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1. INTRODUCTION 2. TYPE OF TWO-PHASE FLOW (FLOW REGIMES IN HORIZONTAL & VERTICAL) 3. BAKER PAREMETER 4. EXAMPLE OF PROCESS CALC 5. EFFECT OF SLUG FLOW 6. METHODS TO AVOID SLUG FLOW 7. SLUG FORCE CALC. 8. RESTRAINT APPLICATION 9. SLUG FLOW ANALYSIS ON CAESAR - STATIC METHOD 10. SLUG FLOW ANALYSIS ON CAESAR - DYNAMIC METHOD
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Two-phase flow can be defined as the flow in which the fluid occurs in both the liquid and gas phases. It is a very important consideration in process plant piping.
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If Two-phase flow is not considered during design, pressure drop will be underestimated. Higher than the expected pressure drop can reduce plant capacity. Ignoring Two-phase flow may also lead to poor process control. Two-phase flow to a control valve is difficult to regulate smoothly and reproducibly. If Two-phase flow is not considered in piping layout & supporting, it will lead to severe vibration causing enormous load on the piping as well as the structure attached to.
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Types of Flow
Two Phase Flow
Intermittent Flow Each phase is discontinuous. Types Plug Flow Slug Flow
Distributed flow One phase is continuous and the other is discontinuous. Types Bubble Flow (Liquid phase is continuous) Mist or Dispersed Flow (Gas phase is continuous)
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Occurrence This type of flow can be expected when the vapor content is less than 30% of total weight flow rate.
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When the gas rate is now increased in stratified flow, a transition to wavy flow occurs. In this regime, the gas moves appreciably faster than the liquid and the resulting friction at the interface causes waves to be formed. The wave amplitude increases with increasing gas rate.
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If the liquid rate is now increased, a transition from segregated to intermittent flow occurs. The higher liquid rate causes the wave crests to touch the top of the pipe and form frothy slugs. The velocity of these liquid slugs and the alternating large gas bubbles is greater than the average liquid velocity. The large gas bubbles occupy nearly the whole pipe cross-sectional area.
Occurrence: This type of flow may occur in a pocketed line between an overhead condenser at grade and an elevated reflux drum. Discharge lines from pressure safety valves, rupture discs may have slug flow. Slug flow will not occur in a gravity flow line.
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Occurrence This type of flow can be expected when the vapor content is more than 30% of total weight flow rate. E.g. some overhead-condenser and reboiler-return lines.
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BAKER PARAMETER
Normally, the two-phase-flow pattern can be established from the chart given below by calculating Baker parameters Bx and By.
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BAKER PARAMETER
Wl V l V v B x ! 531 2 W v V l 3
Thus BX depends on 1. Weight-flow ratio 2. Physical properties of liquid and vapor phases Note: It is independent of pipe size
Q 13 l W l
Wv B y ! 2.16 A V V l v
Thus BY depends on
1. Vapor-phase flow rate 2. Vapor and liquid densities 3. Pipe size Practical significance of pipe size is by changing pipe diameter the type of flow might be changed which changes the friction losses.
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Surface tension ( ) dyn/cm 5.07 From Baker Parameter equations, we can calculate bakers parameters for several sizes of Sch-40 pipe, including and larger than 4. Using the Baker coordinates, we establish the flow region from the fig. Pipe size Baker coordinates Flow Region (in) BX BY 8 245 7,650 Bubble/slug 6 245 13,250 Bubble 4 245 30,000 Bubble As 8 line creates slug flow, it should be avoided. Using appropriate formulae for calculating the pressure drop for the type of flow, it is found that the pressure drop is higher at 4 line. Hence 6 is the optimum line size
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Slug flow causes serious pressure fluctuations which can upset the process conditions and cause inconsistent instrument sensing. Moreover, it causes vibration especially at vessel inlets, pipe bends, valves and other flow restrictions. This can lead to equipment deterioration and operating problems.
Vacuum Transfer Lines. Condenser Outlet Lines. Reboiler Return Lines. Fired Heater outlets. Boiler Blowdown.
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By designing parallel pipe runs that will increase flow capacity without increasing the overall friction loss.
By using a low point effluent drain or bypass or other solutions. By arranging the pipe configurations to protect against slug flow. E.g. in a pocketed line where liquid can collect, slug flow might develop. Hence pocket is to be avoided.
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F
!
2 V AV g
1 . 414
N sin 2
2
F
where
= density of the liquid (lb/ft3) V = Velocity of vapor (ft/sec) A = Area of cross-section (ft) g = gravitational constant (32.2 ft/sec)
V AV g
The Stresses and forces caused by the impact of slug will be 1.5 - 2.0 times the static force. Considering DLF = 1.5 for impact loading (as per Fluor Design Guide),
2 . 12 V AV ! g
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Restraint Application
Restraints designed for slug flow will allow movement due to normal operation conditions; however the design will be primarily for excessive movement due to impact the slug. All changes of pipe run direction will require restraint e.g. the loop shall be restrained as shown. In case of any negative effect of the restraint in thermal case, sufficient gap may be introduced.
Standard guides and anchors are normally inadequate for restraining slug flow. Special design is required. Free standing structural T supports are also inadequate for restraining slug flow. These supports are usually quite tall and tend to offer little resistance to horizontal loads. Consequently, even though they are not overstresses from the effects of the load, they do not sufficiently dampen the impact and the resultant displacement of the pipe at the restraint point can be a serious problem.
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Slug Flow Analysis - Response Spectra Method (Dynamic analysis using CAESAR II- Based on previous experience -Not FD procedure)
Normally, Slug force is treated as an impulsive force. This method is based on the assumption that the slug traverses the elbow and then suddenly drops to zero again. It is also assumed that the slug is formed across the pipe full cross section. The duration of slug is calculated based on the length of slug and stream velocity. This results in short duration impulsive loads on the pipe. The slug size is calculated based on the length of the pipe before the elbow & liquid volume fraction i.e. Length of liquid slug = Length of pipe * Liquid volume fraction Duration of slug is calculated as, Length of liquid slug Time duration = Velocity of flow The slug periodicity is calculated as, Length of liquid slug + Length of gas slug Periodicity of slug = Velocity of flow
SLUGFLOW_CALC.xls
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Slug Flow Analysis - Response Spectra Method (Dynamic analysis using CAESAR II)
Force on the elbow due to fluid flow is calculated as, FAXIAL = V V2 A (1- cos U ) FORTHOGONAL = V V2 A sin U Where FAXIAL FORTHOGONAL V A V U Force on elbow in axial direction ( N ) Force on elbow in orthogonal direction ( N ) Density of liquid ( Kg/ m3 ) Internal cross-sectional area of pipe in ( m2) Stream velocity ( m/Sec ) Angle of bend ( Degree )
It is assumed that the elbow is subjected to force due to liquid slug and drops to a smaller value based on the density of gas, after some duration as the liquid traverses the elbow. This load is treated as a rectangular pulse load with the duration and periodicity calculated as above. The no. of cycles are given as per maximum limit of CAESAR-II package. Natural frequencies of the piping system is calculated for the few modes up to frequency cut-off of 33 Hz.
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Slug Flow Analysis - Dynamic Method (using CAESAR II) Response Spectra - Input
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Slug Flow Analysis - Dynamic Method (using CAESAR II) Response Spectra - Input
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Slug Flow Analysis - Dynamic Method (using CAESAR II) Response Spectra - Input
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Slug Flow Analysis - Dynamic Method (using CAESAR II) Response Spectra - Input
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Slug Flow Analysis - Dynamic Method (using CAESAR II) Response Spectra - Input
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