AFT Technology Seminar India Dec 2011

AFT Technology Seminar
AFT Technology Seminar
New Delhi, India
New Delhi India
December 2, 2011
,
Mumbai, India
December 5, 2011
Trey Walters, P.E.
President and Chief Technology Officer
Applied Flow Technology

Dynamic solutions for a fluid world. ™
AF T Seminar, India December, 2011
AFT Office and Worldwide Distributors
AFT Office and Worldwide Distributors
AFT Office
Colorado Springs, Colorado, USA
Agenda ‐ 2 AF T Seminar, India December, 2011
Seminar Agenda
Seminar Agenda
 Introduction: Overview of AFT Flow  AFT Arrow™: Compressible Pipe
g
Modeling Software Solutions g
Flow Modeling
 AFT Fathom™: Incompressible Pipe  A1. Introduction to AFT Arrow
Flow Modeling  A2. Hands‐on Training
 F1. Introduction to AFT Fathom  A3. Industry Application Examples
 F2. Hands‐on Training  AFT Mercury™/AFT Titan™– Cost
 F3. Industry Application Examples Reduction Using Intelligent System
 AFT Impulse™: Waterhammer/ Sizing ‐
Surge Modeling  M1. Introduction to AFT Mercury &
M1
 I1. Introduction to AFT Impulse AFT Titan
 I2. Hands‐on Training  M2. Example – Cooling System
 I3. Industry Application Examples
3. dust y pp cat o a p es  M3. Industry Application Examples
Ab
About Applied Flow Technology
A li d Fl T h l
 Applied Flow Technology (AFT) is an international software
development and consulting company
 F
Founded in 1993, AFT has rapidly grown to be a leader in the
d d i AFT h idl t b l d i th
pipe flow modeling software market
 Primary business focus is developing high quality fluid flow
analysis products for Microsoft Windows
 Representatives in 23 countries
 Customers in 70+ countries
Introduction ‐ 1 AF T Seminar, India December, 2011
S f
Software Products
P d
 AFT Fathom™ 7.0
 Incompressible pipe network analysis
 Add‐On Modules
Add O M d l
 XTS ‐ eXtended Time Simulation
 GSC ‐ Goal Seek & Control
 CST ‐ CoST calculations of system piping and components
 SSL – Settling Slurry simulation
 NSL Non‐Settling Slurry and Non‐Newtonian simulation
NSL – Non Settling Slurry and Non Newtonian simulation
 AFT Impulse™ 4.0
 Waterhammer/Surge network analysis
/ g y
S f
Software Products (2)
P d (2)
 AFT Arrow™ 4.0
 Compressible flow pipe network analysis
 Add‐On Modules
Add O M d l
 GSC ‐ Goal Seek & Control
 CST ‐ CoST calculations of system piping and components
y pp g p
 AFT Mercury™ 7.0
 Using IntelliFlow®, intelligently determines optimal sizing for
incompressible flow systems
 AFT Titan™ 4.0
 Using IntelliFlow®, intelligently determines optimal sizing for
compressible flow systems
S f
Software Products (3)
P d (3)
 Chempak™ Property Database
 Property database of ~700 fluids
 Ability to define static pre‐mixtures
 Dynamic mixing capability in Arrow
 Chempak Viewer™ & Chempak Add‐in™ (for Excel)

