Investigation of Churn and Annular Flow Transition Boundaries in Vertical Upward Gas-Water Two-Phase Flow

Flow patterns in two-phase flow in vertical upward pipes are crucial for predicting phase distribution, flow transitions, and stability. Existing studies on churn to annular flow transitions primarily focus on flow rates, physical parameters, pressure, and temperature, often overlooking pipe diameter. This study addresses this gap using a multiphase pipe flow experimental setup to examine transitions under varying pipe diameters, gas flow rates, and liquid flow rates. Results show that with a constant liquid flow rate, increasing pipe diameter requires a higher gas flow rate to form annular flow, leading to greater pressure gradients and smoother fluctuations. Conversely, with a constant gas flow rate, larger pipe diameters decrease the liquid flow rate needed for annular flow, resulting in smaller pressure gradients and smoother fluctuations. Smaller pipe diameters make annular flow formation easier, with smaller pressure gradients but larger fluctuations. A novel churn-annular flow transition boundary model was developed, considering factors like gas shear force, surface tension, gravity, viscous force, and pressure gradient. Evaluated with 804 experimental data sets, the new model's prediction accuracy exceeds 98.19%, outperforming traditional models with 53.92%-86.27% accuracy, enhancing applicability across varying diameters.