High-resolution gas–oil two-phase flow visualization with a capacitance wire-mesh sensor

The application of a novel wire-mesh sensor based on electrical capacitance (permittivity) measurements for the investigation of gas–oil two-phase flow in a vertical pipe of 67 mm diameter under industrial operating conditions is reported in this article. The wire-mesh sensor employed can be operated at up to 5000 frames per second acquisition speed and at a spatial resolution of 2.8 mm. By varying the gas and liquid flow rates, different flow patterns, such as bubbly, slug and churn flow, were produced and investigated. From the images of gas void fraction distribution, quantitative flow structure information, such as time series of cross-sectional void fraction, radial void fraction profiles and bubble size distributions, was extracted by special image-processing algorithms.     

Quality check of wire-mesh sensor measurements in a vertical air/water flow

Extensive measurements were executed for a vertical upward air/water flow to generate a high-quality database for the development and validation of CFD-Codes for two-phase flows (e.g. for models on bubble forces or on coalescence and break-up). Thereto, in a pipe with a nominal diameter of 200 mm, the wire-mesh sensor technology was used. The present paper aims on the assessment of uncertainty caused by the experimental procedure and especially global deviations arising from the use of the wire-mesh sensor technology. Special attention was paid to the plausibility and accuracy of the data regarding the evolution of the vertical multiphase flow. In the result, a clear and consistent trend regarding their evolution with increasing distance from the position of the gas injection was found. Comparisons of the trend of time and cross-section averaged gas volume fraction along the pipe height with the theoretically expected values were carried out. From the measured radial profiles of the void fraction and the velocity of the gas phase, the superficial gas velocity at the wire-mesh sensor is integrated over the cross-section and compared with the set value from the test matrix. Thus, a general uncertainty analysis of the sensor data is possible.     

Micro wire-mesh sensor for two-phase flow measurement in a rectangular narrow channel

A micro wire-mesh sensor (μWMS) based on an electrical conductivity measurement between electrodes installed on the walls has been developed for gas–liquid two-phase flow measurements in a narrow rectangular channel. This measuring method applies a principle of conventional wire-mesh tomography, which can measure the instantaneous void fraction distributions in the cross-section of the relatively large flow channel. In two-phase flow measurement using μWMS the void fraction distributions in the narrow channel were obtained by the measured conductivities between electrodes arranged on each wall. Therefore, the gas phase structures and the bubble behaviors can be investigated in the flow channel with narrow gap. In the present paper, a μWMS for the air–water flow between parallel flat plates with a gap of 3 mm was developed and simultaneous measurements with a high speed video camera were conducted to compare the measured results in bubbly flow.     

Miniature conductivity wire-mesh sensor for gas-liquid two-phase flow measurement

A miniature conductivity wire-mesh sensor for gas-liquid two-phase flow measurement in small channels is presented. The sensor design is similar to the conventional wire-mesh sensor for larger flow cross sections with wire electrodes stretched across the flow channel in two adjacent planes and with perpendicular wire orientation between planes. Conductivity measurement is performed by special electronics which consecutively applies bipolar voltage pulse excitation to the sender wires and measures electrical current flow in the wire crossings at the receiver wires. The new design is based on printed circuit board technology. A prototypical sensor made of 2×16 stainless steel wires each of 50 μm diameter was manufactured and applied to two-phase flow measurement inside the mixing chamber of an effervescent atomizer. Accuracy of the sensor was studied for static liquid distributions using microphotography and for dynamic two-phase flow by comparison of wire-mesh sensor data with radial gas fraction profiles obtained from X-ray microtomography measurements.     

Void fraction measurement in steam–water two-phase flow using the gamma ray attenuation under high pressure and high temperature evaporating conditions

