XXIX Congresso UIT sulla Trasmissione del Calore Torino, 20-22 Giugno 2011 AIR-WATER TWO-PHASE FLOW IN A HORIZONTAL T-JUNCTION: FLOW PATTERNS, PHASE SEPARATION AND PRESSURE DROPS. Cristina Bertani, Daniele Grosso, Mario Malandrone, Bruno Panella Dipartimento di Energetica, Politecnico di Torino ABSTRACT This paper reports further results of the experimental campaign on two-phase flow in horizontal T-junction that has being carried out in the thermal-hydraulics laboratory of Dipartimento di Energetica of Politecnico di Torino since 2005. The test facility is provided with a dividing T-junction, used in the branching configuration. The pipes forming the tee junction are about 1 m long, their inner diameter is 10 mm and a mixture of air and water flows at pressures up to 1.5 barg. The present work reports the results with water superficial velocities in the range 0.95-3.61 m/s and air superficial velocities in the range 0.44-34.5 m/s. Flow patterns were also visualised systematically by filming the flow patterns across the three pipes in each experimental run. As far as the evaluation of pressure drops is concerned, experimental results are used to modify the Separated Flow Model: the Zuber formulation for the void fraction is adopted and both the pressure drop correction factor and local pressure loss coefficient are expressed as function not only of the extraction ratio but also of the flow pattern. INTRODUCTION Two-phase flow through T-junctions is frequent in conventional power plants as well as in water nuclear reactors and in chemical industries. Since the 80’s several studies on this subject have been carried out both theoretically and experimentally, for different types of dividing T-junctions, i.e. branching tees and impacting tees [1, 2]. Nevertheless, further experimental studies are necessary in order to improve and validate models able to predict the splitting of phases and the flow patterns in the run and in the branch pipes of the branching-T and pressure drops through the T-junction. In branching tees one of the outlet pipes (named “run”) is aligned with the inlet pipe and the other outlet (named “branch”) is perpendicular to the inlet pipe. The liquid and gaseous phases entering the T-junction can be unevenly split at the junction, so that the flow rates in the run and in the branch depend on the different momentum flux of the two phases: the phase with higher momentum flux tends to flow in the run pipe and the one with lower momentum flux flows preferably into the branch. Also the flow quality can be different in the run and branch pipe. The pressure drop through the T-junction is strongly influenced by the phase separation, as well as by the void fraction and by the flow pattern in the pipes. On the other hand the flow regime affects the pressure drops between the inlet and the outlet pipes. Phenomena are also affected by gravity effects and if the Tjunction lays on a horizontal plane, stratification phenomena can occur. An experimental research is being carried out at Dipartimento di Energetica of Politecnico di Torino in order to investigate pressure drops, phase splitting and flow patterns in a horizontal T-junction with 10 mm inner diameter pipes. In previous works experimental results on the effect of extraction rate (ratio between total branch flow rate and total inlet flow rate) and on phase separation have been performed. In each test the flow patterns in the three pipes have been observed. In the first part of the experimental campaign [3, 4, 5, 6] the superficial velocities of water and air reached maximum values of 0.73 m/s and 63.3 m/s respectively, flow regimes were bubbly, wavy, intermittent and annular. In the second part of the experimental campaign [7] water superficial velocities were raised to the range 1.53-3.61 m/s (with air superficial velocity ranging up to 23.9 m/s) and the flow patterns were bubbly or slug-plug flow. Experimental results of flow patterns, phase separation and pressure drops have been compared with data and correlations available in the literature. In particular, the experimental results allowed to develop a