Two Phase Flow Splitting in Piping Branches by Michael Steven Quintana S.B., Mechanical Engineering Massachusetts Institute of Technology, 1989 Submitted to the Department of Mechanical Engineering and the Department of Nuclear Engineering in Partial Fulfillment of the Requirements for the Degrees of Master of Science in Nuclear Engineering and Master of Science in Mechanical Engineering at the MASSACHUSETTS INSTITUTE OF TECHNOLOGY June 1998 © 1998 Massachusetts Institute of Technology All Rights Reserved. MASSACHUSETTS INSTITUTE OF TECHNOLOGY JUL 2 0 1999 LIBRARIES Auth o r.................................................................................... Depart ent of Nuclear ngineering ~June 1, 1998 , Certified by.......................................................... Professor Peter O-ith, Emeritus Dep artment of Mechanical Engineering /) Toes, is Supervisor Certified by............................................... .................. Professor Neil Emmanuel Todreas Departments of Nuclear and Mechanical Engineering Thesis Reader A ccepted by ........................................ ..................................................................................... Professor Anthony Tyr Patera Acting Chairman, Departmental Committee on Graduate Students epartment of Mechanical Engineering / Accepted by........................ Professor Lawrence Lidsky Chairman, Departmental Committee on Graduate Students Department of Nuclear Engineering Two Phase Flow Splitting in Piping Branches by Michael Steven Quintana Submitted to the Department of Mechanical Engineering and the Department of Nuclear Engineering on June 1, 1998 in Partial Fulfillment of the Requirements for the Degrees of Master of Science in Nuclear Engineering and Master of Science in Mechanical Engineering ABSTRACT The objectives of this research are to evaluate the performance of a flow-splitting tripod, discover the factors which most affect the flow distribution; and quantify the effects of geometry, quality and flow rate on the distribution. Knowing all this allows one to predict the distribution for given conditions. An R-22 test apparatus was constructed for carrying out the experiments. The factors examined were tripod orientation, Froude number, void fraction, and swirl induced by helical grooves in the tube supplying the two-phase flow to the tripod. The flow regime of concern is primarily annular. Experiments were run and data was collected and analyzed. The two piece tripods were generally found to have manufacturing defects which made their performance unpredictable. The hole through which the flow was provided was often off center. This defect greatly affected the distribution and masked other geometric factors. To eliminate this variable a number of tripods were tested, using an air-water rig, to find a tripod that was not defective. Tests using R-22 were then run on this tripod and it was found that inlet swirl had little or no affect on the flow distribution. The factors that had the greatest effect on the flow distribution were the tripod's orientation, the Froude number of the flow, and the void fraction. An empirical correlation for flow splitting was derived including these factors. Thesis Supervisor: Professor Peter Griffith Title: Professor of Mechanical Engineering, Emeritus Acknowledgments I would like to thank my advisor, Professor Peter Griffith, without his patience, kindness, and guidance this thesis would not have been completed. I learned a lot from him during the course of my research from him. His tremendous knowledge and engineering intuition are remarkable. His ability to see a problem in its simplest form came as a great help to me. I am indebted to him. I would also like to thank the Carrier Corporation for funding my research. As well I would like to thank the very knowledgeable and skillful technicians at the Pappalardo Laboratory: Mr. Norman Berube, Mr. Norman MacAskill, and Mr. Robert Nuttall, I am grateful for all the time, skill, and effort that they have given me. Their help with the design and construction of the experimental apparatus was invaluable. I am also indebted to Dr. Wayne Bidstrup and Mr. Richard Fenner, for their time and council. A special thanks goes to Mike Demaree for his advice and help dealing with the refrigerant. A special thanks goes to Professor Ronald M. Latanision for his support. I would not have finished this thesis without him. I would also like to thank Constance Beal, Clare Egan, and Leslie Regan. They truly make the Institute run smoothly. Many thanks go to my friends in the Heat and Mass Transfer Lab: Richard Nelson, Marc Hodes, and Andres Pfahnl and those in the Corrosion Lab: Jason Cline, Dr. Gary Leisk, and Dr Bryce Mitton for their support, encouragement and friendship. Finally, I want to thank my wife Tiffany for all the support that she has given me. This thesis is dedicated to her. To my wife. Table of Contents ............................... .......... 1.1 Problem Statement ......................... ......... 1.2 Geom etric and Property V ariables ...................................................... 1.2.1 Swirl .................................................... ................ 1.2.2 Orientation .................. ....................................................................... ................. . 1.2.3 Geometry of Tripod ............................... 1.2.4 Refrigerant ............................................................... 1.2.5 Property V ariables ........................................ ................. ................ 1.3 Current Work ........................ 1.3.1 Flow Regimes of Interest ........................................ 1.3.2 Refrigerant 23 Tests ..................................................... .................. 1.3.3 Defective Tripods ........................................ .. 1.3.4 Comparison to Air-W ater Tests ...................................... ........ ... 2 Flow Regimes and Conditions of Interest ........................................ 2.1 Range of Pressures, Qualities and Flow Rates of Interest ................................ ............ .... 2.2 Taitel-Dukler Flow Regime M ap ........................................ 2.3 Conditions for the Range of Param eters ............................................................. 2.4 Range of Void Fractions and Froude Numbers ..................................... 2.5 The Selection of the Correlation Factors .................................. ........... 3 Refrigerant 22 Experiments ...................................... 3 .1 A pparatu s ....................................................................... 3.1.1 Flow Loop ...................................................................... ............... 3.1.2 Test Section ................................................................. 3.1.3 Cooling System ........................................................... 3.1.4 Instrum entation ..................................................... 3.2 Parameters Varied ................................................................... 3 .3 Resu lts .......................................................................................................... 9 9 10 10 10 11 11 11 12 12 13 13 13 15 15 15 16 17 17 19 19 19 24 24 24 27 27 4 Comparison of Refrigerant 23 to Air-Water Experiments .......................................... 31 ............... 4.1 Air-Water Experiment Results ......................... .. 4.2 Direct Comparison of Refrigerant 23 and Air-Water Experiments ................. 4.3 Air-Water System's Limitations ........................................ 5 C o nclu sio n s ....................................................................................................................... .................. 5.1 Geometric Variations ....................................... 