 Viewer allows use of Chempak as a stand alone application
 Add‐in makes all of the Chempak functions accessible within an
Excel spreadsheet
p
 SteamCalc™ 2.0
 High accuracy ASME steam/water library for Windows and Excel
 AFT Engineering Utility Suite
l ™ 2.0
 Eight utility programs for Windows
P d
Product Applications
A li i
 AFT products are being  Water and Wastewater
successfully applied to a treatment plant design
broad range of industrial  Aerospace systems
systems:  Air conditioning and
 Power generation systems refrigeration systems
 Chemical and petrochemical  Semi‐conductor
systems manufacturing systems
 Oil and gas production
Oil and gas production,  Pulp and paper processing
transportation, refining and  Fire suppression
delivery  Biomedical products and
 Marine and offshore pharmaceutical processing
 Mining processing and  Municipal water distribution
support systems  Automotive systems
AFT F h
AFT Fathom 7.0 Capabilities
7 0 C bili i
 Models incompressible network pipe systems
 Liquid and low velocity gas systems
 Implements highly advanced Microsoft Windows graphical
interface
 Users give Fathom high marks for ease of use
 Models open and closed systems
 Models systems that are pressure, gravity or pump driven
 Models heat transfer and system energy balance
 Offers broad range of innovative reporting features
 Printed output is of report quality
p p q y
 Offers customizable component and property databases
 Modules for Extended Time Simulation, Goal Seek & Control,
C t l l ti
Cost calculations and Slurries
d Sl i
AFT A
AFT Arrow 4.0 Capabilities
4 0 C bili i
 Models compressible network pipe systems
 High to low velocity gas systems
 High to low pressures
 Implements highly advanced graphical interface very similar to
Fathom
 Accurately models
 Real gases
 Heat transfer
 Highly compressible (sonic and near sonic) systems
 Offers broad range of innovative reporting features
 Balances flow and energy throughout the system
 I l d hi h
Includes high accuracy steam/water properties to ASME
t / t ti t ASME
 Modules for Goal Seek & Control and Cost calculations
AFT I
AFT Impulse 4.0 Capabilities
l 4 0 C bili i
 Models waterhammer/surge flow in pipe networks
 Implements highly advanced Microsoft Windows graphical
iinterface
t f
 Models system transients caused by
 Sudden valve closures
 Pump startups and shutdowns including pump inertia effects
 Relief valve cracking
 Events defined within the system (e.g. flow, pressure, etc.)
d f d h h ( fl )
 Includes modeling of
 Control and relief valves
 Pumps
 Accumulators & surge tanks
 Vacuum relief valves
AFT I
AFT Impulse 4.0 Capabilities (2)
l 4 0 C bili i (2)
 Includes a steady‐state solver to determine initial conditions
 Can also import AFT Fathom models
 Calculates unbalanced transient forces
 Forces can be graphed or exported as Force/Time data files
AFT M
AFT Mercury 7.0 Capabilities
7 0 C bili i
 Models and optimizes incompressible network pipe systems
 Combines a powerful hydraulic solver and flexible graphical
i t f ith d
interface with an advanced optimization engine
d ti i ti i
 Automatically selects optimal pipe and component sizes to minimize
y , g
initial or life cycle cost, size or weight
 Ability to apply multiple constraints to pipes and junctions
 Cost optimization may include;
 non‐recurring costs (materials and installation)
 recurring costs (energy and maintenance) including time varying
cost (energy costs varying with time)
 Offers customizable engineering and cost databases
 Includes powerful modeling and output capabilities of AFT
Fathom 7.0
AFT Ti
AFT Titan 4.0 Capabilities
4 0 C bili i
 Models and optimizes compressible network pipe systems
 Combines a powerful hydraulic solver and flexible graphical
i t f ith d
interface with an advanced optimization engine
d ti i ti i
y , g
 Offers customizable engineering and cost databases
Arrow 4.0
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT F h
AFT Fathom General Description
G lD i i
 General purpose pipe network incompressible flow analysis
 Advanced drag‐and‐drop interface
 Calculates pressure drop, flow distribution and (optionally)
energy balance in pipe networks
 Implements Newton‐Raphson
Implements Newton Raphson matrix techniques to solve 3
equations:
 Continuity (Mass) Equation
y q
 Momentum (Bernoulli) Equation
 Energy Equation (optional)
F1 ‐ 1 AF T Seminar, India December, 2011
AFT F h
AFT Fathom General Description (2)
G lD i i (2)
 Can model systems in any generalized configuration
 Open or closed systems
 Branching systems
B hi
 Looping systems
 Can model any fluid in which the viscosity is Newtonian
 Can model non‐Newtonian fluids using Power Law and Bingham
Plastic
 Can model variable fluid properties
 English and SI units supported
C
Components That Can Be Modeled
Th C B M d l d
 Branching section (up to 25 pipes)
 Known pressure or flow boundaries
 Pumps
 Pump curves follow a polynomial equation or can be linearly
interpolated
 Centrifugal pumps and positive displacement pumps
 Pressure and flow control valves
 Relief valves and check valves
 Spray discharge nozzles
C
Components That Can Be Modeled (2)
Th C B M d l d (2)
 Heat exchangers
 Hydraulic losses
 Heat transfer
H f
 General fittings and components where the resistance curve
follows a polynomial relationship
 Also can be modeled as linearly interpolated data
 Piping insulation
p g
S l i T h i
Solution Techniques
 AFT Fathom uses the Newton‐Raphson Method to solve the flow
distribution in a pipe network
 Th N t R h
The Newton‐Raphson Method for pipe networks is a matrix method
M th d f i t k i t i th d
 This method gained favor with the introduction of the digital
p
computer
 The technique has been considered standard industry practice
for 40 years
B i L
Basic Laws of Pipe Flow
f Pi Fl
 Mass Conservation
  AV
m
 Momentum Equation (Bernoulli)
1 1
P1  V12  gh1  P2  V2 2  gh2  Ploss
2 2
 The dynamic pressure and static pressure can be combined into
o,1 P  gh  P
1 o,2 2  gh  P
loss
the stagnation (total) pressure, and the solution is then for total
pressure
 Therefore, the momentum equation becomes
L
Law of Friction
fF i i
 Traditional method of friction loss calculation uses the Darcy‐
Weisbach friction factor, f
L 1 2
Ploss  f  V 
D2 
 The friction factor is not a constant, but a function of the pipe
The friction factor is not a constant but a function of the pipe
wall characteristics and the Reynolds number
 AFT Fathom uses the iterative Colebrook‐White correlation for
turbulent flow and the traditional laminar flow equation
2
  9.35 
f  114
.  2 log   (Re  4000)
  D Re f 
64
f  (Re  2300 )
Re
Th N
The Newton‐Raphson Method
R h M h d
 The procedure for applying
Newton‐Raphson to a single
equation is as follows
1. Take a guess at the solution to
function F
F(x)
2. Calculate an improved guess
using the following equation:
F(xi)
F xi  -F'(x
-F (xi)
xi  1  xi 
F xi 
33. Substitute the improved guess
p g
back into the above equation x
until the change in x is small xi xi+1
S l i
Solving the System
h S
 When applied to a system of equations with P as the unknown,
Newton‐Raphson looks as follows
  
