Christophe Vallée

Experiments and Numerical Simulations of Horizontal Two-Phase Flow Regimes Using an Interfacial Area Density Model

Stratified two-phase flow regimes can occur in the main cooling lines of Pressurized Water Reactors, Chemical plants and Oil pipelines. A relevant problem occurring is the development of wavy stratified flows, which can lead to slug generation. In the last decade, stratified flows have increasingly been modelled with computational fluid dynamics (CFD) codes. In CFD, closure models are required that must be validated. Recent improvements of the multiphase flow modelling in the ANSYS CFX code, now make it possible to simulate these mechanisms in detail. In order to validate existing and further developed multiphase flow models, a high spatial and temporal resolution of measurement data are required. For the experimental investigation of co-current air/water flows, the HA WAC (Horizontal Air/Water Channel) was built. The channel allows in particular the study of air/water slug flow under atmospheric pressure. Parallel to the experiments, CFD calculations were carried out. The two-fluid model was applied with a special turbulence damping procedure at the free surface. An Algebraic Interfacial Area Density (AIAD) model based on the implemented mixture model was introduced, which allows the detection of the morphological form of the two-phase flow and the corresponding switching via a blending function of each correlation from one object pair to another . As a result, this model can distinguish between bubbles, droplets and the free surface using the local value of the volume fraction of the liquid phase. The behaviour of slug generation and propagation was qualitatively reproduced by the simulation, while local deviations require a continuation of the work.

Image-Processing-Based Study of the Interfacial Behavior of the Countercurrent Gas-Liquid Two-Phase Flow in a Hot Leg of a PWR

The interfacial behavior during countercurrent two-phase flow of air-water and steam-water in a model of a PWR hot leg was studied quantitatively using digital image processing of a subsequent recorded video images of the experimental series obtained from the TOPFLOW facility, Helmholtz-Zentrum Dresden-Rossendorf e.V. (HZDR), Dresden, Germany. The developed image processing technique provides the transient data of water level inside the hot leg channel up to flooding condition. In this technique, the filters such as median and Gaussian were used to eliminate the drops and the bubbles from the interface and the wall of the test section. A Statistical treatment (average, standard deviation, and probability distribution function (PDF)) of the obtained water level data was carried out also to identify the flow behaviors. The obtained data are characterized by a high resolution in space and time, which makes them suitable for the development and validation of CFD-grade closure models, for example, for two-fluid model. This information is essential also for the development of mechanistic modeling on the relating phenomenon. It was clarified that the local water level at the crest of the hydraulic jump is strongly affected by the liquid properties.

Comparison of Countercurrent Flow Limitation Experiments Performed in Two Different Models of the Hot Leg of a Pressurized Water Reactor With Rectangular Cross Section

In order to investigate the two-phase flow behavior during countercurrent flow limitation in the hot leg of a pressurized water reactor, two test models were built: one at the Kobe University and the other at the TOPFLOW test facility of Forschungszentrum Dresden-Rossendorf (FZD). Both test facilities are devoted to optical measurement techniques; therefore, a flat hot leg test section design was chosen. Countercurrent flow limitation (CCFL) experiments were performed, simulating the reflux condenser cooling mode appearing in some accident scenarios. The fluids used were air and water, both at room temperature. The pressure conditions were varied from atmospheric at Kobe to 3.0 bars absolute at TOPFLOW. According to the presented review of literature, very few data are available on flooding in channels with a rectangular cross section, and no experiments were performed in the past in such flat models of a hot leg. Commonly the macroscopic effects of CCFL are represented in a flooding diagram, where the gas flow rate is plotted versus the discharge water flow rate, using the nondimensional superficial velocity (also known as Wallis parameter) as coordinates. However the classical definition of the Wallis parameter contains the pipe diameter as characteristic length. In order to be able to perform comparisons with pipe experiments and to extrapolate to the power plant scale, the appropriate characteristic length should be determined. A detailed comparison of the test facilities operated at the Kobe University and at FZD is presented. With respect to the CCFL behavior, it is shown that the essential parts of the two hot leg test sections are very similar. This geometrical analogy allows us to perform meaningful comparisons. However, clear differences in the dimensions of the cross section (H × W = 150 × 10 mm 2 in Kobe, 250 × 50 mm 2 at FZD) make it possible to point out the right characteristic length for hot leg models with rectangular cross sections. The hydraulic diameter, the channel height, and the Laplace critical wavelength (leading to the Kutateladze number) were tested. A comparison of our own results with similar experimental data and empirical correlations for pipes available in literature shows that the channel height is the characteristic length to be used in the Wallis parameter for channels with rectangular cross sections. However, some limitations were noticed for narrow channels, where CCFL is reached at lower gas fluxes, as already observed in small scale hot legs with pipe cross sections.