5.2 Unnecessary R-23 Tests ........................................ 5.3 Stratified Flow Regime ................................................................ ................. 5.4 Optimum Conditions .......................... ............................................ 31 31 32 34 34 35 35 35 1 Intro du ctio n ....................................................................................................................... Table of Contents (cont.) References ........................ .......... . ..................................................................................... Appendix A Nomenclature and Subscripts ........................................ Appendix B Raw Data .............................................................................. Appendix C Calculations ...................................... ........................... Appendix D Empirical Correlation Derivation ................................ 36 37 38 46 57 List of Figures ........... Figure 1.1: Typical Tripod ......................................... ....... Figure 1.2: Tripod Orientation and Swirl Rotational Direction ......................................... .......................... Figure 1.3: Defective Tripod ........................................ Figure 1.4: Comparison of Distribution Between Defective and Non-defective Tripods ....... ......................... Figure 2.1: Flow Regim e Map .................................................................. Figure 2.2: Flow Regime Schematics ......................................... ............ Figure 2.3: Slip Ratio versus Specific Volume ....................................... Figure 3.1: Test Apparatus Schematic .............................................. Figure 3.2: Test Apparatus ....................................................... Figure 3.3: Inside the Pressure Vessel......................................................................... Figure 3.4: Test Section ................................................................ ................ Figure 3.5: Rotating Brass Guide .......................................................................... ... Figure 3.6: Cooling System Schem atic .................................. ............................ 3.1 . Using Equation Flow Split Calculated Liquid and of Measured 3.7: Comparison Figure Figure 3.8: Comparison of Measured and Calculated Liquid Flow Split Using Equation 3.2. .......... Figure 4.1: Comparison at Low Froude Number ..................................... ......................... Figure 4.2: Comparison at Intermediate Froude Number .................. Figure 4.3: Comparison at High Froude Number ........................................ 10 12 14 14 16 17 18 20 21 22 23 25 26 29 30 32 33 33 List of Tables ................................... Table 2.1: Conditions of Interest ........................... .................... ........................................ Table 2.2: Approach Tube Parameters Table 5.1: Defective Tripod Distribution .......................................................................... .................... Table 5.2: Stratified Flow Distribution ........................................ 8 15 15 34 35 Chapter 1 Introduction 1.1 Problem Statement Flow splitting tripods are needed to complete the U-turn end connections found in the finned tube heat exchangers used in the evaporator of an air conditioning unit. The refrigerant enters the evaporator from the throttle valve. At this point there is a flowing two phase mixture which is below ambient temperature and at various pressures, mass velocities, and qualities. The tripods, which can vary in rotational orientation, are usually connected to horizontal tubes. The Carrier Corporation uses tripods to split the refrigerant flow in the evaporator between two or more parallel tubes to reduce the overall pressure drop across the evaporator. By using a tripod, the velocity in each parallel tube is halved compared to a single pass tube of the same total length. Therefore, in the ideal case of uniform distribution the overall pressure drop is reduced and the thermal efficiency of the system is increased. In general, the flowing refrigerant does not split evenly. Since the liquid refrigerant has a much greater potential for absorbing heat than does the vapor, the tube receiving less liquid often does not absorb as much heat as it was designed to. The tube that receives additional liquid often does not make efficient use of it and can send some liquid refrigerant back to the compressor. A typical tripod, such as is illustrated in Figure 1.1 and is used in this experiment, is made of two pieces which are brazed together. One piece consists of a u-tube with a hole on one side that is slightly smaller than the inner diameter of the supply tube. The supply tube of the tripod is a half of a u-tube that is brazed to the side of the full u-tube as depicted in the Figure 1.1. The flow through the tripod enters the half u-tube and is split as it enters the full u-tube. 1.2 Geometric and Property Variables 1.2.1 Swirl The tube supplying the tripod has helical grooves within it. These are fine grooves which are used to improve heat transfer. This improvement is accomplished by using swirl the grooves induce to throw liquid to the walls and keep them wet. The helically grooved tube has a slightly larger inside diameter than the tripod outer diameter; and is flared for receiving the tripod and providing clearance for the braze. Figure 1.1 shows the dimensions while Figure 1.2 shows the swirl rotational direction for the tripods tested in these experiments. 0.5" 0. 5" R .0.3125" Figure 1.1: Typical Tripod 1.2.2 Orientation The experiments were carried out using four tripod rotational orientations with all supply and discharge tubes always being in the horizontal orientation. The tripod orientations were at 00, 900, 1800, and 2700 and are as illustrated in Figure 1.2. The left and right labels indicate which collection glass in the pressure vessel will receive the tube's discharge. The collection glasses were viewed through a window at the end of the pressure vessel. (See Chapter 3.) The gravity vector is down in this figure and flow is into the paper with an X and out with a e. 1.2.3 Geometry of Tripod The tripod's tubing is a nominal 3/8 inch outside diameter (OD), 0.364 inches actual OD, with a 0.0394 inches wall thickness. The distance between the centers of the full u-tube is 1 inch. The vertical distance from the full u-tube centers to the half (supply) u-tube center is 0.75 inches and the horizontal distance is 0.5 inches. The tips of the tripod tubing are straight for 0.3125 inches then curve forming a semi circle for the full u-tube and a quarter of a circle for the half utube. The centerline radius of the bends is 0.5 inches. 1.2.4 Refrigerant Refrigerant 22 was used in all experiments conducted. R-22 is a very aggressive refrigerant, in that it greatly effects the elasticity of many elastomer materials and is very permeable in many elastomers. These properties greatly affected the design of the test system. They also lead us to look for other simpler and less difficult-to-handle fluids to test the tripods. Air and water were found to be suitable when the experiments were properly scaled. The counterpart air-water experiments were conducted by Richard Perkins (1997) and are used as a comparison to the R-22 experiments. 