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Article history: A new mathematical model was proposed in this paper based on the frequency domain theory to
Received 2 December 2013 investigate two-phase flow instabilities in internally-ribbed tubes. Two significant improvements were
Accepted 27 December 2013 made to conventional models, one of which was that the heat storage of the tube wall metal, the internal
Available online 7 January 2014
wall heat flux and the external wall heat flux were considered as dynamic parameters, and another one
was that a new feedback relationship was established. The new model was verified by comparing the
Keywords:
prediction results to both the corresponding experimental data in literature and the results obtained
Two-phase flow instability
with SIMULINK. Then the two-phase flow instabilities in internally-ribbed tubes were studied system-
Frequency domain theory
Internally-ribbed tube
atically. It was shown that the stability of two-phase flows increased with pressure, mass flux or inlet
Critical heat flux resistance coefficient. It was also found that there existed a worst point of the stability (WPS) of the two-
SIMULINK phase flows when the inlet fluid subcooling increased. Two-phase flows in the 6-head ribs internally-
ribbed tube (f38.1 7.5 mm) was more stable than that in the 4-head ribs internally-ribbed tube
(f28 5.41 mm). The present model and results could provide guidance for the design and operation of
boilers.
Ó 2014 Elsevier Ltd. All rights reserved.
1359-4311/$ e see front matter Ó 2014 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.applthermaleng.2013.12.069
2 Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13
drift-flux model in both vertical and horizontal tubes. Later, a The internally-ribbed tube, as one of the most widely used
multivariable frequency domain mathematical model was estab- enhanced heat transfer tubes, plays an important role in the design
lished by Hou et al. [12], and was applied in the study on the two- and flow stability control of the boiler water-cooled wall system
phase flow instabilities in once-through steam generators, and it and other heat exchanger systems. Hence, many experimental re-
was shown that the methods could conveniently predict the two- searches have been conducted to study the instability phenomena
phase flow instabilities in parallel smooth channels. Su et al. [13] in internally-ribbed tubes. Gao et al. [22,23] proposed four semi-
studied flow instabilities in parallel smooth channels by using the empirical equations to predict the critical points of two-phase
time domain analysis method, and influences of various parameters flow instabilities in the smooth tube (f25 2.5 mm) and in the
on system’s instabilities were also revealed. Similar results also can internally-ribbed tube (f38.1 7.5 mm), based on the experimental
be found in some other works [14e18]. studies. Moreover, experiments were conducted on high pressure
Besides the smooth tubes, there are also a few studies on the two-phase test loops by Huang et al. [24], and revealed the in-
two-phase flow instabilities in enhanced heat transfer tubes. fluences of heat flux, asymmetric heat flux, pressure, mass flux,
Mentes et al. [19] studied the two-phase flow instabilities in six inlet sub-cooling on density wave oscillation in vertical parallel
vertical enhanced heat transfer tubes, and found that the two- internally-ribbed tubes (two internally-ribbed tubes with the same
phase flows in these enhanced heat transfer tubes were more structures, f31.8 6 mm).
stable than that in the smooth tubes. Widmann et al. [20] studied It is worthy to note that most of the previous studies on two-
the two-phase flow instabilities in horizontal enhanced heat phase flow instabilities in the internally-ribbed tubes are carried
transfer tubes, and obtained the similar results. Later, Karsli et al. out by experiments. On the other hand, two-phase flow instability
[21] also carried out experiments to investigate the two-phase flow characteristics in different internally-ribbed tubes are greatly
instabilities in five different enhanced heat transfer tubes. All these different from each other due to the different two-phase flows and
studies showed that the difference in geometrical structures of heat transfer behaviors caused by different internally-ribbed
tubes might cause great differences in the instability behavior of structures. It is very necessary to build proper theoretical models
the two-phase flow. to facilitate the study of the two-phase flow instability
Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13 3
2. Mathematical model
ribbed tube, Qhsm is the heat storage of wall metal per unit length in 2.1. Fundamental equations
axial direction.
