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This paper aims to discuss flow pattern transition (FPT) as an important factor in multiple-phase flow measurements. Several methods have been proposed to control FPT, but those methods fail to address the many issues in complex flow conditions that can affect flow patterns.

In this paper, a non-intrusive sensor instrumentation is applied to extract measurable data under different flow conditions. Using these data, a simple theoretical–mathematical method along with an orthogonal design is applied to FPT optimization. Orthogonal experiments are designed and carried out according to theoretical guidelines. Three selected process parameters – phase fraction, gas pressure in the initial independent process and liquid speed – are optimized for FPT results to produce a minimum FPT time.

The following results are obtained: the phase fraction in the initial independent process can lead to significant reductions in FPT time, gas pressure plays an important role and liquid speed has no apparent effect on FPT results. Under optimized conditions, FPT time can be shortened to 0.3-0.6 times by controlling the above three parameters compared with normal conditions.

The proposed method is simple, rapid and efficient for evaluating an FPT process and lays the foundation for further FPT applications.