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Minimise time-to-production / speed up commissioning

DETERMINE BEFOREHAND THE ENERGY CONSUMPTION OF A PROCESS

 

PIPE SYSTEMS (LIQUID/GAS & HEATING/COOLING)

  • Calculation of pressure drop for gases or liquids.
  • Pump, valve and pipeline sizing.
  • Pump performance adjustment for viscosity.
  • Sizing of control valves and orifices.
  • Design of liquid/gas distribution systems.
  • Flow balancing in branching networks.
  • Analysis of transient events like pressure wave (water hammer/surge) propagation.
  • Control philosophy development and testing using the built-in PLC function block diagrams.
  • Sizing of pressure safety valves.
  • Simulation of a valve failure event.
  • Calculation of heating or cooling requirements for various processes.
  • Heat loss/pickup calculations.
  • Insulation sizing.
  • Pipework velocities, pressure drops.
  • Calculation of NPSH and prediction of cavitation.
  • Water hammer.
  • Sizing of safety relief valves.
  • Cooling tower response.

 

COOLING WATER SYSTEMS

  • Pipeline, valve and pump sizing.
  • Water hammer.
  • Cooling tower response.
  • Heat exchanger sizing.
  • Water reticulation flow balancing and energy efficiency

FIRE PROTECTION SYSTEMS

  • Pump, pipe and tank sizing.
  • Sizing of nozzles and orifices.
  • Flow balancing.

 

COMPRESSED AIR SIMULATION

  • Reticulation system design and pipe sizing.
  • Compressor selection.
  • Energy optimization.
  • Heat exchanger sizing (inter- and after coolers).
Compressed air

HEAT EXCHANGERS

  • Calculating heat transfer and pressure drop for various geometries: finned tube, shell and tube, tube-in-tube, plate heat exchangers.
  • Calculating the heating or cooling requirement for various processes: evaporation, condensation or temperature control.
  • Calculation of natural circulation evaporator recirculation rate.
  • Simulation of transient behavior for startup, shut-down or process upset conditions.
  • Calculation of temperatures and boiling pressure drop.
  • Calculation of metal temperature change rates during transients.

Heat exchanger

INTEGRATED SYSTEMS ANALYSIS

  • Liquefied natural gas (LNG) storage and handling.
  • Interaction between pipeline flow/pressure and the pump/turbine set including its control.
  • Cryogenic system thermal fluid analysis using two-phase flow tanks, pressure drop, heat transfer, incondensable gas mixtures etc.
  • Simulation of refrigeration systems for cryogenic cooling during natural gas liquefaction.
  • Natural gas liquefaction.
  • Design of gas venting and inventory control systems.
  • Simulation of gas turbine driven pipeline booster pumps.
  • Simulation or system integration of gas turbine driven compressors for natural gas liquefaction.
  • Pipe system pressure control design

SLURRIES, PASTES & NON-NEWTONIAN FLUIDS

  • Calculation of Non-Newtonian fluid pressure drop.
  • Balancing of flow in branching pipe networks.
  • Assessment of pressure pulse transients.

HYDRAULIC SYSTEMS

  • Pump selection and pipe sizing.
  • Flow distribution.

TEMPERATURE CONTROL LOOP DESIGN

  • Calculate heat exchange process dynamics.
  • Tune PID controllers before commissioning.
  • Assess the sensitivity to environment temperature.
Process1

STEAM SYSTEMS

BulletSUPER HEATER & MAIN STEAM PIPING

  • Calculation of metal temperatures and change rates.
  • Commissioning assistance.
  • Pipe sizing.

BulletSTEAM TURBINE & SUPPORTING SYSTEMS

  • Start-up and shutdown simulation.
  • Turbine trip control simulation.
  • Gland steam system analysis.
  • Lubrication system analysis.

BulletONCE-THROUGH BOILERS

  • Flow balancing.
  • Assessment of boiling stability.
  • Calculation of flow/boiling regimes.
  • Assessment of control.

BulletFEED WATER

  • Root cause analysis of pump NPSH problems.
  • Analysis of feed water heater tube breaks.
  • Cavitation/phase change detection.

Steam Exchange

BulletNATURAL CIRCULATION BOILERS

  • Calculation of recirculation rate and steam production.
  • Prediction of dry out.

BulletCOOLING WATER CIRCUITS

  • Flow balancing.
  • Pump and pipe sizing.
  • Energy optimization.
  • Heat load calculations.
  • Heat exchanger sizing.
  • Water reticulation system design.
  • Water hammer analysis and prevention.
  • Environment - cooling tower - plant matching. 

FLARES & BURNERS

  • Calculation of gas consumption rates.
  • Pressure-, temperature- and compositiondependent combustion modeling.
  • Calculation of conjugate heat transfer (convective, conductive and radiative heat transfer).
  • Calculation of heat-up or cool-down times.
  • Natural or forced draft stack sizing.
  • Fan sizing.
  • System integration: simulation of flare control and interaction with the main pipe system.

 

I am not aware of any other tool with which I could have obtained the required results in such a short time span. Part of the success must undoubtedly be attributed to the prompt and high level support provided by Flownex® International almost daily in answering all my questions and offering suggestions throughout this very technically challenging simulation. The support fee has been paid for with this one project!

Hannes van der Walt - Senior Thermal & Process Engineer - Gasco