Due to the different structures of a smooth tube and an Dynamic characters of two-phase flows are analyzed by the
internally-ribbed tube, as shown in Fig. 3, the calculation method of equations based on the following assumptions, (1) Subcooling
the heat storage of wall metal (Qhsm) for different tubes is also boiling is neglected; (2) Homogeneous flow model is used to
different. Detailed information of Qhsm for different tubes can be describe flows in the two-phase flow region; (3) The compress-
found in Eqs. (2) and (3), respectively. ibility of liquid in a single phase region can be neglected; (4) Dif-
Heat storage equation of the wall metal of the smooth tube is: ferential pressure from inlet to outlet is constant; (5) Heat flux is
uniform in the axial direction.
The details of the conservation equations are expressed as
" 2 #
vTw vTw Dex 2 D follows.
Qhsm ¼ Cw rw Aw ¼ Cw rw p (2)
vt vt 2 2
2.1.1. Equations for the preheating region
Heat storage equation of the wall metal of the internally-ribbed
Because of the incompressibility of flows in the one-
tube is:
dimensional single phase region, the conservation equations of
mass, energy and momentum can be expressed as Eqs. (4)e(6)
( " # respectively. Eq. (7) is the local pressure drop of inlet throttling.
vTw vTw Dex 2 Dmax 2
Qhsm ¼ Cw rw Aw ¼ Cw rw p Mass conservation equation:
vt vt 2 2
" 2 2 #) vGpr
NLcir Dmax Dmin ¼ 0 (4)
þ $p vZ
pDmin 2 2
Energy conservation equation:
(3)
vhpr vGpr $hpr Q
where, Cw is the specific heat capacity of the metal wall, rw is the rf þ ¼ (5)
vt vZ A
density of the metal wall, Aw is the area of the cross section of the
metal wall, Tw is the temperature of the metal wall, Dex is the Momentum conservation equation:
external diameter of a tube, D is the inner diameter of a smooth
tube, Dmax is the maximum inner diameter of an internally-ribbed vGpr vG2pr =rf vPpr lpr G2pr
þ ¼ rf $g $ (6)
tube, Dmin is the minimum inner diameter of an internally-ribbed vt vZ vZ 2D rf
tube, Lcir is the width of rib in the circumferential direction and N
Local pressure drop of the inlet throttling:
is the number of ribs in an internally-ribbed tube.
According to the two heat storage equations, Eqs. (2) and (3), the
Kin G2in
influences of the different heat storage capacities of different tubes DPin ¼ $ (7)
2 rf
are embodied in the present model, which have not been
mentioned in previous models. In these equations, differences in flow areas between smooth
To establish a new mathematical model for the frequency tubes and internally-ribbed tubes are mainly embodied in the
domain analysis of two-phase flow instabilities in the internally- parameter D and A, while difference in flow conditions, especially
ribbed tubes, three steps are needed. The first step is establishing the effect of rotational flow in the internally-ribbed tubes on the
the fundamental equations which can be used to describe the two-phase flow instabilities, are embodied in the coefficient of
physical phenomenon accurately. The second step is getting the frictional resistance lpr. Calculation methods of D, A and lpr are the
transfer functions from the fundamental equations by using Lap- same as that published in literature [26e28], which provide related
lace transform. The last step is obtaining the feedback relations, semi-empirical equations to calculate the coefficients of frictional
according to the classic automatic control theory [25]. The detailed resistance of internally-ribbed tubes. Detailed calculation methods
process of derivation of the model in the present paper is shown as of D, A and lpr are shown in Section 2.1.6.
follows.
vrtr vGtr
þ ¼ 0 (8)
vt vZ
Energy conservation equation:
per unit length in axial direction under the corresponding static Table 2
working condition and dQ is the perturbation of heat power per Detailed equations of intermediate variables.
