cm) ultrasonic transducers, and a data acquisition system. Four transducers are mounted on a horizontal 2.1 cm inner diameter circular pipe. The system uses a pulse-echo method sampled every 0.5 ms for a 1 s duration. A peak detection algorithm (the C-scan mode) is developed to extract the location of the gas-liquid interface after signal processing. Using the measured instantaneous location of the gas/liquid interface, two-phase flow interfacial parameters in separated flow regimes are determined such as liquid level and void fraction for stratified wavy and annular flow. The shape of the gas-liquid interface and, hence, the instantaneous and cross-sectional averaged void fraction is also determined. The results show that the high speed ultrasonic pulse-echo system provides accurate results for the determination of the liquid level within +/-1.5%, and the time averaged liquid level measurements performed in the present work agree within +/-10% with the theoretical models. The results also show that the time averaged void fraction measurements for a stratified smooth flow, stratified wavy flow, and annular flow qualitatively agree with the theoretical predictions.     

基于激光诱导荧光成像技术的截面含气率检测研究

截面含气率作为气液两相流动过程中的基本参数之一,对石油管道的开采、输运,核反应堆冷却塔的设计等过程具有重要意义。本文提出了基于激光诱导成像技术和高速摄录系统的截面含气率直接检测方法,有效的避免管道曲率和介质折射率导致的光学畸变。在河北大学多相流循环装置进行实验,测量了18个流量点,液相流量测量范围10～35 L/min,气相流量测量范围2.0～3.0 L/min。运用计量比对的思想,对两种检测技术获得的截面含气率值求取偏差并进行修正,最大偏差仅为0.014 59。结果表明两种方法得到的截面含气率值具有较好的一致性,证明本文提出的荧光成像技术对气液两相分层流截面含气率的检测是有效的。     

Application of dual-plane ERT system and cross-correlation technique to measure gas–liquid flows in vertical upward pipe

The progress of process tomography provides a new method for two-phase flow measurement. The dual-plane electrical resistance tomography (ERT) is combined with the correlation measurement technique to carry out the two-phase flow measurement in which the continuous phase is conductive liquid. The method of the estimation of void fraction and the disperse phase velocity by extracting the eigenvalue of the dual-plane ERT boundary measured data is presented. This method is applied to the transient flow-rate measurement of the air–water two-phase flow in vertical pipe. The information of disperse phase void fraction and distribution variation with time change can be considered adequately, and the estimated value of disperse phase void fraction and velocity can be gained fairly accurately in this method, which provides the data for the calculation of the transient flow-rate. The experiment results indicate that this kind of measurement method is valid when the distance between the upstream and downstream measured cross section is short enough.     

Analysis of two-phase flow regimes and parameter distribution in 5 x 5 rod bundle using image processing techniques

With the recent developments in image processing and analysis, this paper presents bubble characteristics distribution in adiabatic air-water two-phase flow through a 5 × 5 rod bundle. The experiment covered water superficial velocities (J_l = 0.012 m/s – 0.421 m/s) and air superficial velocities (J_g = 0.042 m/s – 0.987 m/s) in which three distinct flow regimes were identified. The flow regime map was compared with existing flow regime transition criteria for vertical rod bundles. Distinct features from the two-phase flow images were extracted to train a classifier model to distinguish between regimes from a separate experiment. The model distinguishes between the bubbly flow regime and others accurately. The void fraction and velocity distributions were also extracted from the R–CCN masked images. Bubble-induced turbulence that was dominant in the subchannel at (J_l = 0.28 m/s) shifted to the outer subchannels and gaps when the flow rate increased (J_l = 0.42 m/s). These methods over-predicted the void faction around the surfaces of the inner rods.     

Experimental study of bubbly swirling flow in a vertical tube using ultrasonic velocity profiler (UVP) and wire mesh sensor (WMS)

Two-phase air-water bubbly swirling flow through a pipe is a complex turbulent flow and its prediction is still challenging. The present paper describes the experimental investigation of the air-water bubbly swirling flow in vertical co-current flow. Swirling flow is induced by a twisted tape in a 20 mm inner diameter pipe. The flow is investigated using Ultrasonic velocity profiler (UVP), which allows the measurement of liquid and gas velocities simultaneously. Furthermore, simultaneous measurement of void fraction is performed using Wire mesh sensor (WMS). The experimental results reveal that swirling flow has significant impact on bubbles’ distribution. In low liquid flow rate, the average bubble velocity is fairly uniform along the radial position and void fraction increases in the near wall region. However, increasing liquid flow rate at constant gas flow rate leads to increase in void fraction in the core region, this is mainly due to drift velocity which is affected by centrifugal force. Experimental findings and parametric trends based on the effects of swirling flow are summarized and discussed.     

The parameters measurement of air–water two phase flow using the electrical resistance tomography (ERT) technique in a bubble column

The air–water two-phase flow is investigated in a bubble column with a height of 2 m and a diameter of 0.282 m by using the Electrical Resistance Tomography (ERT) technique. The flow characterization are measured by applying ERT sensors of three vertical sections with superficial gas velocities in the range 0.027–0.156 m/s. Based on the cross-correlation technique and dynamic gas disengagement (DGD) theory, the bubble Saunter diameters are obtained and the local axial velocity about two phases flow can be calculated. The results show that with increased gas superficial velocity the distribution of bubble size is gradually widespread. Moreover, the local velocity of gas bubble swarm has a center peak distribution with increased gas superficial velocity.     