Po,new Po,old  J F 1F
 where P is the vector of pressures and JF is the Jacobian matrix of

error function derivatives ‐ both of a size, n, which is the number
of branches (i.e., equations in the system)
 F1 F1 F1 
 P P  P 
 o,1 o,2 o,n 
 F2 F2 F2 
  
J F   Po,1 Po,2 Po,n 
 
  
 Fn Fn Fn 
  
 Po,1 Po,2 Po,n 
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT F h
AFT Fathom Agenda Details
A d D il
 AFT Fathom™: Incompressible Pipe
Flow Modeling
 F1. Introduction to AFT Fathom
 F2. Hands‐on Training
 Pump Sizing
 Variable speed pumping
 Goal seeking –
g size pump
p p
impeller
 Flow control valve evaluation
 Heat loss in a pipe
 Air flow in a ducting system
 Slurry pipeline pressure loss
 Temperature control with heat
p
exchanger bypass
 F3. Industry Application Examples
1 P
1. Pump Sizing
Si i
 Determine the pump head and power for the following system
 Water system at 21 degrees C
 Reservoir at 3 meters elevation needs to be pumped up a hill to a
R i l i d b d hill
reservoir at 60 meters elevation
 Flow requirement is 110 m
q 3/hr
 The total pipe length is 300 meters
 The pipe is 4 inch (10.23 cm ID) Schedule 40 Steel
 Pump efficiency = 80%
3m
60m
295m
3m 5m
1 P
1. Pump Sizing –
Si i M d l
Model
1 P
1. Pump Sizing –
Si i O
Output
Note:
Pump Head Rise = 93.4 m
This has 2 parts:
Elevation rise = 57.0 m
Frictional Head = 43.4 m
1 P
1. Pump Sizing –
Si i S l
Select a Pump
P
Choose a pump with

adequate head rise at the
design flow
Q dH
(m3/h) (m)
0 102
110 94
220 56
1 P
1. Pump Sizing –
Si i E
Enter Pump Data
P D
1 P
1. Pump Sizing –
Si i Fi C
Fit Curve to Data
D
1 P
1. Pump Sizing–
Si i R i S l
Review Selected Pump
dP
1 P
1. Pump Sizing–
Si i C
Create Pump System Curve
P S C
1 P
1. Pump Sizing –
Si i S
System Curve Components
C C
Pump Curve
System Curve
F i ti
Friction Hf 36
36.9m
9
93.9m
ead
Total Dynamic
y
He
Static Head (TDH)
Hs 57.0m
Flowrate
Operating 110.7
110 7 m3/hr
Flowrate
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
2 V i bl S
2. Variable Speed Pumping
dP i
 After selecting and buying the pump in Example #1, it is
determined the velocity is too high
 A variable speed drive is proposed to reduce the flowrate
A i bl d d i i d t d th fl t from
f
110 to 90 m3/hr
 What is the new efficiency and power usage?
 What speed will the pump operate?
3m
60m
295m
3m 5m
2 V i bl S
2. Variable Speed Pumping –
dP i E
Enter Setpoint
S i
2 V i bl S
dP i O
Output
2 V i bl S
dP i N H d Ri
New Head Rise
Note:
This has 2 parts:
2 V i bl S
dP i S
System Curve
C
Pump Curve (No Control)

System Curve
Pump Curve
(VFD at 92.1% Speed) 93.9m 81.7m
36.9m Hf Hf 24.7m
Head
d
57.0m Hs Hs 57.0m
Flowrate No No VFD
VFD Control Control
90 m3/hr 110.7 m3/hr
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
3. Size Pump Impeller
3. Size Pump Impeller ‐ Goal Seeking (GSC
Goal Seeking (GSC
Module)
 Use goal seeking to find the impeller size needed to reduce the
U l ki t fi d th i ll i d d t d th
flowrate from 110 to 90 m3/hr
3m
60m
295m
3m 5m
3. Size Pump Impeller – Set Impeller
Set Impeller
Modifications
3. Size Pump Impeller – Activate Goal
Activate Goal
Seeking (GSC Module)
3. Size Pump Impeller – Enter Goal and
Enter Goal and
Variable
3 Si P
3. Size Pump Impeller –
I ll R GSC M d l
Run GSC Module
 Trim impeller
8% off of full
size
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
4 Fl C
4. Flow Control Valve Evaluation
lV l E l i
 Use a flow control valve to reduce the flowrate
U fl t l l t d th fl t from 110 to 90
f t
m3/hr
 What is the new efficiency and power usage?
 What speed will the pump operate?
3m
60m
295m
3m 5m
4 Fl C
4. Flow Control Valve Evaluation –
lV l E l i Add V l
Add Valve
 Use SHIFT key and then drag a Control Valve junction onto P2
 This is the “Split Pipe” feature
4. Flow Control Valve Evaluation – Enter
Enter
Setpoint
4 Fl C
4. Flow Control Valve Evaluation –
lV l E l i O
Output
Note:
This has 2 parts:
4. Flow Control Valve Evaluation – System
System
Curve
Pump Curve
93.9m 97.7m
Head Loss Across
Control Valve
Hcv 16.0m
System Curve 36.9m Hf Hf 24.7m