unit length in axial direction. Other dynamic parameters can be C11 ¼ rf ðhin hf Þz*pt =2 C12 ¼ Q * Zpt =A
expressed in the same forms. C13 ¼ ðhf hin Þ$G*pt C14 ¼ Q * Zpt =A
In order to facilitate the analysis, fifteen non-dimensional C15 ¼ G*pt Zpt
* * G*2 =ðDr Þ þ K G*2 =r
C16 ¼ lpr Zpt pt f in pt f
parameters (Shown in Table 1) are defined, which represent the C17 ¼ pr Zpt G*2
* * C18 ¼ DPpr
*
l pt =ð2Drf Þ þ rf gZpt
dynamic parameters in system respectively. zpt represents the start * Z * Þ=2
C21 ¼ ðrf rg ÞðZts * =2
C22 ¼ ðrf rg ÞZpt
pt
boiling point perturbation, zts represents the perturbation of the C23 ¼ G*ts C24 ¼ G*pt
start point of superheating region, gin represents the perturbation of * Z * Þ=2
C25 ¼ ðrf hf rg hg ÞðZts pt C26 ¼ Q * ðZts
* Z * Þ=A
pt
inlet mass flux, gpt represents the perturbation of mass flux at the * =2
C27 ¼ ðrf hf rg hg ÞZpt C28 ¼ Q * Zpt
* =A
start boiling point, gts represents the perturbation of mass flux at the
C29 ¼ G*ts hg C210 ¼ G*pt hf
start point of superheating region, gout represents the perturbation
C211 ¼ Q * ðZts
* Z * Þ=A
pt C212 ¼ DPtr
*
of outlet mass flux, Dppr represents the perturbation of pressure C213 ¼ ðrf þ rg ÞgðZts* Z * Þ=2 þ l ðG*2 =r þ G*2 * *
pt tr ts g pt =rf ÞðZts Zpt Þ=ð4DÞ
drop of subcooling region, Dptr represents the perturbation of * =2 l ðG*2 =r þ G*2 =r ÞZ * =ð4DÞ
C214 ¼ ðrf þ rg ÞgZpt tr ts g pt f pt
pressure drop of two-phase flow region, Dpsr represents the * Z * ÞG*2 =ð2Dr Þ
C215 ¼ ltr ðZts pt ts g
* Z * ÞG*2 =ð2Dr Þ
C216 ¼ ltr ðZts pt pt f
perturbation of pressure drop of superheating region, q represents C31 ¼ G*out h*out C32 ¼ G*out h*out
the perturbation of internal wall heat flux, qex represents the C33 ¼ G*ts hg C34 ¼ Q * ðZout Zts
* Þ=A
perturbation of external wall heat flux, qhsm represents the pertur- C35 ¼ Q * ðZts
* Z * Þ=A
pt C36 ¼ DPsr
*
bation of heat storage of wall metal, hout represents the perturbation C37 ¼ fðrg þ rout Þg=2 þ lsr G*2 * *
out =½Dðrg þ rout ÞgðZts Zpt Þ
* ÞG*2 =½Dðr þ r
C38 ¼ 2lsr ðZout Zts *2
of the enthalpy of fluid at outlet, tout represents the perturbation of out g out Þ Kout Gout =rout
0
C41 0 C0
¼ C32 C17 0
C42 0 C0
¼ C32 C17
the temperature of fluid at outlet, twout represents the perturbation 0
36
0 C0 0
37
0 C0 þ C0 C0
C43 ¼ C32 C17 C53 ¼ C48
of the temperature of tube wall at outlet. These non-dimensional 0
38
0 C0 þ C0 C0 0
51 41 52
0 C0 þ C0 C0
C54 ¼ C49 51 42 52 C55 ¼ C50 51 43 52
parameters equal to the ratios of value differences (value differ- 0 * * Þ
C56 ¼ Cw rw Aw Twout =ð2Qex
ences between dynamic values and static values) and static values.