correction factor to be applied to the Separated Flow Model. The present work reports also the results of the third part of the experimental campaign, covering an intermediate range of water flow rate, with water superficial velocities in the range 0.95-1.36 m/s and air superficial velocities in the range 5.9834.5 m/s [8]. EXPERIMENTAL FACILITY The experimental facility is schematically shown in fig. 1. It mainly consists of the feeding lines for air and water, the mixer, the T-junction, the outlet pipes and an air-water separator having a volume of approximately 0.4 m3. The water is sucked by a centrifugal pump from a tank where the liquid level is maintained constant by feeding water continuously. The two-phase mixture develops in a T-mixer that is located at the inlet of the test section. The test section is shown in fig. 2. It consists of three plexiglas pipes (10 mm in diameter, about 1 m long) named inlet, run and branch. Four pressure taps are placed on each of them. A system of valves allows to obtain different values of the total flow rate in the run and in the branch pipe. compressed air line air discharge air inlet flowmeter air outlet flowmeters separation tank by-pass line water tank pump diaphragm air-water mixer for water flow rate measurement branch tee-junction inlet run Table 1: Test matrix Water inlet flow rate [g/s]: 77295 (six groups of flow rates with average values of 83 g/s, 105 g/s, 132 g/s, 180 g/s, 230 g/s, 283 g/s) Water temperature [°C]: 12.213.5 Inlet pressure at pressure tap I1 [barg]: 0.611.51 Air inlet flow rate [Nm3/h]: 0.2215.9 Inlet flow quality [%]: 0.036.26 Branch flow rate/inlet flow rate: 01 Water superficial velocity at the inlet [m/s]: 0.953.61 Air superficial velocity at the inlet [m/s]: 0.4434.5 Flow pattern in the inlet pipe: annular, intermittent and bubbly EXPERIMENTAL RESULTS water discharge tank Figure 1. Experimental facility. As far as instrumentation is concerned, a resistance temperature detector measures the inlet water temperature, while a pressure transducer (full-scale 5 bar) and a differential pressure transducer (full-scale 0.37 bar) are respectively used to measure the inlet pressure at tap I1 and the pressure drops between the different pressure taps in the test section. Flow meters with full-scale 1050 and 5000 Nl/h measure the air flow rate at the inlet of the test section. The inlet water flow rate is evaluated as function of the pressure drop through a diaphragm, which is measured by a differential pressure transducer (full-scale 0.37 bar). The experimental results on phase separation between run and branch, the pressure drops and the flow patterns are here presented. Phase separation The phase separation is described by the ratio between the flow rates in the branch and the ones in the inlet FBG WG3 WG1 , FBL WL3 WL1 , whose values are reported in fig. 3. In the tested range of conditions, FBG is always much higher than FBL; it reaches a value of approximately 0.9 and remains constant when FBL is higher than 0.3. Therefore air flows preferably into the branch pipe in all the tests, as already shown in [3], [4], [5], [6] and [7]; moreover there is a slight influence of the water flow rate on FBG , which decreases at increasing water flow rates. 1.00 FBG 0.80 0.60 0.40 Figure 2. Test section, with the pressure taps I1I4, R1R4, B1B4. 0.20 Water and air flowing through one of the exit pipes are sent to the separator tank and the separator exit valves are regulated so that the water level in the separator is kept constant. The air flow rate exiting the separator tank is measured by flow meters with full-scale of 340 Nl/h, 1050 N/l and 6000 Nl/h. The flow rate of water through one of the outlet pipes is measured by means of the weighting technique. The data acquisition system makes use of Field Points by National Instruments and works in Labview environment. A Panasonic video camera Model AG-DVC30E was used in order to visualise the flow patterns. Table 1 summarizes the test conditions of the third part of the experimental campaign and also the test matrix of the experiments already reported in [7]. 