In this scenario, an experimental setup of a single pipe with a trapped air pocket at one upper end upstream and an internal diameter of 42 mm was carried out. The experimental setup corresponds to a main linear section with a length of 4160 mm, and a complementary section of 200 mm long, interconnected with the main linear section through a 90° elbow. Different emptying processes were tested using different values of
, ball valve opening degrees (
), and ball valve opening times (
). From this experimental setup, the emptying processes associated with two scenarios were explored: (i) Case 1—without air admission orifice and (ii) Case 2—with air admission orifice. As a measurement parameter, a pressure transducer located at 0.105 m from the upstream end of the pipeline was used to measure the pressure oscillation of trapped air from
t = 0 with a frequency of 7000 Hz.
Figure 8 shows the installation and description of the elements used in the experimental setup, followed by
Table 5, which shows the results four (4) tests, where Tests C1-1 and C1-2 correspond to Case 1, and Tests C2-1 and C2-2 correspond to Case 2.
3.2. Three-Dimensional CFD Model
As with the two-dimensional CFD model described in
Section 2 of this research, Paternina-Verona et al. [
8,
24] ensured the numerical solution of the fluid, PVoF, transport and thermodynamic equations using OpenFOAM software v2012 of CFD Direct (ICL, UK) for application on a three-dimensional computational domain. To simulate the turbulence, SST
k–
model was used, based on the advantages of this model mentioned in
Section 2.2, taking into account that these equations have been used by other authors to analyse two-phase transient flows in three-dimensional CFD models [
25,
32].
First and second order numerical schemes were defined in the different terms of the governing equations, and the PISO algorithm was used. Cases 1 and 2 correspond to a similar experimental setup, so the difference between models is highlighted by the presence of the orifice. In Case 1, the CFD model has four boundaries: (i) outlet, (ii) walls, (iii) moving walls and (iv) Valve Sliding Interface (VSI); in Case 2, the boundary conditions of Case 1 were used, adding a boundary corresponding to Inlet (air admission orifice). Equations of boundary conditions were similar to those presented in
Table 3, where the VSI boundary in contact with the pipes allowed flow circulation to aid water drainage and acted as a wall when the ball valve connections were not in contact with the pipeline.
The CFD model was performed using a structured mesh in all geometric domains: in Case 1, using a square cross-section within the circular cross-section, and for Case 2, using a detailed orifice with small cells, with a cell had a dimension of 3 × 10
m in width. These details are shown in
Figure 9.
A sensitivity analysis of the mesh was performed to verify the independence of the numerical results from the mesh resolution. To that end, Paternina-Verona et al. [
8] performed an independence analysis of this CFD geometry through the analysis of the numerical evolution of the pressure patterns using different meshes, ranging from 43,500 to 1,220,000, cells with different meshing properties (aspect ratio, asymmetry, orthogonality and computational times), where the numerical results with the different meshes presented a good agreement with the reference measurement used. Finally, in this research, a mesh of 507,375 cells was used for Case 1 and a mesh of 173,500 cells in Case 2 [
24].
In addition, a maximum Courant number of 0.5 was used, with an adjustable time step between 10
s and 1.0 s, similar to the 2D CFD model performed in
Section 2.2. To verify the convergence of the numerical solution of the CFD model, the decrease in the residuals of the pressure variable was verified, in which the residuals generated in the 3D CFD models of Case 1 tended on average to values that oscillated on the scale of 10
Pa, in which the numerical solution of this variable converged after a maximum of 8 iterations. On the other hand, the residuals of the 3D CFD models of Case 2, at a general level, tended to values that oscillated on the scale of 10
Pa, reaching convergence after a maximum of 2 iterations. These simulation were executed in an AMD(R) Opteron(TM) 6380 processor, with a frequency of 2.75 GHz, 16 cores, 32 threads and physical memory of 96 GB.
3.3. 3D CFD Model vs. Mathematical Model
In order to compare the 3D CFD model with the information provided by the mathematical model of Fuertes-Miquel et al. [
18], a single pipe without air admission orifice was used as a case study. Tests C1-1 and C1-2 were simulated for 3 s, and Tests C2-1 and C2-2 were simulated until the pipes were drained. Case 1 tests were run up to an instant
t = 3 s since, experimentally, the water column could not be drained due to subatmospheric pressures. In addition, numerical information of pressure oscillations of 3D CFD models were extracted with an internal point located at 0.105 m from the upper end of the pipeline (similar to the location of pressure transducer).
The 3D CFD model was performed, which showed a variety of relevant information that these models offer under a three-dimensional domain, providing an approximation to real conditions. In this model, different hydraulic and thermodynamic phenomena, such as (i) deformation of the air–water interface, (ii) backflow air (DAPs), (iii) transient flows, (iv) velocity distribution curves in different sectors of the pipe due to the influence of backflow air and (v) velocity and temperature distribution in cross-sections were seen in detail (see these in more detail in the contribution of Paternina-Verona et al. [
8]).
The pressure oscillations of the mathematical model and the 3D CFD model were compared to show the similarity between the results, as shown in
Figure 10.