1.2.5 Property Variables The property variables that were recorded for each experiment were pressure, temperature, and mass flow rate. Velocity, quality, phase densities and viscosities, and, surface tension were then determined from these values. See Table 2.1 for ranges tested. Left Right 0 Right 00 2700 Left c' Left * Right 900 1800 Left 0 Right g Swirl Rotational Direction Figure 1.2: Tripod Orientation and Swirl Rotational Direction 1.3 CurrentWork 1.3.1 Flow Regimes of Interest The main flow regime of interest for these flow splitting experiments was annular flow. The range of flow variables was set by the conditions in use at the Carrier Corporation in their air conditioning units. For some of the low velocity runs there was stratified flow present. The flow regimes were determined using 'unified.f, a computer code written by Marc Hodes (1994) based on the Taitel-Dukler (1990) unified model for two-phase flow regimes. The model uses vapor and liquid densities, viscosities, surface tension, tube diameter, and angle of inclination to predict what the flow regime is. 1.3.2 Refrigerant 22 Tests Tests were run at the various orientations described earlier and shown in Figure 1.2. The range of states experienced under normal operating conditions were encompassed in this test matrix. A set of data was taken at each condition. The experimental variables tested were the mass flow rate and the quality of the R-22. 1.3.3 Defective Tripods The first set of results did not match our expectation that gravity was the major factor determining the uniformity of the flow split. At the 00 orientation the left tube (see Figure 1.2) was receiving over 70% of the liquid. The tripod was dismantled and it was found that the hole in the full u-tube was off center, as shown in Figure 1.3. Since the flow regime was annular the liquid was deflected to the left tube from the right tube (of Figure 1.3) by the ridge created by the offset. Figure 1.4 shows the disparity in flow distribution between a defective and a nondefective tripod. The average difference between the flow splits from the two tripods was 20.8%, which is unacceptable. Air-water tests were run on all the tripods. The split at an orientation of 00 varied by as much as 50%±10% for either side (Perkins, 1997). There were however two out of the twelve tripods that gave flow splits that were 50%+1%. One of these tripods was used for the rest of the experiments. The same tripod was used for both the air-water and R-22 experiments. 1.3.4 Comparison to Air-Water Tests The results of the air-water experiments matched the R-22 experiments in shape when the Froude number and void fraction were the same. The magnitude of the amplitude was not quite the same, however. The correlation between the air-water and R-22 tests was only found to be valid in the annular flow regime. With this limitation, the simpler air-water tests could be used to give information about the flow distribution on untested tripods which would be useful for screening the quality of the tripods from various suppliers and selecting the good ones from a batch. ]drilled hole 0.275" 1 0 Ifeed tube ID 0.281" ' I .edtb - I .8 brazed flarejoint Figure 1.3: Defective Tripod 100 90 80 70 60 50o 40 - 30 - - -- - %% - Defective Tripod (avg) -- - - - Non-defective Tripod (avg) 20 10 0 90 180 rotation angle 270 360 (deg) Figure 1.4: Comparison of Distribution Between Defective and Non-defective Tripods Chapter 2 Flow Regimes and Conditions of Interest 2.1 Range of Pressures, Qualities and Flow Rates of Interest The Carrier Corporation chose the range of R-22 conditions which was tested. This range encompassed the range that is found in their products. This range is given in Table 2.1. The range of geometric parameters tested for the smooth and the swirl enhanced supply tube are given Table 2.2. Variable Temperature, 'F Pressure, psia 103 -lb Mass Flux, Shr ft 2 Range 40 to 55 83.2 to 107.3 Nominal Value 45 90.7 20 to 100 80 1.05 to 5.2 18 to 60 0 to 3 4.22 30 0 Superficial Velocity ft/sec Quality, % Back Pressure Imbalance, psi Table 2.1: Conditions of Interest Variable Diameter, inches Inside Surface Tube Orientation Range 0.3 to 0.7 smooth to enhanced horizontal Nominal Value 0.375 enhanced horizontal Table 2.2: Approach Tube Parameters 2.2 Taitel-Dukler Flow Regime Map A flow regime map using a nominal pressure and a horizontal tube with a diameter of 0.375 inches is shown in Figure 2.1. Marc Hodes' 'unified.f program was used to generate the map (Hodes, 1994). It is based on the Taitel-Dukler unified model presented at The Ninth International Heat Transfer Conference (Taitel, 1990). The four regimes that are identified are annular, bubble, intermittent, and stratified as depicted in Figure 2.2. The primary regime of interest is the annular regime. Using the ranges for R-22 given in Table 2.1, the experimental data mostly falls within the annular regime and just borders the stratified regime. 100 OOAAAo OOOOO OOO OOO o00 OOOOOOOO OOOO O OOO OO OOOOO OOOOOAO OO OOOOOOOOOOOOA AAO [ 0 AAAAAAAAAAAAA Ao00 AAAAAAAAAAAAAOOOO0oo 10 AAAAAAAAAAAOOOOOOOOOO AAAAAAAAAAOoo ooooooo 1 0 ANNULAR AAAAAAAAAOOOOooooooo AAAAAAAAO EMOooooooo on0 000000000 00000000000E 000000000OOOO0000000 0000000000 00000 00000000000000000000 00000000000000000000 00000000000000000000 00000000000000000000 00000000000000000000 0.1 0.01 0001 n OBUBBLE AINTERMITTENT OSTRATIFIED 0000000 0000000 000 I 0.01 0.1 Superficial 1 Gas 10 Velocity 100 (ft/sec) 1 )00 Figure 2.1: Flow Regime Map. A Single Shape Identifies Each Flow Regime. Filled Shapes Indicate Experimental Operating Conditions 2.3 Conditions for the Range of Parameters The range of parameters given in Table 2.1. set the conditions of a saturated system where annular flow dominates the flow regime. O 0 0** z*0 o a o C:0 4 Stratified Flow Bubbly Flow 0 .D 0 Annular Flow Intermittent Flow Figure 2.2: Flow Regime Schematics 2.4 Range of Void Fractions and Froude Numbers Once the conditions were set to meet the range of the parameters given in Table 2.1, the void fractions and Froude numbers could be calculated. Void fractions ranged between about 83% to 99% and were calculated using the methods described in the next section. The Froude number in these experiments ranged from about 0.4 to 1. 2.5 The Selection of the Correlation Factors The Froude number and void fraction were selected as the correlation factors needed to scale the air-water experiments to the R-22 experiments. These are the dimensionless variables that are dominate in annular flow. The Froude number was calculated using the equation below: Fr= jg - p )gd (2.1) wherejg is the superficial velocity of the gas, pg and pl are the densities of the gas and liquid R-22 respectively, g is the gravitational constant, and d is the inside diameter of the tube. The gas phase superficial velocity is almost the mixture velocity. It isn't clear which is appropriate. The void fraction is the volume fraction of the gas phase in a two-phase system. The void fraction, a, was calculated using the Thornm correlation. where (2.2) Pg S X P 1 V S (2.3) VI9 V,' S, which is plotted as phase velocity ratio on Figure 2.3, is called the slip ratio, Vg and V are the phase velocities, pg and Pt are the densities of the gas and liquid respectively, and X is the quality. The slip ratio was obtained using Figure 2.3. 10 6 4 S 1 2 4 6 10 20 40 60 100 200 4006001,000 2,000 Specific volume ratio V i O Conditions of Interest for R-22 Experiment Figure 2.3: Slip Ratio versus Specific Volume These are the dimensionless groups found by Flores (1992) and Taitel (1990) among others to be the best descriptors of annular flow. The details of how the flow variables were calculated are given in Appendix C. These variables are given in Table C.1 of Appendix C. Chapter 3 Refrigerant 22 Experiments 3.1 Apparatus A schematic drawing of the apparatus is shown in Figure 3.1 and a photo in Figure 3.2. The apparatus is broken down into four sections; 1) flow loop, 2) test section, 3) cooling system, and 4) instrumentation as described below. 