Static Analysis of Slug flow: A Presentation for Beginners

November 18, 2015

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The purpose of this article is to explain the static analysis of slug flow using Caesar II. This article will
cover the following points in brief:

Introduction

Calculation of Slug Force

Static Analysis

Inputs Required

Assumptions

Case Study showing an example

INTRODUCTION

Slug Flow is typical two phase flow where a wave is picked up periodically by the rapidly moving
gas to form a frothy slug, which passes along the pipe at a greater velocity than the average
liquid velocity.

In this type of flow, slugs can cause severe and, in some cases, dangerous vibrations in piping
systems because of the impact of the high-velocity slugs against fittings such as bend, Tee etc.

Slug flows generate dynamic fluid forces, which may induce structural vibration.

Slug Flow

Excessive vibration may lead to component failures due to fatigue or resonance.

Such vibration problem may be avoided by thorough analysis, preferably at design stage.

Two types of Analysis Methods are prevalent- o Static Analysis and o Dynamic Analysis

Examples of Slug flow: o Vacuum Transfer Lines o Condenser Outlet Lines o Re-boiler
Return Lines o Fired Heater outlets o Boiler Blow down lines.

SLUG FORCE

Slug force is equal to the change in momentum with respect to time. Refer the below attached
figure:

Diagram Showing Slug Force Application

Use the following equations to calculate Slug Force.

Multiply the calculated value with a suitable DLF. Normally a DLF of 2.0 is common to use.

Diagram Showing Slug Force Equation

STATIC ANALYSIS
INPUTS REQUIRED FOR ANALYSIS:

Stress isometrics of complete system.

Line parameters such as line temperatures, pressures, fluid density, pipe material, corrosion
allowance, insulation thickness, density etc.

Parameters required for Slug force calculation like slug density or liquid density, two phase
velocity etc.

Nozzle allowable if connected to equipment.

ASSUMPTIONS FOR ANALYSIS:

It is assumed that the slug is formed across the full cross section of the pipe for the maximum
impact. This configuration is least probable for vertically down word flow as no hold up is
possible for accumulation of liquid and eventual formation of slug. Hence slug force at elbows for
vertically downward flow lines are not considered.

It is assumed that the reader knows normal static analysis of piping system using Caesar II.

CASE STUDY FOR ANALYSIS:

Lets assume the shown system is subjected to slug flow. The parameters for the pipe are as mentioned
below:

Pipe: A106B, 6, Sch 40

CA=3 mm

T1=100 degree C

T2=75 degree C

P1=15 bar

Liquid Density=950 Kg/m^3

Two phase Velocity=10.53 m/s

Stress System under consideration

After modeling the piping system following conventional method we have to calculate the slug force and
apply the same into the system. Normally all organizations have their excel spreadsheet to calculate Slug
Force. A typical excel spreadsheet for slug force calculation is shown in the below attached figure for your
reference.

Excel Spreadsheet for Slug force calculation

So if we use a DLF of 2 then each of axial and orthogonal force will be 4240N. We have to incorporate
this force in Caesar II input spreadsheet. Check the below mentioned figure for direction of forces.

Slug force in Bends with Application direction

Now we will input the axial and orthogonal forces at all changes in direction as shown in attached figure.

To enter forces click on the Forces button in Caesar II spreadsheet.

Provide the node number and magnitude of forces with proper direction.

Similarly input forces in all bends (other than vertically downward bends).

Caesar Spreadsheet Showing input methodology of Slug Force

Next step is to prepare the required load cases. Few additional load cases need to be prepared for static
analysis of slug force. The same has been shown in the below mentioned figure.

Caesar II Load cases for Slug Flow Analysis

Prepare the load cases as mentioned in the figure.

Make stress types as occasional

Use combination methods as Scalar

OUTPUT REPORT

Additionally We have to check code compliance for load cases L14 to L17 and ensure that the
values are well within code allowable values.

We have to check forces and displacements for load cases L1 to L9.

Refer below mentioned figures for reference:

Caesar II Code compliance check report

Caesar II Restraint Summary check report

Few days ago I had posted an article on procedure of Slug Flow Analysis using Static Methods. Click
here to read the same. In this article I will explain the methods for performing the slug flow analysis
using dynamic methods.
For dynamic analysis Caesar II software provides a very nice module, dynamic module where we have to
simply provide the input parameters to get the output result. Before you start the dynamic analysis you
have to perform conventional static analysis of the system (without using any slug force) and qualify the
system from all criteria. To open the dynamic module in Caesar II click on dynamic analysis button as
shown in Fig.1.