The void fraction is one of the most important parameters used to characterize gas–liquid two-phase flow, and a myriad of researchers have investigated it under the adiabatic flow conditions. The gamma ray attenuation is a frequently used non-intrusive method for measuring component volume fraction in gas–liquid two-phase flow system. In this paper, firstly, the influence of the various parameters and test conditions on the gamma ray attenuation have been completely examined, such as the calibration of Count Rate for pure gas and liquid phases, the influences of fluid temperature, phase changing point and fluid mass velocity, distance between gamma ray attenuation measuring instrument and experimental section etc. Secondly, the measurement of void fraction was taken in the vertically upward pipes under high pressure and high temperature evaporating conditions. The experimental results of void fraction were compared with the data in reference literature for measurement, the results from the gamma ray attenuation show good agreement with the literature for air–water two-phase flows, but for the evaporating conditions, a small number of compared data beyond the statistical approach for 90% of confidence interval due to some reasons, such as heat flux, the diameter of Taylor-bubbles, longitude of slugs etc. Finally, six predicted correlations from four groups were selected for comparing with the experimental data. The most of compared data were within the statistical approach for 85% of confidence interval. In general, the void fraction was rarely investigated and the available data was limited under high temperature and high pressure evaporating conditions. The investigations of present study are helpful to resolve the difficulties of measuring for gas–liquid two-phase flows concerning to the heated evaporating condition.     

Experimental investigation on the void fraction characteristics of a sudden expansion tube using wire-mesh sensors

Void fraction is an essential parameter of gas-liquid two-phase flow and experiments were executed to investigate the void fraction fluctuation characteristics of gas-liquid two phase flow through a sudden expansion tube. Two 16 × 16 wires mesh sensors were applied to measure the phase distribution of upstream pipe(pipe-32) and downstream pipe(pipe-50). The superficial gas velocity is in the range of 3.46 m/s - 22.46 m/s and the superficial liquid velocity ranges from 0.034 m/s to 0.414 m/s. Flow pattern evolution of upstream and downstream pipes was reconstructed and compared. The experiment results show that, in contrast to pipe-32, the void fraction of pipe-50 shows different trends with the increase of liquid and gas velocity. Liquid-carrying capacity is essential in the relationship between the void fraction of pipe-32 and pipe-50. The critical superficial liquid and gas velocities are proposed to characterize the liquid-carrying capacity. The maximum critical superficial gas and liquid velocity is 15.56 m/s and 0.207 m/s, respectively. Besides, a model is proposed to describe the relationship of void fraction between pipe-32 and pipe-50. It is found that the prediction error is less than ±10% in the case of annular flow.     

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.     

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.     

Dual-plane ultrafast limited-angle electron beam x-ray tomography

Electron beam x-ray tomography is an imaging technique, which can provide cross-sectional images of an object of interest with about 1 mm spatial resolution at frame rates of up to 10,000 frames per second. As a non-intrusive method it is especially suited for studying multiphase flows. For this purpose we devised an experimental limited-angle scan setup which utilizes linear beam deflection to generate radiographic projections. This setup was employed in the study of gas–liquid flow in an experimental flow loop operated at different liquid and gas flow rates. Electron-beam tomography images were compared with image data of a wire-mesh sensor. The latter is a fast but intrusive imaging device which is commonly used in gas–liquid flow imaging and achieves comparable frame rates but at lower spatial resolution. As a novelty we implemented a dual-plane limited-angle electron beam x-ray tomography which allows us to gain information about the phase velocities using cross-correlation 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.     

Gamma-ray tomography applied to hydro-carbon multi-phase sampling and slip measurements

Gamma-ray tomography is a technique well suited to visualize gas void fraction distribution in two-phase flows. The liquid phase considered in this paper is a homogeneous mixture of oil and water. Gamma-ray tomography will be used to qualitatively visualize the distribution of gas in the flow, and also to provide more quantitative average void fraction measurements. The subject treatment is practical and experimental with a primary focus on multiphase sampling. Experimental results for total average void fraction are compared to the drift–flux model for two-phase flow by comparing measurements with the calculated slip.     

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.     

Time resolving gamma-tomography for periodically changing gas fraction fields and its application to an axial pump

In the paper a novel non-intrusive tomographic method is presented to visualise the gas fraction distribution inside the rotating impeller of an axial pump delivering a two-phase flow. The device has been developed for an axial pump (inducer), which has an impeller with three helical blades rotating at 1500 rpm. Model fluid is air–water mixture created by a gas distributor upstream the pump inlet nozzle. The developed gamma-tomography set-up consists of a Cs-137 source and an arc of 64 scintillation detectors. Each of the detectors is connected to a number of counters grouped into banks. Each bank is active only during a 100 μs long interval of the rotation period, which corresponds to a well-defined angular interval of the impeller rotation. A trigger pulse, generated at the beginning of each revolution, forces the control unit to restart the counting process from the first bank. In this way, the device is able to measure ensemble averaged projections of the gamma absorption density distribution, which are resolved according to the rotating angle of the impeller. An image reconstruction by filtered back-projection provides density distributions inside the impeller. Void fraction distributions are visualised by means of differential tomography, i.e. by subtracting sets of projections obtained for two-phase operation and for plain liquid.     