3.1.1 Flow Loop The metering pump draws R-22 from an internally located sump/reservoir and passes the R-22 through the filter/dryer, the surge suppresser, the heater, metering valves, test section and finally into the measurement glasses. The metering pump is a Barnant PTFE diaphragm pump. The pump can be controlled to meter accurately ( 2% volume variation) from 30 to 300 gallons per day (0.02 to 0.2 gpm). This range covers the desired mass fluxes for this project. There is also very little pressure level effect on pump performance. The heater is a 2000 watt screw plug immersion heater (Omega TMW-1200). It has a 7.9 Ohm resistance. A variac was used to control the heater input by varying the voltage across the heater. Two separate metering valves are used to cover the range of mass fluxes. The high flow-rate metering valve (Whitey 31 Series) covers the range of 0.1 to 0.28 gpm and the low flow-rate valve (Nupro M Series) covers the range of 0.02 to 0.15 gpm. The combination of the heater and metering valves gives the necessary energy increase and pressure drop, respectively, to achieve the desired qualities. The measurement glasses are 5 inches tall and nominal 3 inches in diameter glass cylinders. These cylinders are fastened to an aluminum plate containing drainage ports. Both ports are connected to a single three-way valve that allows for simultaneous isolation and draining of both glasses, see Figure 3.3. The glasses have a level indicator that is read through the viewing window. hoses in the pressure vessel are high quality neoprene. The TEST SECTION PRESSURE VESSEL TRIPOD RETURN TUBES BRASS GUIDE GLASSES II I ENHANCED TUBE A I DRAINAGE SYSTEM ISOLATION VALVE METERING VALVES (NEEDLE VALVES) FILTER/DRYER ISOLATION VALVE TO AND FROM COOLING HEATER SURGE SUPPRESSER Figure 3.1: Test Apparatus Schematic Figure 3.2: Test Apparatus Figure 3.3: Inside the Pressure Vessel Figure 3.4: Test Section 3.1.2 Test Section The test section, (enhanced approach tube, tripod (Figure 1.1), return tubes, and brass guide) can be rotated to adjust the orientation of the tripod, see Figure 1.2. In the drawing, hoses (high pressure refrigerant for external hoses) are depicted by thick black lines. The hoses give the flexibility necessary for rotation. The whole test section is supported by a single PVC pipe with oak supports to eliminate any twisting of the copper tubing. There is a brass guide for the return tubes penetration of the pressure vessel. This guide has an o-ring seal and a Teflon bearing. The Teflon has a very low coefficient of friction which is necessary for rotating the brass guide while the vessel is under pressure. See Figure 3.4 for a photo of the installed test section. A detailed drawing of the brass guide is shown in Figure 3.5. 3.1.3 Cooling System The cooling system is comprised of a pump, coils, and a reservoir as shown in Figure 3.6. The coils are internal to the pressure vessel and made from a single piece of copper tubing as shown in Figure 3.3. The inlet to and outlet from the coils is via penetrations in the bottom of the vessel sump/reservoir. The pump takes the suction off the bottom of the cooling reservoir (ice bath), pumps water through the coils, then back to the reservoir. There is a bypass valve on the discharge of the pump to control the flow through the coils. 3.1.4 Instrumentation There were four thermocouple locations: pump discharge, heater outlet, the enhanced tube inlet, and the pressure vessel. There were four pressure gauge locations: the pressure vessel sump, the pressure vessel, the metering valves inlet, and the metering valves outlet. A volt meter was attached to the heater leads to read the heater's electrical resistance and voltage. NOTE: ALL DIMENSIONS IN INCHES SCALE 1:1 O-RING GROOVE SCALE: 4:1 00 TO 50 0.280 BREAK CORNER APPROX. 0.280 R 4.875 Figure 3.5: Rotating Brass Guide E Pressure Vessel Pump Discharge Cooling Pump Drain Valve Isolation Valve Figure 3.6: Cooling System Schematic 3.2 Parameters Varied Mass flow rate and quality were varied. The mass flow rate was varied by adjusting the metering pump. The quality was varied by varying the voltage applied to the heater and the pressure drop across the metering (needle) valves. After the system reached a steady state, the mass flow rate and quality were calculated. When in the proper range, several data runs were taken. The test section was then rotated and another set of data was collected. The angles used were 00, 900, 1800, and 2700 as depicted in Figure 1.2. 3.3 Results The distribution of the liquid R-22 as a function of the tripod orientation had a roughly sinusoidal shape about the 50% distribution line. The amplitude of the imbalance was affected by both the Froude number and the void fraction. It increased with a decreasing Froude number and/or void fraction. The raw data are given in Table B.1 of Appendix B. An empirical correlation, given in equation 3.1, was developed using the dimensionless parameters of void fraction and Froude number given in Table C.1 of Appendix C, and the angle of orientation. The calculated flow splits using this correlation are within +8% and -6% of the measured data, shown in Figure 3.7. Equation 3.2, developed using the same method as used for equation 3.1 but only using angle of orientation as a factor, gives a correlation of within +9% and -6% of the measured data, shown in Figure 3.8. Both correlations used only the data where the flow was annular. As stated earlier, stratified flow gives very poor distribution. The derivation of equation 3.1 is given in Appendix D. w= w ° 0 2Fr-024, (3.1) 0.5- 0.155 sin 0, (3.2) 0.5 - 0.145 sin 0(1 - a) - W where wl is the mass of liquid distributed to the left tube of the tripod, w is the total mass of liquid distributed, 0 is the tripod's angle of orientation, a is the void faction, and Fr is the Froude number. The main results of these experiments are; 1) manufacturing tolerances are very important. This is the dominate factor in the maldistribution in the annular flow regime. 2) The swirl induced by the helical ribbing in the approach tube has little or no effect of the flow distribution. 3) Tripod orientation is very important, due to gravitational forces. It affects both direction and magnitude of the imbalance. 4) The Froude number and void fraction are also important and affect the magnitude of the maldistribution. 5) Stratified flow regime gives very poor distribution particularly in the air-water experiments because of the effects of non-wetting on the tube. 80% 70% -6% + 60% - 8% II. 50% La 40% E 30% 20% + o% + I I I I I I I I 0.00% 10.00% 20.00% 30.00% 40.00% 50.00% 60.00% 70.00% 0% Calculated Flow 80.00% Split Figure 3.7: Comparison of Measured and Calculated Liquid Flow Split Using Equation 3.1 1= 0.5 - 0.145 sin (1- a)0 02 Fr- 24. 8AO -6% 70% - 60% Ia 70.00 9% 50% - 0 t La 40% - " 30% E 20% + 10% - 0% 0.00% 10.00% 20.00% 30.00% 40.00% Flow Calculated 50.00% 60.00% 70.00% 80.00% Split Figure 3.8: Comparison of Measured and Calculated Liquid Flow Split Using Equation 3.2 W = 0.5 - 0.155 sin 0. Chapter 4 Comparison of Refrigerant 22 and Air-Water Experiments 4.1 Air-Water Experiment The air-water experiments were conducted by Perkins (1997). It was found that there was too much variation in the brazed tripods due to manufacturing defects for us to use as received. A random variation in the flow split up to ±10% existed from tripod to tripod with the tripods tested. An acceptable tripod was selected. The flow distribution for an acceptable tripod was found to be symmetric with respect to the tripod's orientation. This symmetry showed that swirl had little effect on the flow distribution. A unibody tripod was also tested. It did not show the manufacturing deviations observed in the brazed two piece tripods. The unibody tripod's distribution mirrored the distribution of a brazed two piece tripod. The airwater system flow split results for all tripods were found to be erratic at low Froude numbers. The high Froude number air-water tests were useful, however. 