[CRACK Piping System FluidFlow V. 3.09.1 ENG
Gildo Santiago
FluidFlow is designed to allow the modelling of fluid behaviour within complex piping systems and accurately predict how the system will work for a given set of boundary conditions. The software uses a number of well-established models and correlations to solve the piping systems.
The software includes powerful auto-sizing functionality and is provided with a comprehensive database of fluids, pumps, valves, pipes and components. You can also model non-standard fittings. This therefore means we can model practically any pipe fitting. Users can also add new fluids and components to the database, a task which you only need to complete once as the data will be stored for future modeling projects.
Design your liquid pipe flow systems in an instant with the FluidFlow Liquid Module. This calculation module is used by engineers to calculate plant operating pressures, pressure losses and flow distribution in liquid piping transportation systems.
In addition to automatically sizing pumps and equipment, FluidFlow allows you to model vendor pumps in your system and consider changes in pump speed and impeller diameter. Figure 2.1 provides an overview of the pump chart developed by the software. We can clearly see the duty point on the curves thus allowing us to quickly establish how close we are to the best efficiency point on the efficient curve.
The software is provided with a comprehensive database of fluids, pipes, pumps and fittings. You can also add new fluids and components to the database, a task which you only need to complete once as the data will be stored for future modeling projects.
The Liquid Module is used to model a wide range of systems such as, cooling water plant, district heating mains, liquid nitrogen plant, LNG plant, mine dewatering systems, fire protection systems, utility systems etc.
Figure 2.1 gives an overview of an LNG Tanker Unloading plant which considers transporting LNG from loading arms to land tanks. The design inlet pressure and temperature for the LNG in this system was100 m fluid g at -160oC and heat transfer calculations were performed for all pipes which included mineral wool insulation.
FluidFlow can model any component (fluid equipment item) you are likely to come across, these include: boosters (positive displacement and centrifugal types), valves (including 3-way), flow controllers, pressure sustainers, pressure reducers, differential pressure controllers, check and non- return valves, orifice plates, reducers & expanders, venturi tubes, inline nozzles, filters, packed beds, cyclones, centrifuges, labyrinth seals, pipe coils, relief valves, bursting disks, shell & tube exchangers, plate exchangers, auto-claves, knock-out pots, as well as rigorously modelling junctions (tees, wyes, bends, & crosses). For items not covered by the above you can define your own in a matter of minutes and store in the software for future use.
As gas flows in any piping network, the pressure, temperature, density, enthalpy, velocity and other physical properties are constantly changing. FluidFlow calculations take this fully into account to provide an accurate solution without the need to make simplifying assumptions. Figure 3.1 illustrates a typical density chart as generated for a pipeline by FluidFlow. In this chart we can see how the gas density changes over the length of a given pipeline, in this case a natural gas distribution line.
A solution approach often used in literature is to assume ideal gas laws so that analytical equations for energy, momentum and continuity equations can be derived. Rather than make these simplifying assumptions, FluidFlow uses a calculation procedure that solves the conservation equations together with an equation of state for small pressure loss increments. This means FluidFlow obtains a much more rigorous and accurate solution reflective of actual plant performance.
The Gas Module is used to model a wide range of systems such as, natural gas transmission systems, steam systems, compressed air systems, ducted air distribution systems, oxy/acetylene systems, chemical process plant, flue gas, flare stack systems etc.
FluidFlow uses a modelling approach for the pressure loss calculation which is a hybrid between the rigorous and empirical methods. This means the software uses well known empirical correlations which are applied to a differential pipe length. This allows for a flash calculation, liquid holdup and flow regime to be determined for each segment and acknowledges that the pressure loss per unit length changes as the two-phase mixture flows along the pipeline.
Flow pattern maps are automatically generated by the software for each pipe in your system. Figure 4.1 provides an overview of a Geothermal Energy System. We can see on the right hand side the flow pattern map generated for the pipe segment as highlighted on the flowsheet.