ad
Hea
57.0m Hs Hs 57.0m
Flowrate With Without

90 m3/hr Valve Valve 110.7 m3/hr
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
5 H
5. Heat Loss in a Pipe
L i Pi
 Calculate heat transfer in a  There is one layer of
pipe insulation 3 cm thick with a
 Fluid is water at 65 degrees C thermal conductivity of 3.5
W/m‐K
 Length is 150 meters
 External convection
 Steel 4 inch (9.72 cm ID) coefficient is 60 W/m^2‐K
Schedule 80
 Fluid internal convection
 Inlet stagnation pressure is coefficient is calculated by
0.35 MPa Fathom using a correlation,
g ,
 Inlet temperature is 65 and the pipe wall resistance is
degrees C calculated using the material
 Ambient temperature is 10
p database
degrees C  Flow is 4.5 kg/sec
 All elevations are zero
5 H
5. Heat Loss in a Pipe (2)
L i Pi (2)
 What is the exit temperature (deg. C)?
 What is the Heat loss (kW)?
 What is the maximum insulation surface temperature (found on
the Heat Transfer tab)?
5. Heat Loss in a Pipe
5. Heat Loss in a Pipe – Choosing Heat
Choosing Heat
Transfer
5 H
5. Heat Loss in a Pipe –
L i Pi Pi D
Pipe Data
5 H
L i Pi O
Output
5 H
L i Pi O
Output (2)
(2)
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
6 Si D i S
6. Size Ducting System ‐ R
Requirements
i
 Air flow at 20 C
 Fan discharge pressure is
8 mm H2O (g)
8 H O ( )
 Deliver mininum of 25
m3/min to each of 3
rooms
 Maximum allowable
velocity is 600 m/min (to
reduce noise levels)
 Each room has a K factor
of 1 and stagnation
p
pressure of 0 mm H2O
(g)
6 Si D i S
6. Size Ducting System – R
Requirements (2)
i (2)
 Ducts 1, 2 and 3 are the
same
 Sheet metal
Sh t t l
 Cylindrical
 4
40 cm diameter
 Roughness 0.1 mm
 Ducts 4, 5 and 6 are the
same
 Sheet metal
 Square
 30 x 30 cm
 Roughness 0.1 mm
g
6. Size Ducting System
6. Size Ducting System –
Round Duct at P1, Square Duct at P4
6 Si D i S
6. Size Ducting System – R i O
Review Output
 Flow is too low to
rooms #2 (pipe 5)
and #3 (pipe 6)
 Requirement is 25
m3/min minimum
 Velocity is too high
in fan discharge
(pipe 1)
m/min maximum
6. Size Ducting System
6. Size Ducting System – Increase P1 Duct
Increase P1 Duct
Size
 Increase from 40 cm to 50 cm
6 Si D i S
6. Size Ducting System – R i O
Review Output
 Flow is acceptable in
in all rooms (pipes
4 5 and 6)
4, 5 and 6)
m3/min minimum
 Velocity is
acceptable in all
ducts
m/min maximum
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
7 Sl
7. Slurry Pipeline Pressure Loss
Pi li P L
 Determine pump head requirement and verify pipe sizing for a
sand transfer system flowing 1140 m3/hr of slurry
7. Slurry Pipeline
7. Slurry Pipeline – Activate Settling Slurry
Activate Settling Slurry
(SSL Module)
7 Sl
7. Slurry Pipeline –
Pi li I
Input
 All pipe is steel, 10 inch (25.5 cm), schedule 40
7 Sl
Pi li Sl
Slurry Data
D
 Open System Properties window and select the Detailed Slurry
Calculation Method and enter the following solids data:
 Solids Specifications –
S lid S ifi ti select User Specified Solids Added
l t U S ifi d S lid Add d
 Solids Properties:
 M (Stratification Ratio Exponent), select Calculated
( p ),
 Terminal Velocity Parameter, select Vt/Vts and enter a value of 0.55
 Density = 2.65 specific gravity (S.G. water)
 D50 0 7 mm
D50 = 0.7 mm
 D85 = 1 mm
 Clear Water Properties:
 Temperature = 16C
 Slurry Definition:
 Concentration type = Volume Fraction
Concentration type Volume Fraction
 Amount Solids Added = 20%
7 Sl
Pi li S
System Properties
P i
7 Sl
Pi li P
Pump Data
D
 Add flow to pump and de‐rating data for slurry pump sizing
7 Sl
Pi li O
Output Predictions
P di i
7 Sl
Pi li G hS
Graph System Curve
C
Settling Velocity = 3.9 m/s Operating Velocity = 6.2 m/s
Acceptable design!
AFT F h
A d D il
Flow Modeling
 Pump Sizing
g size pump
p p
impeller
p
exchanger bypass
8. Temperature Control With Heat
Exchanger Bypass
Exchanger Bypass – Input
 Open “Temperature Control with Bypass.fth” from disk
 A three way valve splits flow through a pair of heat exchangers
and a bypass
d b
 Determine the valve open percentage that will result in 50C water to
J
tank J10
Exchanger Bypass – GSC Manager
Exchanger Bypass – Output
Trey Walters, P.E.
President, Applied Flow Technology
President Applied Flow Technology
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT F h
AFT Fathom Applications (1)
A li i (1)
 Power
 Static
 Power Plant Auxiliary Feedwater
P Pl t A ili F d t System pressure drop calculation and
S t d l l ti d
flow distribution ‐ Condensate & Boiler Feed.fth
 Cooling tower spray system pressure drop calculation, flow distribution
and spray nozzle sizing ‐
d l i i Cooling Tower System.fth
C li T S fh
AFT F h
A li i (2)
 Oil, Gas and Process
 Static
 Fire suppression spray system design ‐
Fi i t d i Refinery fire protection system.fth
R fi fi t ti t fth
 Acid leach flow in copper processing ‐ Copper Mine Acid Flow.fth
AFT F h
A li i (3)
 Marine and Offshore
 Static
 Fire suppression spray system pressure drop calculation, flow
Fi i t d l l ti fl
distribution and spray nozzle sizing ‐ CargoHoldFireSystem.fth
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
O
Overview of Waterhammer
i fW t h
 Waterhammer is a transient phenomenon that occurs in a liquid
piping system when some event causes a departure from steady
state
 Waterhammer is the process the piping system experiences as it
j
adjusts to the new conditions
 Waterhammer can be caused by many events including
 Valve closure or opening (in full or in part)
 Pump speed change
 Relief valve cracking open
 T k
Tank pressurization
i ti
 Periodic pressure or flow conditions
I 1 ‐ 1 AF T Seminar, India December, 2011
T
Terminology
i l
 Waterhammer can occur in any liquid piping system
 The term “waterhammer” confuses some because it implies a
process only in water systems
l i t t
 Other terms which have been used are
 Fluidhammer
 Hydraulic Transients
 Fluid Transients
 Surge
T
Types of Waterhammer
fW t h
 Waterhammer can be caused by different physical mechanisms
 There is no universal terminology for these mechanisms so the
terminology here is for discussion purposes
 1. “Thermodynamic” waterhammer
 Liquid acceleration caused by local phase change
 2. “Slug” waterhammer
 Liquid flows into an evacuated pipe system or when there are distinct
liquid slugs and gas pockets
 When liquid contacts equipment or direction changes (elbows) pressure
spikes can occur
 3. “Mechanical” waterhammer
“M h i l” h
 Caused by equipment or component operational changes
 Pump trips, valves closed, etc.
 This is the type of waterhammer that Impulse can model
I t t
Instantaneous Waterhammer
W t h
 The magnitude of a waterhammer transient is dependent on the
wavespeed of the liquid
 The wavespeed
Th d (a) is dependent on the:
( ) i d d t th
 liquid acoustic velocity
 pipe modulus of elasticity (E) wall thickness (t) and material
pipe modulus of elasticity (E), wall thickness (t), and material
Poisson Ratio ()
 pipe restraints
 A useful equation for theoretical pressure surge is given by the
“instantaneous waterhammer equation”
P a V
I t t
W t h (2)
 Example:
 Density is 1000 kg/m3
 Wavespeed
W d is 1000 meters per second
i d
 Initial Velocity is 3 meters per second
 Static Pressure is 1 MPa.
P a V
kg m m
Pmax = 1000 3 *1000 *3 + 1 MPa
m s s