0.00 0.00 Group 1 - Wl 83 g/s Group 2 - Wl 105 g/s Group 3 - Wl 132 g/s Group 4 - Wl 180 g/s Group 5 - Wl 230 g/s Group 6 - Wl 283 g/s 0.20 0.40 0.60 0.80 1.00 FBL Figure 3. Phase separation between run and branch. Flow patterns The prevailing flow patterns in the three pipes were intermittent-slug (with slugs of different lengths) and bubbly at higher water flow rates. At low water flow rate annular flow regime was also observed; it most often occurs in the transition region with 2 water flow rate 105 g/s air flow rate 9471 Nl/h FBL 0.31 1.9 Pressure / (bar) intermittent flow; pulsated perturbations are observed to be more consistent near the transition zone. Transition regimes are also observed between intermittent flow and bubbly flow. Sometimes both intermittent and bubbly or intermittent and annular flow patterns occurred simultaneously. There is a good agreement between the flow patterns occurring in our experiments and the prediction of TaitelDuckler’s map [9], as shown in fig. 4a and 4b. 1.8 Inlet Run Branch 1.7 1.6 1.5 1.4 10 1.3 Intermittent + Bubbly Annular 0 1 Fr 1.7 Pressure / (bar) Stratified + Wavy 0.01 Intermittent + Bubbly Intermittent / Annular Annular / Intermittent Annular 0.001 0.01 0.1 1 10 100 1000 Branch 1.3 T Slug / Plug Slug / Plug Bubbly / Intermittent Intermittent / Bubbly Bubbly 0.01 1 10 0.5 1 1.5 2 Distance from I1 pressure tap / (m) 2.5 Figure 5. Examples of pressure behaviour at different air and water flow rates. PRESSURE DROPS IN THE As far as the evaluation of the pressure drops in the teejunction is concerned, the models already reported in [3], [4], [5], [6] and [7] have been used. The differential pressure between inlet and run Δp 12 p1 p 2 is evaluated by a momentum flux balance with a correction factor k12 which is determined experimentally: 1 0.1 Run ANALYSIS OF T-JUNCTION Bubbly 2.5 Inlet 0 10 2 1.5 X Figure 4a. Comparison between observed flow patterns and Taitel-Duckler’s map. 1.5 1.6 1.4 0.001 1 Distance from I1 pressure tap / (m) water flow rate 283 g/s air flow rate 222 Nl/h FBL 0.62 1.8 0.1 0.5 100 1000 10000 X Figure 4b. Comparison between observed flow patterns and Taitel-Duckler’s map for bubbly and plug-slug regimes. Pressure distributions along inlet, run and branch Pressures along inlet, run and branch pipes have been measured. The pressure difference between inlet and run and between inlet and branch have been determined by extrapolating the values measured at the pressure taps to the centre of the junction (a second order polynomial has been used). The extrapolated values of p1-p3 and p1-p2 are respectively in the ranges 14÷126 mbar and (-10)÷(-128) mbar, with an uncertainty of 4 mbar, which correspond to a relative uncertainty of 3÷40 %. Typical pressure values in tests with low water flow rate are shown in fig. 5. As already reported in [7], both linear and non linear pressure distributions have been found: greater nonlinearity occurs at increasing air flow rate, while profiles tend to be more linear at high water flow rate. G2 G2 p12 k12 2 1 2 1 (1) The differential pressure between inlet and branch p13 p1 p 3 is evaluated as the sum of a reversible pressure change due to kinetic energy variation and an irreversible pressure drop that depends on the local pressure drop coefficient k13 referred to the inlet mass velocity: p13 H3 2 G2 G2 G2 23 21 k13 1 2 L 3 1 (2) In the Homogeneous Flow Model (HFM) and in the Separated Flow Model (SFM) the pressure drops are evaluated by means of Eq. (1) and (2) using two-phase multiplier and density calculated in different ways, and the Rouhani void fraction correlation [10]. Instead, in the Reimann & Seeger model (RSM) the pressure drop p12 is given by the sum of the pressure drop through the vena contracta and the one through the successive enlargement, and the pressure difference p13 is evaluated by Eq. (2) using the homogeneous density [11]. In the present work the experimental values for Δp12 and Δp13 are compared with HFM, SFM and RSM. Figure 6 shows a fairly good agreement between experimental data and SFM (as already reported in [7]); on the other hand, the prediction of HFM is less accurate in the tests with low water flow rates and therefore low pressure drops. relatively well with the experimental data for Δp13 , while its accuracy is much lower for the Δp12. 