4.2 Direct Comparison of Refrigerant 22 andAir-Water Experiments The air-water system using the suggested scaling methodology was found to be a good predictor at high Froude numbers of the flow distribution for R-22. The Froude numbers and void fractions were controlled in order to compare the experiments performed on the two systems. Figures 4.1 through 4.3 give a graphical comparison of the two systems' distribution. The shapes of the distribution curves are the same but the magnitudes, to some extent, differ. The air-water system is far easier to build and manipulate than the R-22 system and as it gives relevant data it therefore serves as an attractive screening tool when looking at geometric variables in the flow splitting system. 4.3 Air-Water System's Limitations The air-water system is limited to annular flow which means Froude numbers as defined in this work must be equal to or above 0.4. The air-water flow distribution in the stratified regime does not correlate at all well with the R-22 data. Wetting effects also come into play in the air-water experiments at low Froude numbers. (This would be a contact angle and Webber number effect). R-22 has a low surface tension and more easily wets the tube walls. The airwater system experienced incomplete wetting of the tube walls. These differences were obvious when looking at the experiments. As the velocity (and Froude number) were increased, the R-22 and air-water experiments came into line. 100 90 80 70 60 X- -Air/Water-Fr 0.4, void fraction 88% --- 0-- R 22-Fr 0.4, void fraction 84% -- 50 X11 40 - - 30 20 10 0 0 I I 90 180 rotation angle 270 360 (deg) Figure 4.1: Comparison at a Low Froude Number 100 80t 70 60 - K- -Air/Water-Fr 0.7, void fraction 93% -- 4- - R 22-Fr 0.7, void fraction 93% -- - 50 4 40 30 20 10 a 0 90 180 270 360 rotation angle (deg) Figure 4.2: Comparison at an Intermediate Froude Number 100 90 80 70 60 - -X- 50 I 40 ----- t 30 20 -Air/Water-Fr 1.0, void fraction 96% R 22-Fr 1.0, void fraction 95% + 0 I I 90 180 270 360 rotation angle (deg) Figure 4.3: Comparison at a High Froude Number Chapter 5 Conclusions 5.1 Geometric Variations Geometric variations due to manufacturing defects dominate the flow maldistribution. Table 5.1 shows just how much this affects the distribution. The left side should have less when the tripod is in the 900 orientation, but with the defective tripods it sometimes had more. The offset hole in an asymmetrical tripod, Figure 1.3, creates a barrier that deflects the liquid film flow to one side. As the quality and void fraction are increased, giving a smaller film thickness, the distribution becomes even worse. Figure 1.4 gives a comparison of the liquid flow distribution between a defective tripod and an acceptable tripod. Annular flow in a defective tripod clearly makes the distribution worse rather than better. A symmetrical tripod has the right side flow rate at its maximum at 900 with a 50%-50% split at an orientation of 0Ojust as one would expect. The effect of the swirl on the flow split in all tripods is overwhelmed by the manufacturing defects. Angle (deg) Mass Velocity (104 lb/hr ft 2) Velocity Quality (%) (ft/sec) Split (% Right Left 90 90 10.22 9.30 4.18 5.87 22.72 33.18 52.47 58.72 47.53 41.28 0 7.31 6.76 49.40 68.09 31.91 0 6.82 7.60 59.92 73.59 26.41 Table 5.1: Defective Tripod Distribution 5.2 Unnecessary R-22 Tests The R-22 experiments are not essential for identifying defective tripods. It has been shown that properly scaled air-water tests suffice. An air-water test would save time and money, yet provide a quick and easy way to screen different tripod designs or monitor a supplier's quality control. 5.3 Stratified Regime The R-22 flow distribution in the stratified regime is often very poor. Even at a high quality, if the mass flow rate is low, the distribution is poor. An example of this is given in Table 5.2. Even with the high quality the low flow rate dominated the distribution because the flow was stratified. The air-water flow distribution in the stratified regime is worse than the R22, and does not correlate well. Angle (deg) 0 90 180 270 Flow Fr 4 (10 1b/hr-ft) 4.58 4.14 4.08 5.07 0.62 0.62 0.62 0.61 Left (%) 52.33 16.84 46.67 71.15 Right (%) 47.67 83.16 53.33 28.85 x (%) 52.70 57.90 58.88 47.51 Slip ratio 2.13 2.13 2.13 2.11 a (%) 96.50 97.15 97.25 95.68 Table 5.2: Stratified Flow Distribution 5.4 Optimum Conditions The empirical equation, equation 3.1, developed from the raw data for a symmetrical tripod shows that a tripod orientation of either 00 or 1800 is optimal. If this is not possible, operating at a higher Froude number and void fraction will decrease the magnitude of the imbalance. Flow splitting at very high quality outside the range of desired operation and the correlating equations 3.1 and 3.2, where the films are quite thin, is likely to be poor. References Flores, Aaron, 1992, Dry Out Limits in HorizontalPipes. MS Thesis, Massachusetts Institute of Technology, Cambridge, MA. Hodes, Marc Scott, 1994, Gas Assisted Evaporative Cooling in Downflow Through Vertical Channels. MS Thesis, University of Minnesota. Perkins, Richard, 1997, Air-waterModeling ofRefrigerantDistributionTripods. BS Thesis, Massachusetts Institute of Technology, Cambridge, MA. Taitel, Yehuda, 1990, "Flow Pattern Transition in Two-Phase Flow", Proceedingsof the 9th InternationalHeat Transfer Conference, The Assembly for International Heat Transfer Conferences, Hemisphere Publishing Corporation, Washington. Whalley, P.B., 1997, Boiling, Condensation,and Gas-LiquidFlow, Claredon Press, Oxford. Appendix A Nomenclature and Subscripts Nomenclature: h: enthalpy (BTU/lb) j : superficial velocity (ft/sec) r : mass flow rate (lb/hr) p : pressure (psia) Q : heat input (BTU/hr) R: electrical resistance (ohm) T : temperature (F) V: phase veolicty v : specific volume VD : voltage applied to the heater (volts DC) x : quality subscripts: 1 : denotes outlet of pump and inlet to heater 2 : denotes outlet of heater and inlet to throttle valve 3 : denotes outlet of throttle valve and inlet to test section 4 : denotes pressure vessel (outlet of test section and inlet of pump) g: gas 1: liquid Ig : difference between liquid and gas Appendix B Raw Data Run Angle Heater Voltage T1 T2 T3 T4 P2 P3 P4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 (deg) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 (volts) 50.1 50.0 50.0 49.8 50.0 49.9 49.9 49.8 65.1 65.0 65.0 64.9 49.9 50.4 50.3 50.3 65.4 65.5 65.5 65.5 (OF) 47.93 48.56 48.38 48.16 47.56 47.74 47.76 47.85 47.99 47.96 47.92 48.03 43.73 43.87 43.97 44.06 43.40 43.45 43.43 43.44 (OF) 49.82 49.08 50.22 49.15 52.86 52.90 53.11 52.97 61.48 61.08 61.14 61.09 53.13 53.48 53.68 53.85 58.03 58.29 57.96 58.38 (OF) 38.43 38.38 38.68 38.34 39.17 39.07 39.11 39.01 39.58 39.55 39.56 39.40 40.67 40.80 40.89 41.01 40.00 40.07 40.01 39.95 (OF) 38.77 39.00 39.91 38.77 41.81 39.93 39.67 41.20 40.80 40.72 39.67 39.40 39.84 39.92 40.03 40.08 38.56 38.81 38.87 38.76 (psi) 95.70 95.70 96.70 95.70 101.70 101.70 102.20 102.20 117.70 117.70 117.70 117.70 102.20 103.70 103.70 103.70 112.20 112.20 112.20 112.20 (psi) 82.20 80.70 80.70 80.70 83.70 82.70 83.70 83.70 84.70 84.70 84.70 84.70 84.70 85.70 85.70 85.70 85.70 85.70 85.70 85.70 (psi) 81.97 82.20 83.12 81.97 85.87 83.14 82.87 84.97 84.38 84.26 82.87 82.60 83.05 83.13 83.25 83.32 81.76 82.01 82.07 81.96 Table B.I: R-22 Experiment Raw Data Left th, Right rz, (lb/hr) 8.67 9.18 10.55 10.52 15.27 15.14 14.91 15.89 9.49 10.26 9.57 9.25 28.27 29.75 30.60 30.63 22.42 21.96 23.18 21.25 (lb/hr) 7.58 8.03 8.57 8.55 12.41 12.30 13.05 12.91 8.31 8.98 8.50 8.10 26.51 27.89 28.69 28.71 18.21 19.22 21.73 19.92 Run Angle Heater Voltage TI T2 T3 T4 P2 P3 P4 Left rm, Right ri, 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 (deg) 0 0 0 0 90 90 90 90 90 90 90 90 90 90 90 90 0 0 0 0 (volts) 77.5 77.6 77.6 77.6 78.0 78.0 78.0 77.9 65.6 65.8 65.9 65.8 50.2 50.3 50.4 50.4 49.9 49.9 49.9 49.9 (oF) 43.89 43.98 43.98 44.06 44.11 44.03 43.95 43.98 43.64 43.65 43.67 43.70 43.62 43.62 43.50 43.26 42.04 42.10 42.07 42.01 (oF) 64.08 65.40 64.05 63.49 65.88 65.99 65.90 65.74 57.54 57.42 57.25 57.39 51.40 52.05 52.04 52.08 51.40 51.38 51.50 51.65 (OF) 40.84 40.82 40.87 40.90 40.88 40.81 40.91 40.87 39.98 39.95 40.00 40.01 39.94 39.46 39.24 39.23 37.91 37.92 37.90 37.94 (OF) 39.39 39.34 39.39 39.32 39.31 39.51 39.59 39.57 39.51 38.73 38.78 38.62 38.74 38.27 38.28 38.11 39.45 39.10 38.61 38.86 (psi) 124.70 124.70 124.70 123.70 127.20 127.20 127.20 127.20 112.20 112.20 112.20 112.20 102.20 102.20 102.20 101.70 98.70 98.70 98.70 98.70 (psi) 88.70 88.70 88.70 88.70 89.70 89.70 89.70 89.70 87.20 87.20 86.70 86.70 85.70 85.70 84.70 84.70 82.70 82.20 80.70 80.70 (psi) 82.59 82.54 82.59 82.52 82.51 82.71 82.79 82.77 82.71 81.93 81.98 81.82 81.94 81.47 81.48 81.30 82.65 82.30 81.81 82.06 (lb/hr) 16.44 19.20 18.35 15.56 10.23 12.92 14.38 12.26 11.65 11.17 10.37 10.21 15.28 17.88 19.50 16.63 29.18 29.48 27.85 27.50 (lb/hr) 15.41 16.80 17.21 14.59 23.39 22.96 23.02 21.80 23.30 22.34 23.70 23.34 30.56 35.77 34.67 33.26 27.46 29.48 27.85 27.50 Table B.1: R-22 Experiment Raw Data (continued) Run 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 Angle (deg) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Heater Voltage (volts) 65.3 65.2 65.2 65.2 74.7 74.7 74.8 74.7 65.0 65.0 65.0 65.0 80.0 80.0 80.0 80.0 60.4 60.4 60.4 60.4 T1 (OF) 42.04 42.15 42.20 42.20 42.19 42.48 42.58 42.61 43.61 43.61 43.75 43.71 43.94 44.07 44.09 44.05 44.76 44.71 44.58 44.63 T2 (oF) 60.48 60.46 60.50 60.48 66.68 66.44 66.32 66.25 55.16 55.00 55.27 55.58 63.01 63.27 63.32 63.30 48.49 48.45 48.66 48.42 T3 (OF) 38.60 38.58 38.61 38.59 39.18 39.18 39.19 39.20 38.96 39.00 38.99 39.00 39.81 39.89 39.88 39.86 38.44 38.43 38.39 38.43 T4 (oF) 39.93 39.19 40.74 39.92 39.69 39.50 39.61 39.86 42.04 40.14 41.37 42.11 39.32 42.19 39.65 39.01 39.06 40.61 39.20 37.90 P2 (psi) 116.70 116.70 116.70 116.70 127.20 127.20 127.20 127.70 106.70 106.70 106.70 106.70 120.70 120.70 120.70 120.70 94.70 94.70 94.70 94.70 P3 P4 Left Mh, Right m, (psi) 83.70 83.70 82.70 82.70 84.70 84.70 84.70 84.70 82.70 82.70 82.70 82.70 85.70 85.70 85.70 85.70 81.70 84.70 82.70 82.70 (psi) 83.14 82.39 84.29 83.13 82.89 82.70 82.81 83.07 86.21 83.41 85.22 86.32 82.52 86.44 82.85 82.21 82.26 84.10 82.40 81.09 (lb/hr) 26.57 26.90 28.23 27.42 25.91 25.84 25.78 25.23 16.56 17.00 16.65 17.50 12.85 12.77 13.60 13.36 8.35 8.91 8.53 8.49 (lb/hr) 26.57 26.90 28.23 27.42 25.91 25.84 25.78 25.23 15.52 15.94 15.61 16.41 12.05 11.97 11.90 11.69 7.83 7.97 7.99 7.42 Table B.1: R-22 Experiment Raw Data (continued) Run 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Angle (deg) 0 0 0 0 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 Heater Voltage (volts) 75.1 75.0 75.0 74.9 75.4 74.8 74.8 75.0 60.4 60.3 60.3 60.2 49.9 49.9 50.4 50.7 65.3 65.4 65.4 65.4 T1 (OF) 44.91 45.09 45.00 45.14 45.95 45.95 45.90 45.97 45.37 45.28 45.48 45.18 41.70 41.99 42.01 42.10 42.48 42.50 42.51 42.52 T2 T3 T4 P2 P3 P4 (OF) 53.80 53.50 53.99 53.40 52.72 52.28 52.75 52.90 48.29 48.37 47.90 48.31 51.27 51.34 51.74 51.71 59.95 59.76 60.26 59.97 (OF) 39.45 39.33 39.36 39.42 39.82 39.74 39.44 39.28 38.61 38.80 38.56 38.48 37.91 37.93 37.96 38.03 38.74 38.78 38.71 38.73 (OF) 41.63 40.71 41.39 41.45 39.21 39.38 39.01 38.77 39.31 40.12 39.08 37.71 40.46 40.16 39.17 38.86 39.52 39.68 39.99 40.17 (psi) 103.70 103.70 103.70 103.70 102.70 102.70 102.70 102.70 95.70 96.70 95.70 95.70 100.70 98.70 100.70 100.70 114.70 114.70 114.70 114.70 (psi) 83.70 83.70 83.70 83.70 82.70 83.70 83.70 83.70 82.70 82.70 82.70 81.70 81.70 81.70 81.70 82.20 83.70 83.70 83.70 83.70 (psi) 85.60 84.25 85.25 85.34 82.41 82.58 82.21 81.97 82.51 83.38 82.28 80.90 83.88 83.44 82.37 82.06 82.72 82.88 83.20 83.45 Table B.1: R-22 Experiment Raw Data (continued) Left mi (lb/hr) 3.08 3.53 3.62 3.50 1.46 1.47 1.45 1.42 2.66 2.18 1.94 2.12 18.20 19.61 19.94 19.36 16.98 16.87 17.62 17.29 Right iz, (lb/hr) 3.85 4.12 4.22 4.08 2.93 2.45 2.41 2.36 10.63 11.63 10.34 11.28 36.40 39.23 39.89 38.72 33.96 33.74 35.25 34.59 Run Angle Heater Voltage T1 T2 T3 T4 P2 P3 P4 Left mth Right ri, 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 (deg) 90 90 90 90 90 90 90 90 90 90 90 90 180 180 180 180 180 180 180 180 (volts) 75.1 75.0 75.1 75.1 65.3 65.4 66.3 66.3 80.0 80.0 80.0 80.0 50.0 50.6 49.9 50.5 65.2 65.2 65.5 67.0 (oF) 42.46 42.60 42.75 42.81 43.92 43.74 43.65 43.49 43.97 44.06 44.20 44.14 42.15 42.21 42.04 42.01 42.04 42.24 42.30 42.35 (oF) 65.56 65.27 65.71 65.64 53.92 54.35 55.05 55.19 62.32 61.32 61.32 62.01 51.99 51.84 51.85 51.97 59.75 59.47 59.86 60.90 (oF) 39.22 39.34 39.31 39.32 38.72 38.71 38.74 38.80 39.74 39.76 39.65 39.73 37.91 37.90 37.85 37.83 38.56 38.53 38.55 38.68 (OF) 40.80 39.71 40.16 40.74 41.35 38.38 39.51 39.35 39.62 39.91 39.82 39.83 38.57 38.35 38.47 37.19 39.53 38.91 39.03 39.18 (psi) 125.70 125.70 125.70 125.70 104.70 105.70 106.70 106.70 118.70 118.70 119.70 119.70 101.70 101.70 101.70 101.70 114.70 114.70 114.70 116.70 (psi) 85.70 85.70 85.70 85.70 83.70 83.70 83.70 83.70 84.70 84.70 85.70 85.70 82.70 82.70 82.70 82.70 83.70 84.70 84.70 84.70 (psi) 84.38 82.91 83.44 84.29 85.19 81.58 82.71 82.55 82.82 83.12 83.02 83.03 81.77 81.55 81.67 80.38 82.73 82.11 82.23 82.38 (lb/hr) 15.54 15.39 16.63 13.07 7.61 9.23 7.67 7.74 8.08 6.13 7.95 7.85 28.90 30.19 26.92 30.87 25.97 24.33 22.97 26.87 (lb/hr) 31.07 30.77 29.56 29.86 20.30 21.11 20.46 20.65 12.94 12.26 14.14 13.96 28.90 28.41 30.77 30.87 27.70 27.80 26.25 26.87 Table B.1: R-22 Experiment Raw Data (continued) Run Angle Heater Voltage T1 T2 T3 T4 Left t, Right ith P2 P3 P4 (psi) 82.91 82.74 (lb/hr) 22.90 21.09 (lb/hr) 26.17 24.10 101 102 (deg) 180 180 (volts) 75.1 75.0 (OF) 42.46 42.71 (OF) 66.02 65.53 (oF) 39.21 39.26 (OF) 39.71 39.54 (psi) 126.70 125.70 (psi) 86.70 86.70 103 180 74.9 42.88 65.30 39.29 39.38 125.70 85.70 82.58 22.54 24.04 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 74.8 65.1 65.0 64.9 64.9 79.9 79.9 80.1 80.0 60.2 60.3 60.3 60.3 75.0 74.9 75.2 75.3 42.80 43.71 43.69 43.62 43.46 43.35 43.56 43.83 44.00 44.92 45.11 45.21 45.28 45.24 45.27 45.27 45.27 65.80 54.26 54.10 54.73 54.64 61.60 61.74 62.28 61.15 47.53 47.40 47.70 47.49 52.38 52.90 52.80 53.02 39.24 38.74 38.60 38.61 38.61 39.50 39.55 39.62 39.79 38.45 38.50 38.47 38.41 39.48 39.52 39.48 39.53 39.48 40.51 40.00 39.29 39.71 40.19 40.05 39.55 40.30 39.01 39.54 38.68 40.08 40.26 39.49 40.46 41.45 125.70 104.70 104.70 105.70 105.70 118.70 118.70 118.70 118.70 93.70 94.70 94.70 94.70 102.70 102.70 102.70 102.70 86.70 83.70 83.70 83.70 83.70 85.70 85.70 85.70 85.70 80.70 80.70 80.70 80.70 82.70 82.70 82.70 82.70 82.68 83.95 83.21 82.49 82.91 83.48 83.28 82.75 83.65 82.21 82.74 81.88 83.32 83.59 82.69 83.88 85.34 25.59 12.93 13.12 14.47 15.22 9.69 10.18 11.43 11.04 5.86 6.31 5.73 5.79 2.67 2.88 2.77 2.63 25.59 14.77 16.15 16.54 17.40 11.63 11.10 11.43 11.04 6.70 7.21 6.55 6.61 2.13 1.44 1.38 1.31 Table B.1: R-22 Experiment Raw Data (continued) Run 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 Angle (deg) 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 Heater Voltage (volts) 49.8 49.7 49.7 49.7 65.1 65.4 64.7 65.1 75.2 74.8 75.0 75.8 65.2 65.0 65.1 65.2 79.8 79.8 79.8 79.9 T1 (oF) 41.74 41.78 41.90 41.94 42.04 42.24 42.35 42.41 42.60 42.78 42.85 42.89 43.49 43.52 43.64 43.50 43.51 43.80 43.89 43.84 T2 (OF) 52.71 52.55 52.39 52.50 60.61 60.81 60.55 60.59 66.55 66.24 66.36 66.51 55.88 55.65 55.62 55.77 62.67 62.20 61.90 62.60 T3 (OF) 37.95 37.92 37.97 37.96 38.68 38.78 38.75 38.81 39.34 39.40 39.48 39.44 39.04 39.05 38.91 38.85 39.66 