In fact, these non-dimensional parameters are also equal to the
ratios of small perturbation values and static values. This can be
described by Eq. (26), and the other non-dimensional parameters
C21 $s$zts þ C22 $s$zpt þ C23 gts þ C24 gpt ¼ 0 (30)
are similar.
Gin G*in dGin ðC25 $s þ C26 Þzts þ ðC27 $s þ C28 Þzpt þ C29 gts þ C210 gpt þ C211 q ¼ 0
gin ¼ ¼ (26)
G*in G*in (31)
C212 Dptr þ C213 zts þ C214 zpt þ C215 gts þ C216 gpt ¼ 0 (32)
To get the transfer functions, three steps are carried out one by
one. Firstly, the fundamental differential equations are integrated
gout ¼ gts (33)
in their own regions. Secondly, the small perturbations are taken
into the system, and the fundamental equations are translated into
perturbation equations, and higher order infinitesimals of small C31 gout þ C32 hout þ C33 gts þ C34 q þ C35 zts ¼ 0 (34)
perturbations are neglected. Thirdly, instead of dimensional pa-
rameters, non-dimensional parameters are used in these equations, C36 Dpsr þ C37 zts þ C38 gout ¼ 0 (35)
and then Laplace transform is carried out.
Eqs. (27)e(39) show the detailed transfer functions derived
* * *
from the fundamental equations. In these equations, all the non- Dppr $DPpr þ Dptr $DPtr þ Dpsr $DPsr ¼ 0 (36)
dimensional parameters are functions of s (s is the Laplace trans-
fer factor) instead of time, because of Laplace transform. 0
C56 $s$twout ¼ qhsm (37)
ðC11 $s þ C12 Þzpt þ C13 gpt þ C14 q ¼ 0 (28) qex ¼ q þ qhsm (39)
C16 gpt þ C17 zpt þ C18 Dppr ¼ 0 (29) where, C11 w C18 are the intermediate variables for preheating re-
gion, C21 w C216 are the intermediate variables for two-phase flow
region, C31 w C38 are the intermediate variables for superheating
region, and C10 wC56
0 are the intermediate variables for other equa-
gpt ¼
Gpt G*pt
gts ¼
Gts G*ts
gout ¼
Gout G*out 2.3. Feedback relations
G*pt G*ts G*out
DP DP *
Dptr ¼ DPtrDP *DPtr Dpsr ¼ DPsrDP*DPsr
* *
Dppr ¼ prDP* pr sr To form the feedback relations, transfer functions must be
pr tr
Q Q * *
Qex Qex qhsm ¼ Qhsm written in the classic forms like Eqs. (40) and (41).
q ¼ Q* qex ¼ * *
Qex
Qex
hout h*out *
Tout Tout *
Twout Twout
hout ¼ tout ¼ twout ¼
h*out *
Tout *
Twout
Output ¼ GðsÞ$Input (40)
Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13 7
Table 4
Working conditions of the two-phase flows in the internally-ribbed
tube [23].
Parameter Range
and smaller with time until disappearing. It means that the closed-
Table 5 loop system of Case 1 is stable.
Detail parameters of three working conditions.
It can be concluded from Figs. 8 and 9 that the system is stable in
Parameter Case1 Case 2 Case 3 Case 1. The present model can predict the stable condition well.
Total length of the channel (m) 5.250 5.250 5.250
Inner diameter (mm) 12.5 12.5 12.5
Outer diameter (mm) 15 15 15 4.2.2. Case 2
Pressure (MPa) 3.8 3.8 3.8 Fig. 10 shows the Nyquist analysis of Case 2. The curve passes
Heat power (kW) 76.24 79.83 80.23 through the point (1, j0) twice along the anticlockwise direction,
Mass flux (kg/m2 s) 240 240 240
Inlet fluid subcooling ( C) 152 152 152
i.e., Nd ¼ 2. According to the present model, the poles of the open-
Inlet resistance coefficient 600 600 600 loop transfer function equal to 0, 0.59153 þ 2.29130i,
Working condition Stable Critical Unstable 0.59153 2.29130i, i.e., P0 ¼ 2. Despite Nd ¼ P0, Case 2 is the critical
condition, because Nd is the times that the Nyquist curve passes
through the point (1, j0).