0.20 +50% 0.15 0.20 0.10 Δp predicted / (bar) +50% 0.15 Δp predicted / (bar) 0.10 -50% 0.05 -50% 0.05 0.00 -0.05 0.00 -0.10 -0.05 -0.15 -0.10 -0.20 -0.20 -0.15 -0.10 -0.05 0.00 0.05 0.10 0.15 0.20 -0.15 Δp measured / (bar) -0.20 Δp12 SFMZF - Wl 83 g/s Δp12 SFMZF - Wl 105 g/s Δp12 SFMZF - Wl 132 g/s Δp12 SFMZF - Wl 180 g/s Δp12 SFMZF - Wl 230 g/s Δp12 SFMZF - Wl 283 g/s -0.20 -0.15 -0.10 -0.05 0.00 0.05 0.10 0.15 0.20 Δp measured / (bar) Δp13 SFM - Wl 83 g/s Δp13 SFM - Wl 105 g/s Δp13 SFM - Wl 132 g/s Δp13 SFM - Wl 180 g/s Δp13 SFM - Wl 230 g/s Δp13 SFM - Wl 283 g/s Δp13 HFM - Wl 83 g/s Δp13 HFM - Wl 105 g/s Δp13 HFM - Wl 132 g/s Δp13 HFM - Wl 180 g/s Δp13 HFM - Wl 230 g/s Δp13 HFM - Wl 283 g/s Figure 6. Comparison of experimental pressure drops and the predictions of HFM e SFM. As in [7], a new correlation has been developed in order to improve the agreement with the experimental data; the following correction factor has been applied to the loss coefficient k13 of SFM: Firr 0.534 0.946 W3 W1 (3) A better agreement with SFM can be achieved by substituting the Rouhani correlation with the Zuber formulation and using the drift velocity ugj = 0 and C0 = 1.2, i.e. the values for slug flow in horizontal pipes. The comparison between the modified separated flow model (hereafter indicated as SFMZ) and experimental data is shown in fig. 7. No satisfying correction factor has been found to improve the prediction of Δp12. Finally, the accuracy of the Reimann & Seeger model has been evaluated. In order to evaluate Δp13 , the correlation originally suggested by Reimann & Seeger for k13 has been substituted with the correlation more recently proposed by Buell [10], as this latter allows a slightly better prediction of the experimental data. As shown in fig. 8, the RSM agrees Figure 7. Comparison of experimental pressure differences and the value predicted by SFMZ. 0.2 +50% 0.15 0.1 Δp calcolata (bar) Δp12 SFM - Wl 83 g/s Δp12 SFM - Wl 105 g/s Δp12 SFM - Wl 132 g/s Δp12 SFM - Wl 180 g/s Δp12 SFM - Wl 230 g/s Δp12 SFM - Wl 283 g/s Δp12 HFM - Wl 83 g/s Δp12 HFM - Wl 105 g/s Δp12 HFM - Wl 132 g/s Δp12 HFM - Wl 180 g/s Δp12 HFM - Wl 230 g/s Δp12 HFM - Wl 283 g/s Δp13 SFMZF - Wl 83 g/s Δp13 SFMZF - Wl 105 g/s Δp13 SFMZF - Wl 132 g/s Δp13 SFMZF - Wl 180 g/s Δp13 SFMZf - Wl 230 g/s Δp13 SFMZf - Wl 283 g/s -50% 0.05 0 -0.05 -0.1 -0.15 -0.2 -0.20 -0.15 -0.10 -0.05 0.00 0.05 0.10 0.15 0.20 Δp measured / (bar) Δp12 RSM - Wl 83 g/s Δp12 RSM - Wl 105 g/s Δp12 RSM - Wl 132 g/s Δp12 RSM - Wl 180 g/s Δp12 RSM - Wl 230 g/s Δp12 RSM - Wl 283 g/s Δp13 RSM - Wl 83 g/s Δp13 RSM - Wl 105 g/s Δp13 RSM - Wl 132 g/s Δp13 RSM - Wl 180 g/s Δp13 RSM - Wl 230 g/s Δp13 RSM - Wl 283 g/s Figure 8. Comparison of experimental pressure drops with the prediction of the Riemann & Seeger model. Finally, as far as the evaluation of pressure drops is concerned, we attempted to develop a new model (hereafter indicated as PM) that takes into account the different flow patterns occurring in the experimental tests. As a basis, the typical correlations of the SFMZ have been used, but we introduced coefficients k12 e k13 that also depend on flow pattern and extraction ratio. The structure chosen for the above mentioned coefficients is the one proposed by El-Shaboury, Soliman and Sims [12]: Figure 9 shows that, by the use of the above mentioned coefficients, the data dispersion is reduced and the most part of points are within ±25%. Almost all the points for Δp13 lay within ±20%. 