39.72 39.57 39.61 T4 P2 P3 P4 Left m, Right ih, (OF) 40.01 40.90 40.09 39.12 39.30 39.50 39.86 39.61 39.80 39.13 39.59 39.52 40.88 38.42 39.24 40.20 39.83 39.84 40.32 38.85 (psi) 101.70 100.70 100.70 101.70 115.70 116.70 115.70 115.70 127.70 126.70 126.70 127.70 107.70 106.70 106.70 106.70 119.70 119.70 119.70 119.70 (psi) 81.70 81.70 81.70 81.70 84.70 84.70 84.70 84.70 86.70 85.70 86.70 86.70 84.70 84.70 84.70 84.70 85.70 86.70 86.70 86.70 (psi) 83.22 84.52 83.34 82.32 82.50 82.70 83.07 82.81 83.00 82.33 82.79 82.72 84.49 81.62 82.44 83.50 83.03 83.05 83.67 82.05 (lb/hr) 40.26 37.12 37.98 39.05 35.58 33.85 34.69 33.84 28.89 30.13 30.84 30.22 19.76 20.93 21.61 20.37 13.28 12.62 13.86 12.33 (lb/hr) 22.65 18.56 18.99 19.52 17.79 19.04 17.35 19.03 18.06 18.83 15.42 17.00 9.88 10.46 12.15 8.91 8.30 9.46 8.66 8.48 Table B.1: R-22 Experiment Raw Data (continued) Run Angle Heater Voltage T1 T2 T3 T4 P2 P3 P4 Left ri, Right rill 141 142 (deg) 270 270 (volts) 60.0 59.9 (oF) 44.89 44.82 (oF) 48.96 48.93 (OF) 38.50 38.54 (OF) 39.87 41.47 (psi) 95.70 95.70 (psi) 80.70 80.70 (psi) 83.08 85.37 (lb/hr) 13.92 14.25 (lb/hr) 5.22 6.24 143 270 60.1 44.74 49.14 38.44 40.38 95.70 80.70 83.76 14.28 5.36 144 145 146 147 148 149 150 151 152 270 270 270 270 270 270 270 270 270 60.0 75.4 74.9 75.2 74.8 74.9 74.8 74.8 74.8 44.69 45.56 45.71 45.70 45.74 45.67 45.55 45.62 45.58 49.34 53.69 52.22 52.77 52.67 52.75 52.96 52.85 53.30 38.43 39.59 39.67 39.37 39.40 39.34 39.30 39.41 39.34 40.18 40.31 39.95 40.56 39.96 40.62 41.20 41.27 40.05 95.70 102.70 101.70 102.70 102.70 102.70 102.70 102.70 102.70 80.70 82.70 82.70 82.70 80.70 82.70 82.70 82.70 82.70 83.47 83.66 83.16 84.03 83.17 84.11 84.97 85.07 83.28 14.78 3.51 3.76 3.49 3.52 3.66 3.59 3.63 3.88 6.46 1.75 1.88 1.75 1.76 2.74 2.69 2.72 2.91 Table B.1: R-22 Experiment Raw Data (continued) Appendix C Calculations The schematic in Figure C.1 was used to calculate the quality, X, of the flow in the approach tube, point 3. Nomenclature and subscript definitions are given in Appendix A. 3r-------------------- i L --------- Throttle Valve I Test Section Sectio Pump Figure C.I: Schematic of Refrigerant Cycle Assumptions 1. A P2, negligible pressure drop across the heater because of the low velocity. 2. v, v4 , specific volume change across the pump is minimal 3. h3 1, constant enthalpy across the throttle valve. Calculations An energy balance across the pump between points 4 and 1 and assumption 2 gives A= h4 (C.1) (p -p4). Using assumption 1 and substituting it into equation C.1 we get A = h4 + v(2 - ). (C.2) Now looking at the energy balance between points 1 to 2 we have + (C.3) m where V2 R (C.4) Q is the heat input from the heater, V is the voltage applied to the heater, and R is the electrical resistance of the heater, 7.9 ohms, and th is the total mass flow rate. Substituting equations C.2 into equation C.3 the result is S=h 4 V 4(p 2 4)+ m . (C.5) The R-22 is at saturated conditions at point 3 and we have h = I +Xhg. (C.6) Assumption 3, h3 = , allows us to equate equations C.5 and C.6 to get h4 + v4(p2 p,)+ -4 - = m (C.7) + Xg i Since the mass flow rate of the liquid, mi, is measured substitute (C.8) I-x into equation C.7 h4 + v4(p2 -4) 1 -+ m,, X+ , (C.9) and solve for X [(h4 - ,) + v4(), - P,)z + Q mA,, +Q Calculated data is given in Table C.1 below. (C.10) Run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 -0 Angle (deg) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0- Mass Flux (1041b/hr-ft2 ) 3.80 3.93 4.19 4.16 5.35 5.28 5.35 5.48 5.17 5.35 5.18 5.07 8.87 9.28 9.49 9.49 8.16 8.24 8.74 8.24 2 Fr 0.43 0.43 0.43 0.42 0.43 0.42 0.42 0.43 0.72 0.72 0.71 0.71 0.41 0.42 0.42 0.42 0.71 0.72 0.72 0.72 -.7 Left (%) 53.33 53.33 55.17 55.17 55.17 55.17 53.33 55.17 53.33 53.33 52.94 53.33 51.61 51.61 51.61 51.61 55.17 53.33 51.61 51.61 Right (%) 46.67 46.67 44.83 44.83 44.83 44.83 46.67 44.83 46.67 46.67 47.06 46.67 48.39 48.39 48.39 48.39 44.83 46.67 48.39 48.39 8.9 x (%) 43.48 42.02 39.64 39.33 31.61 31.31 30.84 30.49 54.45 52.44 53.84 54.75 18.31 17.84 17.37 17.34 34.15 33.96 32.05 33.97 3 -. Slip Ratio 2.14 2.14 2.13 2.14 2.13 2.13 2.13 2.13 2.12 2.12 2.12 2.13 2.11 2.11 2.10 2.10 2.12 2.12 2.12 2.12 -16 Table C.1: R-22 Calculated Data at (%) 95.04 94.75 94.23 94.17 91.96 91.87 91.70 91.58 96.72 96.46 96.64 96.76 84.55 84.11 83.66 83.62 92.73 92.67 92.07 92.68 jl (ft/sec) 0.08 0.08 0.09 0.09 0.13 0.13 0.13 0.13 0.08 0.09 0.08 0.08 0.25 0.27 0.28 0.28 0.19 0.19 0.21 0.19 jg (ft/sec) Flow Regime 3.08 3.07 3.08 3.05 3.12 3.05 3.04 3.09 5.16 5.15 5.12 5.10 2.93 2.98 2.96 2.96 5.09 5.11 5.11 5.12 stratified stratified stratified stratified stratified stratified stratified stratified stratified stratified stratified stratified annular annular annular annular annular annular annular annular Angle Mass Flux (deg) (1041b/hr-ft 2) 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 0 0 0 0 90 90 90 90 90 90 90 90 90 90 90 90 0 0 0 8.14 8.70 8.64 7.93 8.43 8.73 8.93 8.48 7.45 7.26 7.34 7.26 7.69 8.73 8.81 8.24 9.17 9.47 9.02 40 0 8.93 Run Fr 1.00 1.00 1.00 1.00 1.01 1.01 1.01 1.01 0.72 0.72 0.73 0.72 0.42 0.42 0.42 0.42 0.43 0.43 0.43 0.43 j jg Flow (%) (ft/sec) (ft/sec) Regime 95.79 95.28 95.33 96.01 95.62 95.35 95.15 95.56 93.77 94.02 93.94 94.00 86.90 85.07 85.06 86.06 84.88 84.28 84.91 85.11 0.15 0.17 0.16 0.14 0.16 0.17 0.17 0.16 0.16 0.16 0.16 0.16 0.21 0.25 0.25 0.23 0.26 0.27 0.26 0.25 7.08 7.10 7.09 7.09 7.16 7.18 7.17 7.16 5.17 5.17 5.18 5.16 2.99 3.01 3.04 3.03 3.15 3.13 3.10 3.11 annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular Left Right x Slip tg (%) (%) (%) Ratio 51.61 53.33 51.61 51.61 30.43 36.00 38.46 36.00 33.33 33.33 30.43 30.43 33.33 33.33 36.00 33.33 51.52 50.00 50.00 50.00 48.39 46.67 48.39 48.39 69.57 64.00 61.54 64.00 66.67 66.67 69.57 69.57 66.67 66.67 64.00 66.67 48.48 50.00 50.00 50.00 48.30 45.30 45.61 49.72 47.25 45.67 44.64 46.91 37.97 38.97 38.65 38.91 21.24 18.75 18.71 19.96 18.33 17.66 18.37 18.61 2.11 2.11 2.10 2.10 2.10 2.11 2.10 2.10 2.12 2.12 2.12 2.12 2.12 2.12 2.13 2.13 2.14 2.14 2.14 2.14 Table C.1: R-22 Calculated Data (continued) Left Right x Slip a jl jg Flow (%) (%) (%) Ratio (%) (ft/sec) (ft/sec) Regime 0.73 0.73 0.74 0.73 0.95 0.95 0.95 0.95 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 50.00 28.86 28.39 27.77 28.16 35.05 35.07 35.21 35.69 2.13 2.14 2.13 2.13 2.13 2.13 2.13 2.13 90.98 90.79 90.53 90.70 93.04 93.04 93.08 93.22 0.25 0.25 0.26 0.25 0.24 0.24 0.24 0.23 5.29 5.24 5.33 annular annular annular 5.28 6.82 6.81 6.83 6.83 annular annular annular annular annular 7.09 0.73 51.61 48.39 40.19 2.13 94.34 0.15 5.27 annular 0 0 0 0 0 7.16 7.10 7.34 7.50 7.55 0.72 0.73 0.73 1.08 1.09 51.61 51.61 51.61 51.61 51.61 48.39 48.39 48.39 48.39 48.39. 