Air/Water Counter-Current Flow Experiments in a Model of the Hot Leg of a Pressurized Water Reactor

Different scenarios of small break loss of coolant accident for pressurized water reactors (PWRs) lead to the reflux-condenser mode in which steam enters the hot leg from the reactor pressure vessel (RPV) and condenses in the steam generator. A limitation of the condensate backflow toward the RPV by the steam flowing in counter current could affect the core cooling and must be prevented. The simulation of counter-current flow limitation conditions, which is dominated by 3D effects, requires the use of a computational fluid dynamics (CFD) approach. These numerical methods are not yet mature, so dedicated experimental data are needed for validation purposes. In order to investigate the two-phase flow behavior in a complex reactor-typical geometry and to supply suitable data for CFD code validation, the “hot leg model” was built at Forschungszentrum Dresden-Rossendorf (FZD). This setup is devoted to optical measurement techniques, and therefore, a flat test-section design was chosen with a width of 50 mm. The test section outlines represent the hot leg of a German Konvoi PWR at a scale of 1:3 (i.e., 250 mm channel height). The test section is mounted between two separators, one simulating the RPV and the other is connected to the steam generator inlet chamber. The hot leg model is operated under pressure equilibrium in the pressure vessel of the TOPFLOW facility of FZD. The air/water experiments presented in this article focus on the flow structure observed in the region of the riser and of the steam generator inlet chamber at room temperature and pressures up to 3 bar. The performed high-speed observations show the evolution of the stratified interface and the distribution of the two-phase mixture (droplets and bubbles). The counter-current flow limitation was quantified using the variation in the water levels measured in the separators. A confrontation with the images indicates that the initiation of flooding coincides with the reversal of the flow in the horizontal part of the hot leg. Afterward, bigger waves are generated, which develop to slugs. Furthermore, the flooding points obtained from the experiments were compared with empirical correlations available in literature. A good overall agreement was obtained, while the zero penetration was found at lower values of the gaseous Wallis parameter compared with previous work. This deviation can be attributed to the rectangular cross section of the hot leg model.

Effects of Shape and Size on Countercurrent Flow Limitation in Flow Channels Simulating A PWR Hot Leg

Abstract A numerical study is presented to examine the effects on countercurrent flow limitation (CCFL) of the shape and size of hot leg models with a rectangular cross section. The CCFL was described in terms of Wallis parameters using the channel height H as the characteristic length. Numerical simulations, using the computational fluid dynamics software code FLUENT 6.3.26, were done for the air-water CCFL experiments carried out previously at Helmholtz-Zentrum Dresden-Rossendorf in a 1/3-scale hot leg model with a rectangular channel (H×W = 0.25×0.05 m2), and the results were compared with the air-water CCFL data obtained at Kobe University in a 1/5-scale hot leg model with rectangular cross section (H×W = 0.15×0.01 m2) and the results of simulations. It was found that both the height-to-width ratio and the size of the cross section affected the CCFL characteristics in the Wallis diagram. Comparison of CCFL characteristics in rectangular channels with those in circular channels showed that the hydraulic diameter Dh was a major cross-section geometry term influencing the CCFL characteristics. CCFL constants of the Wallis correlation were ~0.61 on average for the range 0.05 m ≤ Dh ≤ 0.75 m but became small for Dh ≤ 0.0254 m, and these tendencies were well reproduced by the numerical simulations.

Experimental Characterisation of the Interfacial Structure during Counter-Current Flow Limitation in a Model of the Hot Leg of a PWR

In order to investigate the two-phase flow behaviour during counter-current flow limitation in the hot leg of a pressurised water reactor, dedicated experiments were performed in a scaled down model of Kobe University. The experiments were performed with air and water at atmospheric pressure and room temperature. At high flow rates, CCFL occurs and the discharge of water to the reactor pressure vessel simulator is limited by the formation of slugs carrying liquid back to the steam generator. The structure of the interface was observed from the side of the channel test section using a high-speed video camera. An algorithm was developed to recognise the stratified interface in the camera frames after background subtraction. This method allows extracting the water level at any position in the image as well as performing further statistical treatments. The evolution of the interfacial structure along the horizontal part of the hot leg is shown by the visualisation of the probability distribution of the water level and analysed in function of the liquid and gas flow rates. The data achieved are useful for the analysis of the flow conditions as well as for the validation of modelling approaches like computational fluid dynamics.

Experimental investigation and CFD simulation of horizontal air/water slug flow

Abstract For the investigation of air/water slug flow, a horizontal channel with rectangular cross-section was built at Forschungszentrum Rossendorf. The channel allows the investigation of air/water co- and counter-current flows at atmospheric pressure, especially the slug behaviour. Optical measurements were performed with a high-speed video camera, and were complemented by simultaneous dynamic pressure measurements. Moreover velocity-fields were measured using Particle Image Velocimetry (PIV). A CFD simulation of the stratified co-current flow was performed using the code CFX-5, applying the Euler-Euler two fluid model with the free surface option. The grid contains 4105 control volumes. The turbulence was modelled separately for each phase using the k- based shear stress transport (SST) turbulence model. To achieve wave generation in such a short channel, the inlet water level had to be varied in time. For this purpose, the water level history was taken from a recorded image sequence and set as time-dependent boundary condition at the model inlet. The results show a wave formation up to slug development with closure of the whole channel cross-section and consequently an increase of the pressure level behind the slug. Despite unsteady conditions at the inlet of the test channel and simplified initial conditions in the model, the slug simulation with CFX is in good qualitative agreement with the experiment, while the slug length increases during its progression, witch was not observed in reality.