Research on wet gas separation method based on swirl and ejection cycle technology

Gas-liquid co-production often occurs in the middle and late stages of natural gas production. Efficient wet gas separation is very important in natural gas transportation and measurement. The traditional separation device has a relatively low separation efficiency due to the flow patterns, a new type of pipe separator was designed based on the swirl and ejection cycle technology. A new systematical separation procedure with three main steps was proposed simultaneously. The wet gas was forced to form an annular flow by a swirler. Then, the liquid film flows into the annular gap. The wave layer was introduced into the swirl separation again with the self-circulating ejection system for fine separation finally. Laboratory experiments and Computational Fluid Dynamics (CFD) simulations show that the additional swirl process can decrease the flow pattern influence effectively, and the separation efficiency can increase to more than 90%. The separation efficiency is mainly determined by the gas superficial velocity, and while the velocity of the inlet gas is less than 21 m/s, the separation efficiency is up to 93%. The separation efficiency prediction model was established based on liquid film porosity, and the prediction relative error is less than 10%. The new device, the separation procedure, and the test results can provide constructive technical reference for the real-world pipe separator application.     

一种测量液膜厚度的超声相控阵实验装置

气液两相流存在于核反应堆蒸发、飞行器冷却、化工生产降膜蒸发等过程,界面波的动态测量对工业过程监控和生产优 化具有重要意义。 界面波的准确识别与特性参数测量是开展科学研究与工程实践的重要前提。 基于超声相控阵测量系统,设 计了扇扫的测量方式,可以用于气液界面清晰的流型中液膜厚度和界面波形态三维测量。 通过静态标定和圆管验证,确定了像 素点和液膜厚度之间的关系,在气相表观流速为 0. 071 9~ 0. 431 6 m/ s,液相表观流速为 0. 056 7~ 1. 416 1 m/ s 的工况下进行实 时动态实验,获得了实时流动过程中较高精度的截面气液相界面信息,并构建了管道内部界面波三维分布形态,为界面波特性 研究提供了一种实验参考方法。     

Model analysis for differential pressure two-phase flow rate meter in intermittent flow

Multiphase flow rate metering is a challenging problem, specially for flow patterns other than wet-gas. This paper brings forward a new comparative analysis of three differential pressure calibration models suited for liquid dominated two-phase flows, in a total of seven model configurations. First, the models are compared theoretically and classified in terms of the type of input data required. Then, experimental data of over 300 horizontal air–water experiments, for $1$” and $2$” pipe diameters, supports quantitative analyses of the prediction accuracies and sensitivity of the superficial velocities of gas and liquid to measurement errors in the model input variables. Finally, a method for assessing the decoupled measurement errors for the void fraction and gas velocity is shown, as these variables are typically subject to higher uncertainties. It results that, though the void fraction is shown to be systematically under evaluated in more than 10%, the total mass flow rate is estimated through the Paz et al. (2010) model with an overall root mean squared deviation (RMSD) of 5.75% for the $2$” data. Also, the use of gas velocity measurements, even if subject to considerable errors, decreased the RMSD for the gas superficial velocity by more than half for the $1$” data.     

An experimental study on characteristics of two-phase flows in vertical pipe

The characteristics of two-phase flow in a vertical pipe are investigated to provide information for understanding the excitation mechanisms of flow-induced vibration. An analytical model for two-phase flow in a pipe was developed by Sim et al. (2005), based on a power law for the distributions of flow parameters across the pipe diameter, such as gas velocity, liquid velocity and void fraction. An experimental study was undertaken to verify the model. The unsteady momentum flux impinging on a ‘turning tee’ (or a ‘circular plate’) has been measured at the exit of the pipe, using a force sensor. From the measured data, especially for slug flow, the predominant frequency and the RMS value of the unsteady momentum flux have been evaluated. It is found that the analytical method, given by Sim et al. for slug flow, can be used to predict the momentum flux.     

科氏流量计应用于气液两相流测量的实验研究

以空气-水为介质,对科氏流量计应用于气液两相流双参数测量进行了实验研究.实验过程中保持液相流量一定,通过加入不同体积分数的空气来分析含气率对科氏流量计测量精度的影响,采用Weisman垂直上升管气液两相流流型图与实验数据进行了比较.结合实验结果,初步归纳出含气量、流型和科氏流量计测量精度之间的关系,总结出液相中含气影响科氏流量计测量精度的主要因素及其影响规律,为进一步研究科氏流量计气液两相流测量误差修正提供了一种技术方法.     

Electrical resistance tomography coupled with differential pressure measurement to determine phase hold-ups in gas–liquid–solid outer loop bubble column

Radial variation of the gas hold-ups and mean hold-ups are investigated in a 90 mm outer loop bubble column using electrical resistance tomography (ERT) with two axial locations (Plane 1 and Plane 2). In all the experiments, air is used as the gas phase, tap water as liquid phase, and polypropylene particles as solid phase where the superficial gas velocity is varied from 0.02 to 0.25 m/s. The effect of operating conditions, solid concentration on mean hold-ups and radial gas hold-ups distribution is discussed. Gas hold-ups and solid hold-ups results using ERT are in very good agreement with conventional estimation and correlations obtained using pressure transmitter methods. Meanwhile, the results show that the gas hold-ups in the centre region increase constantly with an increase in the superficial gas velocity, namely there is a maximum hold-up at the centre of cross-section. But, solid hold-ups distribution is very homogeneous for high gas velocity. According to the visible image, the gas–liquid flow behaviours are obtained for gas–liquid–solid outer loop bubble column. Furthermore, the results also indicate that ERT is a very powerful tool for diagnosing the ‘inside’ flow behaviour of gas–liquid–solid three phase bubble column.