The Two-Phase Module is used to model a wide range of systems such as, flashing steam/water systems, cryogenic and refrigeration systems, power generation and energy conservation plant, oil and gas lines etc.
Settling slurry calculation methods available include Durand, Wilson-Addie-Sellgren-Clift (WASC), WASP, Liu Dezhong and the Four Component Model. Non-settling slurry calculations methods depend on rheology data. These can be described as Power Law, Bingham Plastic, Hershel Buckley or Casson. Pulp & Paper Stock loss correlations include TAPPI & Moller K.
Simulating the performance of settling slurries is dependent on the solid density, concentration, particle shape and size distribution, as well as the properties of the carrier fluid. Selecting the optimum pipeline velocity is usually the most important factor in the design and operation of slurry systems. Developing plant which operates with high flowing velocities is wasteful of energy while operating with velocities too low can lead to blockage of pipelines due to a build-up of particle deposition. FluidFlow helps engineers develop and optimize plant designs resulting in efficient system operation.
Figure 5.1 provides an overview of a coal slurry transportation system including the settling slurry pipe resistance curve. We can clearly see the duty point on the resistance curve and its proximity to the point of maximum deposition.
The Slurry Module is used to model a wide range of systems such as, mine tailings systems, metal concentrate processing plant, hydro-transportation of ores and minerals, dredging and waste systems, food industry process plant, pulp and paper stock flow systems.
The above is just a brief list of some of the studies which can be completed. Scripting is a powerful tool which helps engineers optimize system performance, producing lower operating costs and lowering carbon emissions.
Figure 6.1 provides an illustration of a mine water removal system which includes a total of seven pumps. The Scripting Module was used to optimize the performance of this system for any given number of pumps in operation at any one time.
Figure 6.2 shows the spreadsheet output which was created automatically by the program. The software completed a simulation and exported results for Flow, Efficiency, Power and Specific Power to Excel. A graph curve relationship of specific power vs speed was generated from where we can clearly identify the most optimum specific power/speed. In this case with 5 pumps in operation, the optimum speed would be 1040 RPM as this produces the lowest specific power requirement (425 W/kg).
FluidFlow includes heat transfer functionality on all modules. Engineers can study heat transfer effects at heat exchangers, pipes and junctions. The software is provided with a library of pipe materials, insulation materials and soil types for buried pipe calculations.
The results generated by FluidFlow for liquids, gases, two-phase fluids and slurries are rigorously tested and verified against published data and real-world operating systems on a continuous basis. An extensive library of Quality Assurance test models are also installed with the software.
FluidFlow has been used successfully in industry since it was first launched 1984. The software has undergone extensive development since first launched ensuring the product is up to date, includes the very latest solution technology and offers engineers a fast and effective design simulation tool.
Yes. All FluidFlow modules are provided with heat transfer functionality - As Standard. This includes the ability to perform pipe heat loss calculations whilst taking into account the effect of local wind speed, surface emissivity & ambient temperature.
A library of pipe insulation materials is provided with the software As Standard and you can select the required thickness for each pipe. Convection, conduction and radiation losses are calculated automatically. This means FluidFlow can be used to quickly optimize energy use by selecting the economic insulation thickness.
The software also allows engineers to analyze the effect of a fixed temperature change or energy transfer rate across a pipe or fitting. FluidFlow completes an energy balance throughout all piping systems.
Engineers can create a new non-Newtonian fluid by either entering the shear rate vs shear stress relationship or directly define the fluid constants. This data is readily available from fluid rheology data.
Users can choose from a total of five correlations when modelling settling slurry systems. When developing the model, the software will enunciate warning messages to assist the engineer in developing an efficient system design. This includes messages identifying the risk of saltation or, pipe blockage.
Yes. FluidFlow includes a proprietary fire sprinkler and hydrant node and includes a comprehensive database of components - As Standard. Additional sprinklers can be added to the database by either entering a single nominal K value or entering the flow vs pressure loss relationship and additional hydrants can also be added by either entering a single K value or a pressure loss relationship of % open vs Kv/Cv.
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