Pmax 3+1 MPa
Pmax  4 MPa
I t t
W t h (3)
 Most engineers believe the instantaneous waterhammer
equation defines the maximum possible pressure from
waterhammer.
waterhammer
 This is incorrect. Several real world affects can increase the
waterhammer pressure:
p
 Pipe friction
 Cavitation
 Network effects (superposition of pressure waves)
C
Communication Time
i ti Ti
 The communication time is a helpful concept in understanding
waterhammer
 The communication time is the time it takes for transient events
Th i ti ti i th ti it t k f t i t t
to communicate their existence to boundaries in the piping
y
system
 The communication time is given by the following
L
t  2
a
 Any event that occurs in a time frame less than the
communication time is in effect instantaneous
ff
W t h
Waterhammer Sequence
S
V=Vsteady V= Vsteady
V=0 V=0
a a
a c
b d
V= Vsteady V= Vsteady
V=0 V=0
a a
W t h
Waterhammer S
Sequence – 0 t < L/a
0 < t L/
Valve closed
instantaneously at t=0
V=Vsteady
V 0
V=0
a
P
Pinstantaneous
Psteady
x
V
Vsteady
x
W t h
Waterhammer S
Sequence – L/ < tt < 2L/a
L/a 2L/
Valve closed
V=Vsteady
V=0
a
P
 Pinstantaneous
Psteady
x
V
x
-Vsteady
W t h
Waterhammer S
Sequence – 2L/ < tt < 3L/a
2L/a 3L/
Valve closed
V=Vsteady
V=0
P
Psteady
 Pinstantaneous
x
V
x
-Vsteady
W t h
Waterhammer S
Sequence ‐ 3L/ < tt < 4L/a
3L/a 4L/
Valve closed
V=Vsteady
V=0
P
Psteady
 Pinstantaneous
x
V
Vsteady
x
W
Waterhammer Videos
h Vid
 Instructor – show video files
 waterhammer.wmv (2:03)
 Video of piping system
Vid f i i t
 online version ‐ http://www.youtube.com/watch?v=oZbguheiVs4&NR=1
 Waterhammer 4‐0ms‐Bruecke.wmv (1:04)
4 4
 Video of piping system
 online version ‐ http://www.youtube.com/watch?v=U0XfYCKxZks
 CFD Si l ti f th W t H
CFD Simulation of the Water Hammer.wmv (2:39)
( )
 Computer simulation showing pressure waves with color
 online version ‐ http://www.youtube.com/watch?v=ng__hdZ8yD8
F d
Fundamental Equations
t lE ti
 Mass / continuity equation
 