In Test C1-1 (
Figure 10a), a critical subatmospheric pressure occurred at
t = 0.64 s, where the minimum value reached by the mathematical model was 8.34 m-H
O, and the value of minimum pressure in the CFD model reached a maximum value of 8.29 m-H
O. Subsequently, it was identified that the CFD model predicted the behaviour of the pressure oscillations recorded by the mathematical model which occurred after the minimum pressure value. It was possible to identify that the pressure oscillations in the CFD model presented a delay in their peaks and valleys with respect to the oscillations detected by the mathematical model, an effect that is mainly influenced by the backflow air phenomenon. On the other hand, in Test C1-2 (
Figure 10b), with a lower valve opening degree than Test C1-1, a good agreement with the pressure oscillations of the mathematical model was presented, reaching a minimum pressure of 8.20 m-H
O.
Tests C2-1 and C2-2 (scenarios with air admission orifices) were also compared, where CFD model results were similar to pressure patterns of the mathematical model. In Test C2-1 (
Figure 10c), the emptying process resulted in an expansion of the trapped air, reaching a minimum pressure of 9.55 m-H
O at
t = 0.58 s and then gradually rising until it reached atmospheric pressure again at
t = 16 s, which coincided with the instant of time at which the pipe had been completely drained. On the other hand, Test C2-2 (
Figure 10d) showed a decrease in trapped air pressure, down to a minimum value of 9.87 m-H
O at
t = 0.60 s, then returning to atmospheric pressure after
t = 18 s.
In addition to pressure patterns, the water flow patterns obtained from the 3D CFD model were compared with the results of the mathematical model, using all tests of this scenario.
Figure 11a shows the flow patterns of Test C1-1 of the CFD model, compared with the results of the mathematical model associated with the test in reference. Transient flow with higher amplitudes compared to the mathematical model were observed, except for the first flow peak, for which there was a maximum value of 0.29 L/s in the mathematical model, and a value of 0.22 L/s in the 3D CFD model. There were maximum peaks in the flow patterns of the mathematical model and the 3D CFD model of 0.08 and 0.11 L/s, respectively, in Test C1-2 (
Figure 11b). In this case, the peak flow of the three-dimensional CFD model was greater than the peak flow of the mathematical model. In Test C2-1 (
Figure 11c), water flow patterns of the mathematical and CFD models showed good agreement in their physical behaviour, whereas the mathematical model predicted a peak discharge flow of 0.636 L/s, while the peak discharge flow predicted by the 3D CFD model was 0.632 L/s. Finally, in Test C2-2 (
Figure 11d), the numerical pattern of the CFD model adequately predicted the trend of the volumetric flow rate of the mathematical model, presenting a good agreement in the physical behaviour. On the one hand, the mathematical model of Test C2-2 reached a maximum flow rate of 0.49 at
t = 0.465 s, whereas the 3D CFD model predicted two maximum peaks flows with values of 0.50 L/s at
t = 0.27 s and 0.516 L/s at
t = 1.15 s.
In addition, the utilisation of the turbulence model was validated as a function of the maximum Reynolds number presented in the different tests, given through the information of the maximum flow rate and the hydraulic section for diameter
= 0.042 m.
Table 7 shows the general distribution of the maximum Reynolds numbers predicted in each numerical model, where the range presented was from 2.667 to 19.183, so the hydraulic scenarios were in the turbulence and transition region, which are suitable indicators to validate the use of the SST
k–
turbulence model.
The water flow patterns during drainage processes obtained from the 3D CFD models show similar behaviour to the results obtained from the mathematical model; nevertheless, there is a difference in the peak flow values of the two models. It is important to mention the difference between the mathematical model and the 3D CFD model, in terms of the influence on water flow patterns, which is based on the simulation conditions of the ball valve opening percentage. The mathematical model considers the addition of a coefficient of resistance () equivalent to the head losses generated by the opening percentage of the ball valve. The value of is variable from t = 0 s to the end of the opening manoeuvre, which depends on the degree of opening at different time instants. On the other hand, the 3D CFD model uses a solid-body motion function to simulate the ball valve through a cylinder with curved surfaces. When the cylindrical mesh contacts the pipes in the 3D CFD model, it allows water to pass between the upstream and downstream sections. Proper simulation of a valve opening manoeuvre has been a challenge in modelling, since it is a manual procedure in practice and susceptible to errors during its representation in hydraulic models. A correct simulation of the ball valve-opening manoeuvre guarantees a higher accuracy of the results and allows an adjustment of the model to real hydraulic conditions.
Differences between oscillations in water flow and pressure patterns in the CFD and mathematical models were also due to the effect of backflow air, which influences the hydraulic conditions of drainage, a phenomenon that was not considered in the physical equations of the mathematical model. This delay in the drainage pressure and flow rate oscillations was significantly evidenced in Test C1-1 (see
Figure 12 and
Figure 13), which is influenced by the presence of air bubbles entering upstream. It could be observed that the 3D CFD model was able to adequately represent the behaviour of the air pocket, i.e., the movement of the backflow air, forming an appropriate stratification of air pockets, wherein the mixing of these fluids is rarely generated. In contrast, there were no air bubbles in Test C1-2. This is evident in the good agreement between the pressure oscillations and water discharge flow rate of the CFD model with the recorded oscillations of the mathematical model (see
Figure 11d).