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。     

Two-phase flow metering of heavy oil using a Coriolis mass flow meter: A case study

The use of Coriolis mass flow metering for two-phase (gas/liquid) flow is an emerging theme of both academic research and industrial application. The key issues are maintaining flow-tube operation, and modelling and correcting for the errors induced in the mass flow and density measurements. Experimentally-derived data is used to illustrate that these errors vary most notably with gas void fraction (GVF) and liquid flow rate, but other factors such as flow-tube geometry and orientation, and fluid properties such as viscosity are also influential. While undoubtedly a universal two-phase flow correction model is the ultimate research goal, there is currently no obvious candidate to explain the range of behaviours observed. This paper describes and demonstrates an empirical methodology that has proven effective in developing good correction models for a given choice of Coriolis flow-tube and flow mixture.

A growing proportion of the world’s oil reserves may be described as “heavy”, implying high density and high viscosity. Of the various metering challenges heavy oil poses, one of the most significant is its ready entrainment of gas, and the difficulties entailed in separating gas from the oil. Accurate two-phase measurement of heavy oil is therefore an especially desirable technical goal.

Trials were carried out at the National Engineering Laboratory (NEL), Scotland on a 75 mm flowmeter using a high viscosity oil. Flowrates from 1 kg/s to 10 kg/s were examined, with gas void fraction (GVF) up to 80%. The resulting models were tested online in a commercial Coriolis mass flow meter and demonstrated good performance for both steady and slugging two-phase flows, with the corrected measurements typically within 1%–5% of the nominal mass flow and density.

Field trials in Venezuela have confirmed the performance of this two-phase solution.

While research continues into the development of a generic two-phase correction, this case study demonstrates that the current state of the art can provide, for economically important fluids, tailored models with good two-phase flow performance.     

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.     

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.     

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.     

Air–water two-phase flow measurement using a Venturi meter and an electrical resistance tomography sensor

A method for air–water two-phase flow measurement is proposed using a Venturi meter combined with an Electrical Resistance Tomography (ERT) sensor. Firstly, the real-time flow pattern of the two-phase flow is identified using the ERT sensor. Secondly, the void fraction of the two-phase flow is calculated from the conductance values through a void fraction measurement model, developed using the LS-SVM regression method. Thirdly, the mass quality is determined from the void fraction through void fraction-quality correlation. And finally, the mass flowrate of the two-phase flow is calculated from the mass quality and the differential pressure across the Venturi meter. Experimental results demonstrate that the proposed method is effective for the measurement of the mass flowrate of air–water flow. The proposed method introduces the flow pattern information in the measurement process, which minimizes the influence of flow pattern on the conventional differential pressure based methods. In addition, the mass quality is calculated from the void fraction, so the difficulty to obtain the mass quality in conventional methods is also overcome. Meanwhile, the new method is capable for providing concurrent measurements of multiple parameters of the two-phase flow including void fraction, mass quality and mass flowrate as well as an indication of the flow pattern.     

Parametric study of two-phase flow by integral analysis based on power law distribution

To understand the fluid dynamic forces acting on a structure subjected to two-phase flow, it is essential to obtain detail information on the characteristics of that flow. The distributions of flow parameters across a pipe, such as gas velocity, liquid velocity and void fraction, may be assumed to follow a power law (Cheng 1998; Serizawa et al. 1975). The void fraction profile is, for example, uniform for bubbly flow, whereas for slug flow it is more or less parabolic. In the present work, the average values of momentum flux, slip ratio and other parameters were derived by integral analysis, based on approximate power law distributions. A parametric study with various distributions was performed. The existing empirical formulations for average void fraction, proposed by Wallis (1969), Zuber et al. (1967) and Ishii (1976), were considered in the derivation of the present results. Notably, the unsteady momentum flux for slug flow was approximated.