a2 V  P  0
 x t
 Momentum equation
1 P  V fV V
  g sin( )  0
x t 2D
Where :
a = wavespeed
V = velocity
x = distance along pipe
P = pressure
t = time Note: These are only the
g = gravitational constant primary equations, not the
 = slope of pipe
complete set.
f = friction factor
D = diameter of pipe
M h d f Ch
Method of Characteristics
i i t = 5t
t = 4t
 By combining the mass and
momentum equations linearly and t = 3t
substituting mass flow rate m', for
substituting mass flow rate, m for t = 2t
velocity, V, one obtains P
t = t
a f C+ C-
 dP     gdz
dm m  dx  0
 m A B
A 2DA2 t=0
x=0 x = i-1 x=i x = i+1 x=L
 Integrating along the “characteristic
line” from A to P yields the positive
characteristic
a P
PP m zP x
P
f
 dP     g  dz 
 dm   dx  0
 m
m
PA AmA zA 2DA2 xA
PP  PA  a m P  m A   gzP  zA  fx

A 0
P m
m
A 2DA2
M h d f Ch
Method of Characteristics (3)
i i (3) t = 5t
t = 4t
 By combining the mass and momentum
equations linearly and substituting mass t = 3t
flow rate m', for velocity, V, one obtains
flow rate, m for velocity V one obtains t = 2t
a f
 dP     gdz
dm  dx  0
 m
m P
A 2DA2 t = t
C+ C-
A B
t=0
 Integrating along the “characteristic x=0 x = i-1 x=i x = i+1 x=L
line” from A to P yields the positive
characteristic (a similar equation can be
written for the negative characteristic)
a P
PP m zP x
P
f
 dP     g  dz 
 dm   dx  0
 m
m
PA AmA zA 2DA2 xA
PP  PA  a m P  m A   gzP  zA  fx

A 0
P m
m
A 2DA2
M h d f Ch
i i (4) t = 5t
t = 4t
 Introducing two convenient parameters
t = 3t
 Impedance
a Where:
B t = 2t
A A = cross sectional
area P
t = t
C+ C-
 Resistance A B
t=0
f x x=0 x = i-1 x=i x = i+1 x=L
R
2
2DA
 Note that after the initial calculations the impedance and
resistance have constant property values for each pipe, except for
the friction factor f
the friction factor, f
M h d f Ch
i i (5) t = 5t
t = 4t
 The equations can now be written
Pi ,new  CP  BPm
 i ,new
t = 3t
Pi ,new  CM  BM m
 i ,new t = 2t
P
t = t
where: C+ C-
 i 1,old   gzi  zi 1
CP  Pi 1,old  Bm t=0 A B
x=0 x = i-1 x=i x = i+1 x=L
 i 1,old   gzi  zi 1
CM  Pi 1,old  Bm
BP  B  R m
 i 1,old
BM  B  R m
 i 1,old
 Here the subscript new refers to point P
 The subscript i‐1, old refers to point A
p , p
 The subscript i+1, old refers to point B
M th d f Ch
Method of Characteristics (cont.)
t i ti ( t )
t = 5t
t = 4t
 These two equations are known as the
compatibility equations t = 3t
Pi ,new  CP  BPm
 i ,new t = 2t
Pi ,new  CM  BM m
 i ,new t = t
P
C+ C-
 Note that there are two equations and t=0 A B
two unknowns x=0 x = i-1 x=i x = i+1 x=L
 For example, to solve for the pressure at
p , p
an interior pipe location, apply the
compatibility equations and eliminate
flo rate
flow rate
C P B M  C M BP
Pi ,new 
BP  B M
St d St t D t i T
Steady‐State Data in Transient Solver
i tS l
 The Transient Solver requires the following:
 Initial steady‐state flow rates in all pipes
 Initial pressures at all junctions
I i i l ll j i
 Initial states of all junctions
 Pumps on or off
p
 Valve open or closed
 Check valves open or closed
 Et
Etc.
 Pipe resistance (friction factors)
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT I
AFT Impulse Agenda Details
l A d D il
 AFT Impulse™: Waterhammer/
Surge Modeling
 I1. Introduction to AFT Impulse
 I2. Hands‐on Training
 Valve closure surge transient
 Pump trip surge transient in
pipeline
 Spray system transient
I2 ‐ 1 AF T Seminar, India December, 2011
1 V l Cl
1. Valve Closure Surge Transient
S T i
 Determine the surge pressures in an ammonia transfer system
when a valve is closed in 0.5, 1 and 2 seconds
 All pipe is steel with standard wall thickness, thin‐walled anchored
All i i t l ith t d d ll thi k thi ll d h d
upstream
P1 P2 P3
L = 30 m L = 91 m L = 46 m
8 inch (20.3 cm ID) 10 inch (25.5 cm ID) 10 inch (25.5 cm ID)
1 2 3 4
Surface Elev. = 12 m Surface Elev. = 6 m