Fig. 11 shows the response curves of Case 2. After importing a
small perturbation to the external heat power, Tout and Twout rise
slowly in the form of fluctuation. Seconds later, self-sustaining
Fig. 8. Result of Nyquist analysis of Case 1 by using the present model. Fig. 9. Result of response curves of a step disturbance in Case 1 by using SIMULINK.
10 Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13
Fig. 10. Result of Nyquist analysis of Case 2 by using the present model. Fig. 12. Result of Nyquist analysis of Case 3 by using the present model.
fluctuations occur, with the same frequency and amplitude. From 5. Effect of flow parameters on the two-phase flow
Fig. 11, the oscillation period of this system equals to 2.89 s, which instabilities in internally-ribbed tubes
means a classical density wave oscillation.
It can be concluded from Figs. 10 and 11 that the system in Case After the verifications, two-phase flow instabilities in internally-
2 is at the critical state and the critical heat power equals to ribbed tubes were studied systematically by using the present
79.83 kW. The present model can predict the critical condition well. model. As contrasts, study of two-phase flow instabilities in smooth
tubes was made to verify the difference between two-phase flow
instabilities in internally-ribbed tubes and that in smooth tubes.
4.2.3. Case 3
In the present paper, three representative tubes are studied,
Fig. 12 shows the Nyquist analysis of Case 3. The Nyquist curve
which are widely used in manufacture of boiler water-cooled walls.
does not surround point (1, j0), and Nd ¼ 0. According to the
Table 6 gives the detailed parameters of tubes, and Table 7 shows
present model, the poles of the open-loop transfer function are 0,
the ranges of working variables.
0.61067 þ 2.28856i, 0.61067 2.28856i, and P0 ¼ 2. Nd sP0 means
the closed-loop system is unstable.
Fig. 13 shows the response curves of Case 3. Oscillation ampli- 5.1. Effects of inlet resistance coefficient
tudes of Tout, Twout and Gout become bigger and bigger with time,
especially after the 100th second. Obviously, this system is According to the definition of CHF, CHF can be considered as the
unstable. demarcation point of stable region and unstable region [24], and
It can be concluded from Figs.12 and 13 that the system is unstable CHF is widely used to represent the two-phase flow instability
in Case 3. The present model can predict the unstable condition well. behaviors in tubes [22e24,31,32]. The system is unstable when the
Generally all results of the present model agree well with that heat flux is greater than CHF, and it is stable when the heat flux is
obtained by SIMULINK. It indicates indirectly that the present lower than CHF. A system with high CHF means a large stable re-
model can be used to predict the two-phase flow instabilities in gion, i.e., this system can be more stable than other systems. In this
tubes accurately. paper, the effect of inlet resistance coefficient on two-phase flow
instabilities is studied by using the CHF parameter.
Fig. 11. Result of response curves of a step disturbance in Case 2 by using SIMULINK. Fig. 13. Result of response curves of a step disturbance in Case 3 by using SIMULINK.
Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13 11
Table 6 that of Tube 1 (the smooth tube, f28 6 mm), while CHF of Tube 3
Detailed parameters of the three tubes. (the 6-head ribs internally-ribbed tube, f38.1 7.5 mm) is 50%
Parameter Tube 1 Tube 2 Tube 3 greater than that of Tube 1. Two-phase flows in the internally-
Type Smooth Internally- Internally-
ribbed tubes show greater stability than that in the smooth one.
tube ribbed tube ribbed tube Further analyses of the stability differences of the two-phase flows
Outside diameter (mm) 28 28 38.1 in these tubes are showed in Section 5.5 in specialty.