Fig. 1: Opening the Dynamic Module in Caesar II

When you click on the dynamic analysis button following window (Fig.2) will open. Select Slug Flow
(Spectrum) from drop down menu. The window will be filled with some pre-existing data. For clarity simply
select all those and delete. Now we have to provide inputs for analysis.

Fig. 2: Selecting Slug Flow Module in Caesar II

During dynamic analysis our first input will be the generation of spectrum profile. Slug load is one type of
impulse load. So the magnitude of load varies from zero to some maximum value, remains constant for a
time and then reduces to zero again. The force profile can be represented by a curve as shown in Fig. 3.

Fig. 3: Graphical Representation of Slug Force Profile

So from the above profile it is clear that in addition to slug force (Refer Static method of Slug Flow using
Caesar II for calculation of slug force), we need to calculate two additional parameters, a) Slug Duration
and b) Slug Periodicity.
1. Slug Duration: Slug duration is defined as the time required for the slug to cross the elbow.
Mathematically it can be denoted as, Slug Duration=Length of Liquid Slug/Velocity of Flow.

2. Slug Periodicity: Slug Periodicity can be defined as the time interval for two consecutive slugs
hitting the same elbow. So mathematically it can be denoted as, Slug Periodicity = (Length of
Liquid Slug + Length of Gas Slug)/Velocity of Flow.
Lets assume that the calculated slug duration is 8 milliseconds and periodicity is 400 milliseconds as
shown in Fig. 3. We will use these data for generation of spectrum profile.
Now Refer Fig. 4 and input the data as mentioned below:

Fig.4: Generation of Spectrum Profile for Slug flow Analysis

When you click on Enter Pulse data it will open the window where we have to enter the data for spectrum
profile generation. From the above curve at time 0 the force is 2120 N the same force will be active for
next 8 milliseconds till the slug crosses the elbow. Then at time 8.1 forces will be reduced to zero. And the
same zero force will be there till 400 milliseconds. Then the next cycle will start. i.e, at time 400.1 seconds
the force will be again 2120 N. That way enter data for at least two cycles as shown in Fig. 5:

Fig.5: Typical Spectrum Profile for Slug flow Analysis

Click here to read Part 2 of this article

Clicking Save / Continue button will convert the time history into its equivalent force response
spectrum in terms of Dynamic Load Factor versus Frequency and the screen Spectrum Table
Values as shown in Fig. 5 will appear.

Be sure to specify a unique spectrum name, as this processor will overwrite any existing files of
the same name.

By clicking OK, the processor will load the appropriate data in the Spectrum Definitions tab in
Dynamic Input and move the data to the dynamic input

Once the spectrum profile is generated click on force sets button and enter the slug force with proper
direction in the fields as shown in Fig. 6:

Fig.6: Entering slug forces for dynamic slug flow analysis.

Click on the + button to add more rows and button to delete rows.

In force set field input a numeric id which will be used to construct dynamic load cases.

After that click on Spectrum load cases menu and create the required load cases for dynamic analysis.
You have to specify at least two load cases as shown.

Operating + Dynamic for nozzle and support load checking.

Sustained + Dynamic for stress checking.

Refer Fig. 7 for load case preparation

Fig. 7: Load Case preparation for dynamic slug flow analysis

Finally click on control parameters button and select the load case for which you want to perform the
analysis. Normally operating load case is selected (Refer Fig. 8) for dynamic analysis. Keep all other
parameters as it is. Now click on batch run to obtain the analysis results. Fig 9 shows a typical analysis
results.

Fig.8: Selecting the load case for slug flow analysis

Fig. 9: Typical Dynamic Slug Flow Output Reports

This figure shows a typical output screen for dynamic slug flow analysis.

The highlighted node 10 is for nozzle.

All support and nozzle loads to be checked.

Stresses to be kept below code allowable values.

The highlighted direction sign will show other load case combinations.

Few Important Points:

1. Vibration due to any two phase flow can be reduced / arrested by proper supporting of the piping
system. Normally following supports are used:

HOLD DOWN SUPPORTS WITH 0 GAP

GUIDE SUPPORTS WITH 0 GAP

AXIAL STOPS WITH 0 GAP

Whenever modifying any support perform static analysis and keep the system stresses within allowable
limit.
2. Sometimes Vibration Absorbing Material (like PTFE) is used to reduce the Transfer of vibration to
connected systems.
3. It is preferred to keep natural frequency of piping system above 4 Hz for Vibration prone lines.
4. The formation of Slug Flow can be reduced:

By reducing line sizes to a minimum permitted by available pressure differentials.

By using a low point effluent drain or bypass.

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.