Surface Pressure = 1.72 MPa(g) Abrupt Expansion Surface Pressure = 1.72 MPa(g)
Pipe Depth = 6 m Elevation = 0 m Pipe Depth = 1.5 m
Valve
Ammonia at 24C Elevation = 0 m
0 to 5 seconds t (sec) Cv
Model Cavitation 0 1000
? 0
1. Valve Closure Surge Transient – Valve
Valve
Input
1 V l Cl
1. Valve Closure Surge Transient –
S T i R l
Results
 Results
Closure Max Stag. Pressure*
Time (sec) (MPa(g))
0.5 4.183
1 4.145
2 2 502
2.502
 (*) The first two cases yield
different pressures when the
p
sectioning is varied
 This is a result of the
cavitation model
 The 2 second closure case
does not cavitate
1. Valve Closure Surge Transient –
Animation
 Animation for 2
second closure case
AFT I
l A d D il
Surge Modeling
pipeline
2 P
2. Pump Trip Surge Transient in Pipeline
Ti S T i i Pi li
 Determine the surge pressures in gasoline product pipeline when
the pumps trip
 All pipe is steel with standard wall thickness, thin‐walled anchored
All i i t l ith t d d ll thi k thi ll d h d
upstream
2 P
2. Pump Trip Surge Transient ‐
Ti S T i I
Input
2. Pump Trip Surge Transient
2. Pump Trip Surge Transient – Gasoline
Gasoline
Data
2 P
2. Pump Trip Surge Transient –
Ti S T i P
Pump Data
D
2. Pump Trip Surge Transient – Pump Data
Pump Data
(2)
 This one pump junction represents 3 pumps in parallel
2. Pump Trip Surge Transient – Pump Data
Pump Data
(3)
2. Pump Trip Surge Transient – Maximum
Maximum
and Minimum Pressures
2. Pump Trip Surge Transient – Animate
Animate
Pressures
AFT I
l A d D il
Surge Modeling
pipeline
3 S
3. Spray System Transient
S T i
 Find how long it takes for the flowrate to come up to the
full flow of 22.7 m3/hr at each spray from the closure state
 Pipe data:
Pi d t
 Steel pipe, all schedule 40, standard roughness of 0.004572 cm
 Fluid is water at 21 deg. C
Fluid is water at 21 deg C
 Inlet stagnation pressure is 1200 kPa
 Spray nozzle data:
 Sprays discharge to atmosphere and open in 0.1 second
 Flow Area = 3.23 square cm, Discharge coefficient = 0.6
Time (sec) CdA (cm2)

0 0
0.1 1.94
10 1 94
1.94
3 S
3. Spray System Transient (2)
S T i (2)
L=3 meters L=3 meters L=3 meters L=3 meters L=3 meters L=3 meters L=3 meters
L=3 meters
1-1/2 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch 1-1/2 inch
1-1/2 inch (4.1 cm ID)
(4.1 cm ID) (4.1 cm ID) (4.1 cm ID) (4.1 cm ID) (4.1 cm ID) (4.1 cm ID)
(4.1 cm ID)
El = 3 meterrs
4 inch
(10.2 cm ID) L=0.5 m
El=0.3 meters L=3 m El=0.3 meters 1-1/2 inch
(4.1 cm ID)
Typical
L=152 meters L=152 meters
8 inch El=0.3
El 0.3 meters 8 inch
(20.3 cm ID) (20.3 cm ID)
3 S
3. Spray System Transient –
S T i S
Spray Data
D
3 S
3. Spray System Transient –Predictions
S T i P di i
 It takes about 0.85 seconds for the final spray to reach 22.7 m3/hr
 After slightly less than 1 second the flow drops below 22.7 m3/hr
Nearest Supply
Farthest From
Supply
Trey Walters, P.E.
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT I
AFT Impulse Applications (1)
l A li i (1)
 Power
 Static
 Power plant cooling water system pressure drop calculation and flow
P l t li t t d l l ti d fl
distribution ‐PowerPlantCoolingSystem.imp
 Transient
 Power plant Cooling water system water hammer analysis ‐
PowerPlantCoolingSystem.imp
AFT I
l A li i (2)
 Static
 LNG transfer cooling water system pressure drop calculation and flow
LNG t f li t t d l l ti d fl
distribution ‐ LNG_Water_Service.imp
 Transient
 LNG transfer system water hammer analysis ‐ LNG Transfer.imp
 Product oil long distance transfer system water hammer analysis ‐
p
Sinclair Medicine Bow Pipeline.impp
 Oil field water injecting system water hammer analysis ‐ Oil Field Water
Injection.imp
AFT I
l A li i (3)
 Transient
 Sub Sea Blow Out Preventer system
S b S Bl O t P t t pressure drop calculation and flow
d l l ti d fl
distribution ‐ Sub Sea Blowout Preventer.imp
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
Wh ’ S i l Ab
What’s Special About Compressible Flow?
C ibl Fl ?
 Compressible flow is defined as fluid flow where density changes
are significant
 Changing density has several important ramifications
Ch i d it h l i t t ifi ti
 Velocity changes in a pipe (velocity change is generally non‐linear)
 Density depends on temperature so that flow is coupled to energy
equation
 Accelerating flow is limited to sonic velocity, thus sonic choking can
b
become a dominant characteristic of the system
d i h i i f h
 Sonic choking may occur in multiple locations
 All governing equations are strongly coupled
 An accurate solution must address all aspects of the gas flow
 Pipe networks introduce an order of magnitude complexity into
compressible flow analysis
A1 ‐ 1 AF T Seminar, India December, 2011
P ibl M h d f A l i
Possible Methods of Analysis
 Use incompressible flow methods
 Inherently inaccurate
 Large safety margins required
L f i i d
 Engineer is never sure of analysis results
 Sonic choking glossed over
 Use simplified compressible flow pressure drop correlations
 Crane manual isothermal flow equation (Eqn. 1‐6) , Weymouth,
Panhandle, etc.
 Thermal and real gas effects are ignored
 Cannot extend method to pipe networks
Cannot e tend method to pipe net orks
 Large safety margins required
 Engineer is never sure of analysis results
g y
 Sonic choking glossed over
B i P bl
Basic Problems With Traditional Methods
Wi h T di i lM h d
 Engineer is never sure of analysis results
 Gases frequently are not ideal
 Gases frequently are not isothermal or adiabatic
G f l i h l di b i
 In many cases engineers believe their analysis is better than it
really is
 Sheer quantity of important variables means that important data
can be easily overlooked
 Low quality analysis leads to higher costs and reduced safety
 Over‐design costs more during construction and over the life‐cycle
 Safe operation of design is jeopardized if analysis is not properly
performed
 Parallel flow pipe networks cannot be properly analyzed
AFT A
AFT Arrow Approach to Compressible Flow
A h C ibl Fl
 Solve all governing equations simultaneously
 Include all thermal and real gas effects
 Balance mass and energy throughout the network
 Implement special flow and energy balance iterative methods
 Offer several solution methods to increase flexibility
Offer se eral solution methods to increase fle ibilit
 Encapsulate powerful solution method in an easy‐to‐use
graphical Windows interface
Governing Equations of Compressible Flow
 Equations for each pipe
d dV
 0
[1] Mass:  V
1 f
[2] Momentum: dP  V 2 dx  VdV   gdz  0
2 D
 d  h  V 2 gz  q
1
[3] Energy: m
 2 
[4] E
Equation
ti off State:
St t P  ZRT
V
[5] Mach Number: M
ZRT
 Equations for each junction
n
[6] Balance Mass: m
 ij  0 [8+] Balance Species:
j 1
ngases npipes
[7] Balance Energy:
n
 ij  hij  Vij 2   0
m

