Prediction of the transition from stratified to slug flow or roll-waves in gas–liquid horizontal pipes

In stratified gas–liquid horizontal pipe flow, growing long wavelength waves may reach the top of the pipe and form a slug flow, or evolve into roll-waves. At certain flow conditions, slugs may grow to become extremely long, e.g. 500 pipe diameter. The existence of long slugs may cause operational upsets and a reduction in the flow efficiency. Therefore, predicting the flow conditions at which the long slugs appear contributes to a better design and management of the flow to maximize the flow efficiency.In this paper, we introduce a wave transition model from stratified flow to slug flow or roll-wave regimes. The model tracks the wave crest along the pipe. If the crest overtakes the downstream wave end before hitting the top of the pipe, a roll-wave is formed, otherwise a slug.For model validation we performed measurements in air–water horizontal pipe flow facilities with internal diameters of 0.052 and 0.06 m. Furthermore, we made numerical calculations using a transient one-dimensional multiphase flow simulator (MAST) which adopts a four-field model. The model presented in this paper successfully predicts the evolution of waves and their transition into either slugs or roll-waves. It also predicts the formation time of slugs and roll-waves with a satisfactory agreement.