Numerical Calculations for Air-Water Tests on CCFL in Different-Scale Models of a PWR Hot Leg

Air-water CCFL (countercurrent flow limitation) tests using the 1/5th scale rectangular channel and 1/15th scale circular tube simulating a PWR hot leg and both air-water and steam-water CCFL tests using the 1/3rd scale rectangular channel were previously carried out at Kobe University and Forschungszentrum Dresden-Rossendorf (FZD), respectively. In this paper, numerical calculations for the air-water CCFL tests at FZD using FLUENT6.3.26 are presented and compared with the experimental data at Kobe University and FZD. In the calculations, the VOF (volume of fluid) model or two-fluid (2F) model was used. Major results were as follows: (1) the calculated CCFL characteristics using the 2F model for the FZD tests agreed well with the 1/15th scale circular tube data obtained at Kobe University and the calculated results for full-scale PWR conditions, which supported the validity of the 1/3rd scale rectangular channel to simulate CCFL in circular tubes; and (2) comparison with the FZD data showed that the calculations using the 2F and VOF models overestimated the falling water flow rates.Copyright

Erratum: "Air/Water Counter-Current Flow Experiments in a Model of the Hot Leg of a Pressurized Water Reactor" (Journal of Engineering for Gas Turbines and Power, 2009, 131(2), p. 022905)

An error in the implementation into the test facility of the air flow meter used during the experiments was noticed after publication of the paper. As a consequence, the raw flow rates recorded by the digital data acquisition system with this flow meter are wrong. In order to correct the measured flow rates, a calibration curve was recorded with a certified rotameter. The obtained calibration points could be correlated in order to obtain the correction function applied to the raw measuring values. This resulted in the following modifications compared to the original paper: • p. 1, last two sentences of the Abstract: A good overall agreement was obtained, especially for the zero liquid penetration, while the slope of the CCFL characteristics was lower compared to previous work. This deviation may be attributed to the rectangular cross-section of the hot leg model. • p. 3, end of Sec. 3.1: (…) the air mass flow rate was varied between 0.23 and 0.41 kg/s.

Comparison of CCFL Experiments Performed in Two Different Models of the Hot Leg of a PWR With Rectangular Cross-Section

In order to investigate the two-phase flow behaviour during counter-current flow limitation in the hot leg of a pressurised water reactor, two test models were built: one at the Kobe University and the other at the TOPFLOW test facility of Forschungszentrum Dresden-Rossendorf (FZD). Both test facilities are devoted to optical measurement techniques, therefore, a flat hot leg test section design was chosen. Counter-current flow limitation (CCFL) experiments were performed, simulating the reflux condenser cooling mode appearing in some accident scenarios. The fluids used were air and water, both at room temperature. The pressure conditions were varied from atmospheric at Kobe to 3.0 bar absolute at TOPFLOW. According to the presented review of the literature, very few data is available on flooding in channels with rectangular cross-section, and no experiments were performed in the past in such rectangular models of a hot leg. Usually, the macroscopic effects of CCFL are represented in a flooding diagram, where the gas flow rate is plotted versus the discharge water flow rate. Commonly, the non-dimensional superficial velocity (also known as the Wallis parameter) is used to plot the flooding diagram. However, the classical definition of the Wallis parameter contains the pipe diameter as characteristic length, which was originally defined by Wallis (1969) for counter-current flow limitation in vertical pipes and not in near horizontal channels with rectangular cross-section. In order to be able to perform comparisons with pipe experiments and to extrapolate to the power plant scale, the appropriate characteristic length should be determined. Because the experimental projects on this subject at the Kobe University and at FZD were launched independently, a detailed comparison of both test facilities is presented. With respect to the CCFL behaviour, it is shown that the essential parts of the two hot leg test sections are very similar. This geometrical analogy allows to perform meaningful comparisons. However, clear differences in the dimensions of the cross-section (H × W = 150 × 10 mm2 in Kobe, 250 × 50 mm2 at FZD) make it possible to point out the right characteristic length for hot leg models with rectangular cross-sections. The hydraulic diameter, the channel height and the Laplace critical wavelength (leading to the Kutateladze number) were tested. The experimental results obtained in the two test facilities clearly show that the channel height is the suited characteristic length. Finally, the experimental results are compared with similar experiments and empirical correlations for pipes available in the literature. In spite of the scatter of the data and of the different correlations, it was noticed that flooding is reached at slightly lower gas fluxes in the hot leg models with rectangular cross-section compared to pipes.Copyright