On the other hand, the thermodynamic behaviour between air and water corresponds to a phenomenon that can be captured by 3D CFD models, which has been rarely studied in the literature. Zhou et al. [
33] performed a study of the heat transfer between the air and water phases in a rapid filling process and compared with experimental results through the development of a 3D CFD model, which observed an increase in the temperature of the entrapped air pocket to values of more than 100 °C, which could be observed during the experimental measurements performed. Currently, there are no detailed studies of the thermodynamic behaviour between the air and water phases in pressurised pipe emptying processes. The water phase is characterised by a lower compressibility than the air phase, so its temperature variations are insignificant during transient events. However, the water phase plays an important role in the heat transfer process, as shown in
Figure 14, where the temperature gradients that occur from the water phase to the air phase in the emptying processes of Tests C1-1 and C1-2, respectively, are visualised. Additionally, this information is complemented with the air–water interface location during the thermodynamic interaction.
Figure 15 shows the variation in the temperature patterns in the air pockets of Tests C1-1 and C1-2, where it is observed that the temperature of the entrapped air pockets decreases during the expansion processes, proceeding from 20 °C to minimum values of 1.5 °C and 2.3 °C, respectively, at
t = 0.5 and 1.0 s. In Test C1-1, temperature oscillations occur due to the smooth oscillations in the water column velocity, which cause compression of the air pocket, accumulating compression energy that is subsequently transformed into heat energy. In Test C1-2, there is a temperature drop at
t = 1.0 s, and, thereafter, the temperature increases progressively, causing the compression and expansion energy to be present in smaller proportions in the air pocket, facilitating its return to ambient temperature by heat transfer between water and air.
Comparison of 2D/3D CFD Models
The authors of [
23] used an experimental setup similar to the single pipe to represent the scenario associated with Case 2 (emptying process with an air admission orifice), where Test C2-1 was compared with the simulation performed by these authors in their research. An analysis of the physical phenomena in Test C2-1 was performed between the results obtained by the 3D CFD model of Paternina-Verona et al. [
24] and the 2D CFD model of Paternina-Verona et al. [
23], where the behaviour of the air–water interface and the velocity distribution of the air flow admitted to the hydraulic system through the orifice were compared.
Figure 16 showed that the displacement of the air–water interface in the 2D and 3D CFD models was similar at
t = 0, 1, 5, and 10 s, and a difference in the location of the air–water interface occurred at the instant
t = 15 s, just before total drainage of the water in this test. In this sense, the prediction of the air–water interface can be carried out adequately in both the two- and three-dimensional conditions.
On the other hand, in the 2D and 3D CFD models of Test C2-1, an evaluation of the spatial distribution of the velocity at the upper end of the pipe was carried out, corresponding to the air phase. In order to make an adequate comparison of the velocity gradients between the 2D and 3D CFD models, a cut of the geometry of the 3D CFD model was made on the XY plane to obtain the information of the two-dimensional profile of the pipe axis, as shown in
Figure 17.
After cutting on the XY plane, the comparison of the velocity gradients presented in the air admission zone of the single pipe of both CFD models was performed.
Figure 18a shows the distribution of velocity produced by the 2D CFD model, where it can be seen that the air admission velocity reached its maximum value at
t = 1.0 s and gradually decreased over time, as evidenced at
t = 5.0, 10.0 and 15.0 s, a similar trend to the results presented by the 3D CFD model (
Figure 18b).
During air admission, three fronts of flow velocity were observed at the upper end of the pipe profile. These fronts reached velocity values between 7 and 10 m/s at the top wall, bottom wall and the central axis of the pipe (see
Figure 18a at
t = 0.5 and 1.0 s). On the other hand, in the 3D CFD model scenario, a predominant flow velocity front generated by the air admission orifice was observed. This front was attenuated towards the bottom of the upstream end of the pipe, reaching a magnitude greater than 10 m/s. In addition, a small velocity front was generated, which was seen at
t = 0.5 and 1.0 s in the upper zone of the upstream end of the pipe (see
Figure 18b). In that sense, the velocity contour results of both CFD models presented some discrepancies in terms of the generation of velocity gradients inside the geometrical domain, especially in complex areas such as the air admission orifice. From the above comparison, it was possible to verify some elements that are important to take into account to identify the behaviour of velocity gradients in 2D and 3D CFD models. In particular, 2D CFD models require a geometric aspect ratio to simulate the diameter of the air admission orifice to adjust the mass flow rate conditions, as has been used in previous research [
22,
34,
35], whereas the 3D CFD model allows the generation of an orifice with a diameter equal to the study cases, being an appropriate condition in the evaluation of diameter changes in pipes. In this regard, the simulation of orifices in 2D CFD models requires a geometric aspect ratio that has been favoured in the representation of emptying processes with admitted air; however, it is an element that must be suitably adjusted during the development of the computational model, depending on the geometric conditions of the pressurised pipes.