39.19 39.93 38.90 56.11 56.67 2.13 2.13 2.13 2.12 2.12 94.11 94.28 94.04 96.92 96.99 0.15 0.15 0.16 0.12 0.11 5.19 5.24 5.27 7.70 7.82 annular annular annular annular annular 55 0 7.59 1.08 53.33 46.67 55.57 2.12 96.85 0.12 7.71 annular 56 57 58 59 60 0 0 0 0 0 7.51 4.54 4.66 4.59 4.49 1.07 0.62 0.63 0.62 0.62 53.33 51.61 52.78 51.61 53.33 46.67 48.39 47.22 48.39 46.67 55.93 52.92 52.11 52.43 53.18 2.12 2.14 2.14 2.14 2.14 96.90 96.55 96.44 96.49 96.58 0.12 0.07 0.08 0.08 0.07 7.69 4.47 4.52 4.48 4.45 annular stratified stratified stratified stratified Angle Mass Flux (deg) (1041b/hr-ft2) 41 42 43 44 45 46 47 48 0 0 0 0 0 0 0 0 9.88 9.93 10.33 10.09 10.55 10.52 10.52 10.37 49 0 50 51 52 53 54 Run Fr Table C.1: R-22 Calculated Data (continued) Slip Ratio 2.12 2.13 ca (%) 99.02 98.91 j (ft/sec) jg (ft/sec) Flow Regime 55.56 53.85 x (%) 80.36 78.65 0.03 0.04 6.88 6.85 stratified stratified Right 4.66 4.73 0.96 0.95 Left (%) 44.44 46.15 0 4.77 0.96 46.15 53.85 78.26 2.13 98.89 0.04 6.87 stratified 0 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 90 4.73 4.32 4.20 4.19 4.19 4.16 4.23 4.02 4.14 8.93 9.48 9.62 9.39 9.57 9.53 9.85 9.72 0.95 0.96 0.94 0.94 0.95 0.62 0.62 0.62 0.61 0.44 0.44 0.44 0.44 0.73 0.73 0.74 0.74 46.15 33.33 37.50 37.50 37.50 20.00 15.79 15.79 15.79 33.33 33.33 33.33 33.33 33.33 33.33 33.33 33.33 53.85 66.67 62.50 62.50 62.50 80.00 84.21 84.21 84.21 66.67 66.67 66.67 66.67 66.67 66.67 66.67 66.67 78.78 86.56 87.64 87.81 88.10 57.81 56.88 59.60 57.24 19.14 17.96 17.75 18.26 29.60 29.83 29.01 29.44 2.13 2.12 2.12 2.12 2.13 2.13 2.13 2.14 2.14 2.14 2.14 2.14 2.14 2.13 2.13 2.13 2.13 98.92 99.37 99.43 99.44 99.46 97.15 97.04 97.35 97.09 85.54 84.55 84.36 84.80 91.26 91.35 91.04 91.20 0.04 0.02 0.02 0.02 0.02 0.06 0.06 0.06 0.06 0.25 0.27 0.28 0.27 0.24 0.23 0.24 0.24 6.85 6.84 6.74 6.76 6.80 4.47 4.46 4.45 4.41 3.20 3.19 3.19 3.21 5.25 5.27 5.30 5.31 stratified stratified stratified stratified stratified stratified stratified stratified stratified annular annular annular annular annular annular annular annular 61 62 Angle (deg) 0 0 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 Run Mass Flux Fr (1041b/hr-ft2) (%) Table C.1: R-22 Calculated Data (continued) Run 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Angle Mass Flux (deg) (1041b/hr-ft2 ) 90 90 90 90 90 90 90 90 90 90 90 90 180 180 180 180 180 180 180 180 - 9.93 9.82 9.85 9.44 6.55 6.82 6.63 6.66 6.99 6.65 7.14 7.10 9.30 9.44 9.28 9.82 9.92 9.70 9.35 10.08 Fr 0.97 0.95 0.96 0.97 0.74 0.72 0.75 0.75 1.08 1.08 1.08 1.08 0.43 0.44 0.43 0.43 0.73 0.72 0.73 0.77 j jg Flow Ratio at (%) (ft/sec) (ft/sec) Regime 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.12 2.12 2.12 2.12 2.14 2.14 2.14 2.14 2.14 2.14 2.14 2.13 93.80 93.78 93.82 94.25 95.06 94.56 95.10 95.05 97.40 97.72 97.27 97.30 84.48 84.56 84.45 83.55 90.84 91.03 91.56 91.23 0.22 0.21 0.21 0.20 0.13 0.14 0.13 0.13 0.10 0.09 0.10 0.10 0.27 0.27 0.27 0.29 0.25 0.24 0.23 0.25 6.95 6.85 6.90 6.93 5.30 5.20 5.39 5.38 7.72 7.73 7.74 7.73 3.11 3.18 3.10 3.11 5.26 5.22 5.28 5.52 - Left Right x Slip (%) (%) (%) 33.33 33.33 36.00 30.43 27.27 30.43 27.27 27.27 38.46 33.33 36.00 36.00 50.00 51.52 46.67 50.00 48.39 46.67 46.67 50.00 66.67 66.67 64.00 69.57 72.73 69.57 72.73 72.73 61.54 66.67 64.00 64.00 50.00 48.48 53.33 50.00 51.61 53.33 53.33 50.00 37.95 37.88 38.02 39.86 43.65 41.16 43.88 43.61 60.27 63.45 59.12 59.41 17.88 17.97 17.83 16.88 28.51 28.97 30.38 29.50 Table C.1: R-22 Calculated Data (continued) annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annularmmm 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 Angle (deg) 180 180 180 180 180 180 180 180 180 180 180 180 180 180 180 117 118 119 120 180 180 180 180 Run 116 180 Mass Flux (1041b/hr-ft2 ) 10.22 9.69 9.86 10.46 6.49 6.68 6.88 7.11 7.04 7.03 7.25 7.15 4.05 4.19 4.01 4.35 4.26 4.28 4.28 4.05 Right (%) 53.33 53.33 51.61 50.00 53.33 55.17 53.33 53.33 54.55 52.17 50.00 50.00 53.33 53.33 53.33 X (%) 36.54 38.36 37.55 35.34 43.53 42.04 40.45 39.32 59.96 59.99 58.32 59.18 58.97 57.33 59.56 Slip Ratio 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.13 2.12 2.12 2.12 2.12 2.14 2.14 2.14 a (%) j (ft/sec) jg (ft/sec) Flow Regime 0.96 0.95 0.95 0.95 0.73 0.72 0.72 0.72 1.08 1.08 1.08 1.08 0.62 0.62 0.62 Left (%) 46.67 46.67 48.39 50.00 46.67 44.83 46.67 46.67 45.45 47.83 50.00 50.00 46.67 46.67 46.67 93.44 93.90 93.70 93.12 95.04 94.75 94.41 94.16 97.37 97.37 97.18 97.28 97.28 97.10 97.34 0.23 0.21 0.22 0.24 0.13 0.14 0.14 0.15 0.10 0.10 0.11 0.10 0.06 0.06 0.06 6.89 6.85 6.82 6.82 5.23 5.21 5.17 5.19 7.76 7.74 7.75 7.75 4.44 4.47 4.45 annular annular annular annular annular annular annular annular annular annular annular annular stratified stratified stratified 0.95 0.95 0.96 0.96 55.56 66.67 66.67 66.67 44.44 33.33 33.33 33.33 85.41 86.62 87.19 87.83 2.12 2.12 2.12 2.12 99.31 99.38 99.41 99.44 0.02 0.02 0.02 0.02 6.82 6.78 6.86 6.90 stratified stratified stratified stratified Fr 0.62 46.67 53.33 59.50 2.14 97.34 Table C.1: R-22 Calculated Data (continued) 0.06 4.48 stratified Left Right x Slip cc jl jg Flow (%) (%) (%) Ratio (%) (ft/sec) (ft/sec) Regime 0.44 0.44 64.00 66.67 36.00 33.33 16.94 18.84 2.14 2.14 83.60 85.30 0.29 0.26 3.17 3.20 annular annular 9.22 0.44 66.67 33.33 18.29 2.14 84.83 0.26 3.15 annular 9.40 9.87 9.83 9.67 9.81 9.95 10.16 9.83 10.04 6.76 6.92 7.26 6.70 7.05 7.12 7.19 6.94 0.43 0.72 0.73 0.72 0.72 0.96 0.94 0.95 0.97 0.73 0.71 0.72 0.73 1.08 1.08 1.08 1.07 66.67 66.67 64.00 66.67 64.00 61.54 61.54 66.67 64.00 66.67 66.67 64.00 69.57 61.54 57.14 61.54 59.26 33.33 33.33 36.00 33.33 36.00 38.46 38.46 33.33 36.00 33.33 33.33 36.00 30.43 38.46 42.86 38.46 40.74 17.64 28.49 28.89 28.86 28.73 37.63 36.26 37.79 37.80 42.00 40.01 38.52 42.19 59.56 59.00 58.59 60.37 2.14 2.13 2.13 2.13 2.13 2.13 2.13 2.12 2.12 2.13 2.13 2.13 2.13 2.12 2.12 2.12 2.12 84.26 90.83 90.98 90.97 90.91 93.72 93.36 93.75 93.76 94.72 94.29 93.96 94.77 97.32 97.26 97.22 97.41 0.27 0.25 0.24 0.24 0.24 0.22 0.23 0.21 0.22 0.14 0.15 0.16 0.14 0.10 0.10 0.10 0.10 3.10 5.22 5.26 5.17 5.22 6.89 6.78 6.83 6.97 5.24 5.11 5.17 5.23 7.70 7.70 7.74 7.69 annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular annular Angle Mass Flux (deg) (1041b/hr-ft2) 121 122 270 270 10.01 9.07 123 270 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 270 Run Fr Table C.1: R-22 Calculated Data (continued) Angle Mass Flux (deg) (1041b/hr-ft 2) 141 142 143 144 145 146 147 148 270 270 270 270 270 270 270 270 4.92 5.11 5.00 5.20 4.45 4.44 4.43 4.39 149 270 150 151 152 270 270 270 Run Fr Left Right x Slip a jl jg Flow Regime (%) (%) (%) Ratio (%) (ft/sec) (ft/sec) 0.61 0.62 0.62 0.62 0.96 0.95 0.96 0.95 72.73 69.57 72.73 69.57 66.67 66.67 66.67 66.67 27.27 30.43 27.27 30.43 33.33 33.33 33.33 33.33 48.53 47.03 48.07 46.01 84.36 83.24 84.37 84.09 2.14 2.14 2.14 2.14 2.12 2.12 2.13 2.13 95.91 95.67 95.84 95.50 99.25 99.19 99.26 99.24 0.09 0.09 0.09 0.10 0.02 0.03 0.02 0.02 4.44 4.47 4.47 4.45 6.89 6.78 6.88 6.79 stratified stratified stratified stratified stratified stratified stratified stratified 4.56 0.95 57.14 42.86 81.44 2.13 99.09 0.03 6.83 stratified 4.54 4.55 4.59 0.95 0.95 0.95 57.14 57.14 57.14 42.86 42.86 42.86 81.70 81.53 80.45 2.13 2.13 2.13 99.10 99.09 99.03 0.03 0.03 0.03 6.83 6.82 6.80 stratified stratified stratified Table C.1: R-22 Calculated Data (continued) Appendix D Empirical Correlation Derivation First an equation, equation D.1, was assumed. The Froude number, void fraction, and the angle of orientation were used as correlating factors because, from the data, it could be seen that they had the largest effects on the flow distribution. A least squares solution to was used to derive the empirical correlation. -= 0.5- c sinO (1- a)2 Frc (D.1) The natural log of equation D.1 was taken ( 0.5 - wl\ - InnIsinOWI=Incq + c2 In(1- a) + c3 In(Fr) | m This was put into a matrix for using the data for annular flow conditions. 0.5 b, = In sinO . (D.2) a, 1 =1 (D.3) a, = In(Fr) rln c, X= C2 (D.4) C3 where i = 1... n, n being the number of data points, b, is the ith term in the vector b, ai, is the component of the matrix A in the ith row andjth column. We now have the matrix equation (D.5) Ax = b. We can now use the least squares method as follows A TAx =A Tb, (D.6) (ATA)I ATAx =(ATA)-I ATb, (D.6) x= (ATA)IA b, (D.8) giving 1 [ -1.93 x= 12.2710 [ -0.24 -3 i, ] c = e x' C2 = X 2 C3 = X 3 Finally we have c = 0.145, c2 = 2.27- 10- 3 , and c3 = -0.24 and Equation 3.1. = 0.5 - 0.145 sin 01 - a) 002Fr-04 (3.1) w A comparison between the measured and correlated data is illustrated in Figure 3.7. The calculated data is within +8% and -6% of the experimental data. An equation, equation 3.2, was derived using the method as above with the exceptions of using the void fraction and Froude number as factors. -= 0.5 - 0.155 sin 80, (3.2) This equation gives calculated data within +9% and -6% of the experimental data as illustrated in Figure 3.8.