Wikipedia definition - "In fluid mechanics, two-phase flow occurs in a system containing gas
and liquid with a meniscus separating the two phases."
Two-phase flow is simultaneous flow of gas and liquid. Such flow is frequently found in
heat exchange equipment. Two-phase flow can be termed as multiphase flow also. Water
at saturation conditions exists as both a liquid and a vapor.
Two-phase flow is usually experienced in plants, where boiler produces vapor /
steam. Pressurized water-filled tubes while heated through furnace, steam are generated.

In a piping system, at certain locations (viz. long horizontal / inclined run of pipe with
relatively shorter riser / down comer), fluid flow can be such that there exists combination
of liquid and vapor (gas) flowing. It can be condensate and steam.
Behavior of two-phase fluid flow is different from single-phase fluid flow. Simple
relationships used for analyzing single-phase flow do not apply for analyzing two-phase

flow. Example: The two-phase flow head loss can be many times greater than that of singlephase flow.
Various types of two-phase flow regimes can exist at different conditions. Few of
them are depicted herein for reference.

The most common two-phase flow regime is called slug flow, in which pipe cross section
is filled alternatively with gas and liquid. Slug flow belongs to a class of intermittent flow

that has very distinctive features and it occurs under special circumstances of two-phase
gas-liquid flow.
Slug flow is an unsteady phenomenon with combination of stratified flow with separated
flow (single-phase gas or vapor) i.e. moving liquid-bubble mass is being pushed by gaseous
mass. When these two states act in random-like manner, unstable flow starts occurring in
the form of oscillations and / or flow reversals, inducing pressure and velocity fluctuations,
resulting in undesirable mechanical vibration of components in piping system. Thus, slug
flow constitutes the most serious implication in two-phase flow.
In slug flow, velocity of gas or vapor portion is approximately 2 to 2.25 times of that of
liquid portion. In slug flow regime, generally liquid rich slugs occupy the entire straight run
of pipe and it travels at a speed that is a substantial fraction (half or slightly less) of the gas
velocity and it occurs intermittently. This causes large pressure and liquid flow rate
fluctuations and it looks like a large flow surge or a large wave. The length to diameter ratio
of slugs varies with flow rates, pipe diameter and fluid properties.
Prior analyzing further, recapitulation on Froude Number is required.
Froude Number is a dimensionless number, defined as the ratio of inertia force on a
fluid element to the weight of the fluid element i.e. the inertial force divided by the
gravitational force.
Froude Number can be expressed as:

Froude Number has significance in fluid dynamic problems, where fluid weight plays
an important role. It is proven that the slug characteristics are strongly influenced by
Froude number in the liquid film, ahead of the slug.
Fr < 1 signifies a subcritical flow. For Fr > 1, the flow is characterized as supercritical flow.
Fr 1 denotes a critical flow.
The mixing length of slug is a function of slug velocity. It has been derived that the
mixing length increases with increasing slug velocities. Assimilation of the liquid film into
the slug occurs in the mixing zone. The length of the mixing zone is determined by the
mixing of gas and liquid and not the liquid alone.
The mixing length of slug can be expressed as an empirical function of the film Froude
number. And, the mixing length has direct dependence on the film Froude number. The
dependence is given by:

Slug flow ceases to be uniform, as the process of slug formation is random. Therefore, it
is difficult to predict slug forces accurately. Characterization of slug flow pattern is mostly
carried out by flow visualization method. Further reading of research articles is
recommended.
In a piping system, slug forces are generated when the slug encounters change in
flow direction. And, it generally occurs at elbows and tees. Slug force occurs due to change
in momentum. The amplitude of the slug force for a 90 degree elbow is expressed as:

For an inclined pipe or riser, if gas flow can be cut off for substantial period until
the accumulated liquid has been mobilized; dynamic piping load is generated from
unsteady lumped mass traveling in the system. Such load has potential to heavily
damage pipe supports, pipe bends and pipe tees.
Slug flow occurs mostly in piping networks transporting wet gas. Condensate collects
gradually in horizontal segments of piping to form a plug and then the liquid plug