0.20 +25% 0.15 +50% -25% 0.10 k12 C1 W3 W1 C 2 W3 W1 C3 k13 C 4 W3 W1 2 C5 W3 W1 C 6 (4) where: C1 A logRe 1 B logRe1 C 2 C2 D logRe 1 E logRe 1 F Δp predicted / (bar) 2 -50% 0.05 0.00 -0.05 -0.10 2 C3 G logRe 1 2 H logRe 1 I C4 J logRe 1 2 K logRe 1 L -0.15 -0.20 -0.20 -0.15 -0.10 -0.05 0.00 0.05 0.10 0.15 0.20 Δp measured / (bar) C5 M logRe1 2 N logRe1 O C6 P logRe1 2 Q logRe1 R Re 1 4 Wl D G The Reynolds number is relative to the total inlet flow rate considered as gaseous. The values of the constants A, B, C, D, E, F, G, H, I, J, K, L, M, N, O, P, Q, R have been evaluated as function of flow patterns by Ordinary Least Squares method. Depending on the flow regime, the experimental data have been divided in 3 categories: groups 1 and 2 (prevailing annular flow), groups 3, 4 and 5 (prevailing intermittent flow) and group 6 (prevailing bubbly flow). The values of the coefficients are reported in table 2. Table 2. Coefficients of C1, C2, C3, C4, C5, C6 Groups Coefficients 1, 2 3, 4, 5 6 A -4.60269 -1.78736 -0.9042 B 18.94891 9.432442 5.289937 C 6.935419 3.449248 2.134877 D -2.46753 0.39601 -0.84824 E 18.03551 -1.45399 5.058304 F 6.605532 -0.19884 2.062545 G 1.331346 0.231864 -0.02306 H -8.38945 -1.88181 -0.36177 I -0.8198 2.144975 3.836273 J -0.8876 -0.13973 -1.21451 K 4.459246 0.824035 7.206477 L 1.572819 0.284914 2.383148 M -0.49942 -0.10123 -1.14079 N 3.670348 0.796002 7.06621 O 1.295305 0.275062 2.346834 P 0.317543 0.016217 0.795197 Q -1.88525 -0.05564 -4.73273 R -0.6322 -0.00984 -1.46615 Δp12 PM - Wl 83 g/s Δp12 PM - Wl 105 g/s Δp12 PM - Wl 132 g/s Δp12 PM - Wl 180 g/s Δp12 PM - Wl 230 g/s Δp12 PM - Wl 283 g/s Δp13 PM - Wl 83 g/s Δp13 PM - Wl 105 g/s Δp13 PM - Wl 132 g/s Δp13 PM - Wl 180 g/s Δp13 PM - Wl 230 g/s Δp13 PM - Wl 283 g/s Figure 9. Experimental pressure drops versus the prediction of the PM. Table 3 summarizes the accordance between PM and the experimental data of respectively Δp12 and Δp13 in terms of percentage of data that fall into ±20%, ±30% and ±50%. It is evident the very good agreement between experimental data and the predictions of the PM. Table 3. Prediction of Δp12 and Δp13 SFM HFM SFMZF RSM p12 ±50% 63 39 76 44 ±30% 52 33 61 30 ±20% 30 28 37 24 SFM HFM SFMZF RSM p13 ±50% 68 42 99 79 ±30% 40 31 92 53 ±20% 24 18 78 36 PM 94 89 78 PM 97 97 93 CONCLUSIONS The present experimental results on two-phase flow through a T-junction extend the analysis of ref. [7] to an intermediate range of water flow rates. The flow patterns observed in the junction were predominantly annular flow (at lower liquid flow rates), intermittent-slug and bubbly flow (at higher liquid flow rates), and are substantially in good agreement with Taitel-Duckler map. The phenomena of phase separation reported in references [4], [5], [6] and [7] have been confirmed, and a bigger part of the air flow rate flows through the branch pipe. The pressure has been measured along the inlet, the branch and the run pipes and pressure drops in the junction from inlet to run and from inlet to branch have been evaluated by extrapolation and compared with homogeneous and separated phase models and Reimann & Seeger model. Especially for the pressure difference between inlet and run the SFM resulted to be more accurate, in particular in the modified version SFMZ, than HFM and RSM. The agreement of the SFM predictions with experimental pressures drops through the T-junction, as proposed in the PM, strongly improves by using corrective factors of the pressure drop coefficients that are dependent on the extraction ratio and flow patterns. ACKNOWLEDGMENT The authors wish to thank Gladis Di Giusto e Rocco Costantino for their support in the facility setup and the development of the experimental campaign. NOMENCLATURE Symbol Quantity C0 D ER FBG, FBL Distribution parameter (Zuber model) Inlet diameter Extraction ratio ER=W3/W1 FBG = WG3/WG1, FBL = WL3/WL1 Froude number Fr SI Unit Fr G g g l g d g g G p Gravity acceleration Mass velocity Pressure T T dp dzL ugj V W x Drift velocity (Zuber) Superficial velocity Mass flow rate Flow quality WGi/Wi Martinelli’s parameter X z 12 g L G X dp dzL dp dzG m/s2 kg/(s m2) Pa 1 2 m/s m/s kg/s 1 2 Axial coordinate Void fraction Two-phase multiplier Dynamic viscosity Density Superficial tension Subscripts E G H L M 1, 2, 3 m Referred to energy conservation Gas Referred to homogeneous model Liquid Referred to momentum flux Inlet,run, branch pipes m kg/(m s) kg/m3 N/m REFERENCES [1] B. J. Azzopardi, P. B. Whalley, The effect of flow patterns on two-phase flow in a T junction, Int. J. 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