Inside diameter (mm) 16 17.1 23.23
Maximum wall thickness 6 5.41 7.5
(mm) 5.2. Effects of inlet fluid subcooling
Number of ribs / 4 6
Rib width (mm) / 9 5.59
Rib height (mm) / 0.81 0.99
Inlet fluid subcooling is one of the factors which may affect the
Pitch (mm) / 21 21.06 flow instabilities, and how does it work is a meaningful question.
Lead (mm) / 92.53 126.37 Keeping mass flux, inlet resistance coefficient and pressure as
Lead angle ( ) / 61.5 60 constants, values of inlet fluid subcooling from 10 C to 300 C are
selected for this analysis. According to the present model, CHF can
be determined and detailed CHF curves are shown in Fig. 15.
Table 7 Every CHF curve shown in Fig. 15 has an extreme point, which is
Ranges of working variables. the worst point of the stability (WPS) of two-phase flows. In the left
side of the extreme point, CHF become lower with the inlet fluid
Parameter Range
subcooling, but in the right side, CHF become greater with the inlet
Pressure (MPa) 2e15
fluid subcooling. The WPS corresponds to the Minimum Critical
Heat flux (kW/m2) 0e800
Mass flux (kg/m2 s) 200e1500
Heat Flux (M-CHF) of two-phase flows in tubes, while it represents
Inlet fluid subcooling ( C) 10e300 that the two-phase flows at this inlet fluid subcooling show the
Inlet resistance coefficient 0e600 worst stability. According to Fig. 15, M-CHFs of the three tubes equal
to 53.4 C, 51.7 C and 72.6 C respectively.
Physically, M-CHF is the point where the proportion of two-
Keeping mass flux, inlet fluid subcooling and pressure as con- phase flow region occupies the most major status in the system,
stants, inlet resistance coefficient from 0 to 600 are selected for this and the influences of two-phase region are more greater than other
analysis. Values of CHFs under different working conditions in parts in this condition. That means two-phase flow instability may
every tube are calculated by using the present model, and then the occur more easily at M-CHF. When inlet fluid subcooling is lower
CHF curves are formed, shown in Fig. 14. than M-CHF, the lower the inlet fluid subcooling is, the greater the
The CHF curves, shown in Fig. 14, increase with the inlet resis- proportion of preheating region may become, and the more stable
tance coefficient for all three tubes. This means the inlet resistance the system may be, because the non-compressible water in pre-
coefficient plays a positive role in the system’s stability. The heating region plays a stable role in the system. When inlet fluid
consequence agrees with the physical mechanism well. Because the subcooling is greater than M-CHF, the higher the inlet fluid sub-
rising of inlet resistance coefficient may cause the inlet pressure cooling is, the greater the proportion of preheating region may
drop increasing, then the increasing of inlet pressure drop may become, and the more stable the system may be, because the
reduce the proportion of the two-phase flow pressure drop rela- superheating region is also non-compressible according to the
tively. That means the influences of two-phase flow on the stability hypothesis in this paper. Hence, the results based on the present
of system decrease, and it may make the system more stable finally. model in Fig. 15 reveal the physical phenomena compendiously and
So the two-phase flows in the system may become more stable exactly.
with the increasing of inlet resistance coefficient, based on the Generally, in the design and operating process of a boiler sys-
calculations and analyses here. tem, M-CHF is a notable point to be avoided, and the value of M-
In the situations showed in Fig. 14, CHF of Tube 2 (the 4-head CHF can be determined by using the present model.
ribs internally-ribbed tube, f28 5.41 mm) is 10% greater than
Fig. 14. The effects of inlet resistance coefficient on CHF. Fig. 15. The effects of inlet fluid subcooling on CHF.
12 Y. Zhang et al. / Applied Thermal Engineering 65 (2014) 1e13
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