undergoes hydraulic transport to the segments of piping where it is being "shot" with high
velocity by over-pressure. This is like a slug in a barrel of a gun. The slug then hits opposite
bend in piping and it generates heavy blow loads on piping.
For piping systems, having tendency of having possible slug flow, all changes of pipe
run direction shall require adequate restraints, to arrest sudden pressure thrust and
associated dynamic load due to slug flow. Based on historical data, it is seen that standard
guides and anchors (or line stops) are found to be inadequate to restrain slug flow. In many
cases, special design of pipe supports is required. For slug flow, special design of pipe
supports mainly offer adequate resistance to horizontal "shot" loads.
This slug load, as calculated is ideally suited for time-history analysis, to study the
movement of liquid lumped mass w.r.t. time and its impact on elbows and tees. Todays pipe
stress analysis software (viz. CAESAR II, AutoPIPE) has features to carry out such analysis.
Thus, it has become easier to predict theslug flow, to calculate slug frequency, to work out
dynamic forces acting on piping components over time. In turn, it helps to appraise
preventive measures to avoid slug flow or to diminish its effects.
In a piping system, slug flow problems can be overcome with slug catchers (which collect
the slugs) or by developing a pipe system that has provisions to break the slugs along the
piping length.
For a steady state gas and liquid flow, the "average" flow rate of liquid can be
adequately handled with a small knockout pot. However, in slug flow, due to variation in
pressures and flow rates, large slug catcher is required to catch big liquid slugs with
relatively short slug arrival time.

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#43370 - 06/16/11 11:31 PM

AAD

Dynamic Analysis of Slug Flow in CII

I have got few quries below:

Member
Registered: 12/13/08
Posts: 25
Loc: uk

1) How many number of slug cycles should be input for dynamic

analysis of slug flow ? and is it depend upon type of slug ( like repeating
& overlapping) ?
Because when we input one slug cycle for spectrum generation the DLF
limits to value of 2 and when we input more than one number slug cycles
the DLF value is more than 2.
2) What is the limliting value of DLF for dynamic analysis of slug flow
and why ?
3) How does Caesar calculate DLF?
4) In which method we should carry out slug flow analysis either in time
history or spectrum method?
Thanks in advance.
Regards,
AAD

Top
#43386 - 06/17/11 12:41 PM

Richard
Ay
Member
Registered: 12/13/99
Posts: 5491
Loc: Houston, Texas,
USA

Re: Dynamic Analysis of Slug Flow in CII [Re: AAD]

1) That depends on your degree of certainty regarding the slugs. From an

analysis point of view, I'd suggest a time history analysis if you start
loading the system with mulitple slugs. This will be more complicated,
but I don't think a response spectrum analysis can do this justice if you
have more than one slug.
2) The limiting DLF value for a single impact load is 2 (from dynamic
theory). Once you have multiple impacts, this limit is no longer
applicable.
3) There is a big article in the November 1994 newsletter on how this is
computed.
4) For a single slug I think the spectrum method is a better approach.

However, regardless of what you do, your results are only as good as
your estimate of the slug.
_________________________
Regards,
Richard Ay
Intergraph CAS

Top
#43418 - 06/21/11 12:34 AM

AAD

Re: Dynamic Analysis of Slug Flow in CII [Re: Richard Ay]

Thank you richard for your useful reply.

I have got few queries concerning to single slug as you mention.

Member
Registered:
12/13/08
Posts: 25
Loc: uk

Slug Duration 82.32 millisecond

Slug Periodicity 120.17 millisecond
Slug Force 60.83 kg

Sr.No. | Time | Force |

___________________________________________
1 | 0 | 60.83 | Beginning Of 1st Cycle
__________________________________________
2 | 82.32 | 60.83 |
__________________________________________
3 | 83 | 0 |
__________________________________________
4 | 120.17 | 0 |
________________________________________________________________
________
5 | 121 | 60.83 | Beginning Of 2nd Cycle
__________________________________________
6 | 203.02 | 60.83 |
__________________________________________
7 | 203 | 0 |
__________________________________________
8 | 240.34 | 0 |
________________________________________________________________
__________

9 | 241 | 60.83 | Beginning Of 3rd Cycle

___________________________________________
10 | 322.66 | 60.83 |
__________________________________________
11 | 323 | 0 |
__________________________________________
12 | 360.51 | 0 |
__________________________________________
By reviewing above time vs force profile can you advise us we can categorize
this as single slug or multiple slug?
If above profile is of single slug type then how many number of slug cycles
should be input in CII.Also if it is single type then we have to input in spectrum
method or in time history method ?
If above profile is of single slug type then can you provide multiple slug type
profile.( any case)

Edited by AAD (06/21/11 12:43 AM)

Top
#43440 - 06/22/11 08:29 AM

Richard
Ay
Member
Registered: 12/13/99
Posts: 5491
Loc: Houston, Texas,
USA

Re: Dynamic Analysis of Slug Flow in CII [Re: AAD]

Your describing multiple impulses, multiple slugs. For a response

spectrum approach, you can model one cycle per load case.
_________________________
Regards,
Richard Ay
Intergraph CAS