Experimental investigation of interfacial waves in stratified liquid-liquid flows in horizontal pipelines: Characteristics and pressure gradients

Abstract The increasing use of commercial flow simulators in the oil and gas industry provides the impetus to accurately model multiphase flows in pipelines. The current work investigates stratified oil-water flows in horizontal pipelines by experimentally measuring interfacial deformations, correlating them to interfacial friction. The derived interfacial model is then implemented into the two-fluid model to predict pressure losses in pipelines. An experimental campaign was undertaken using process oil ( ρ = 845 k g / m 3 , μ = 0.03 P a . s ) and water as the test fluids in acrylic pipes of 40 mm diameter, with objectives of capturing interfacial deformations via image processing techniques, while also measuring pressure gradients in the pipe. The interfacial deformations were seen to increase with increasing flow velocities, plateauing with wave amplitudes of 3 mm. Further tests with identical fluids, conducted on larger diameter pipes (54.8 mm and 108.4 mm) also showed similar trend. Wave aspect ratios were correlated with a modified Froude number, linking the interfacial deformations to input flow variables. An empirical equation, utilizing the amplitude of interfacial deformations as roughness heights is derived for the interfacial friction factor. Incorporating the derived equation into the one dimensional two-fluid model, pressure losses were calculated and compared against experimental pressure drop measurements conducted in current work, as well as with those in literature. The performance of this model is also compared with existing prediction models and is found to provide improved accuracies across wide range of viscosity ratios and pipe diameters.