1

  m c,ij  0
j 1
2 c1 j 1
AFT A
AFT Arrow’s Solution Methods
’ S l i M h d
 AFT Arrow offers six solution methods altogether
 Two methods are "lumped" methods
 Lumped Adiabatic and Lumped Isothermal
 These are not as accurate but solve much faster
 Cannot model heat transfer
 Cannot model elevation changes (usually this is not very important)
 Four methods are marching methods
 Length March
 Mach Number March
 Two hybrid methods based on these two
 These four methods are highly accurate but have longer run times
 Can accurately model heat transfer, elevation changes and rotating
y , g g
systems
L
Length March: Single Pipe
h M h Si l Pi
Using substitution and calculus, the following equation can be derived: *
dPo M 2  dTo fdx dZ d  g sindx Flow
      
Po 2  To D Z   ZRT
1 2
Integration of the above yields:
 M 2  To,2  f x2  x1 g sin x2  x1
Po,2  Po,1 exp   ln Z
 ln 2  ln 2  
 T   
 2  o,1 Z1 1 D  RZT 
In this approach, each distance step, x2, allows calculation of a new Po,2.
The solution is obtained by marching down each pipe until x2 = L.
* See AFT Arrow 4.0 User’s Guide , ChapterA1 ‐

8, for complete derivation
7 AF T Seminar, India December, 2011
M h N b M h Si l Pi
Mach Number March: Single Pipe
Using substitution and calculus, the following equation can be derived:*
dM 2  dT dZ   
 FT  o    F d  F f fdx  Fg g sin dx  0
M2
o
 To Z   D ZRT Flow
where:
1 2
 1
1 M 2  1  2 1M 2  Ff 
M 2  1 
 2

M2 

FTo 
1 M 2 1 M 2
  1 2 
M 2  11  2 1M 2  Fg 
2 1 
 2
M 

F 
1 M 2 1 M 2
* See AFT Arrow 4.0 User’s Guide , Chapter 8, for complete derivation
M h N b M h Si l Pi (
Mach Number March: Single Pipe (cont.)
)
Integration of the above yields: *
I i f h b i ld *
M 22  T Z     Flow
ln  FTo  ln o2  ln 2   F  ln 2 
 T Z1   1 
M12  o1
x2  x1 
   1 2
 F f f  Fg g sin 
 D RZT 
By selecting a target Mach number M2 for each step, one can march
pp p g 2 distance.
down a pipe to calculate the corresponding x
* See AFT Arrow 4.0 User’s Guide , ChapterA1 ‐

8, for complete derivation
9 AF T Seminar, India December, 2011
S i Ch ki O
Sonic Choking Overview
i
 Sonic choking is a phenomenon that can occur in gas piping
systems where the local gas velocity reaches sonic speed
 Since sonic speed is the maximum speed the gas can reach
Si i d i th i d th h
(unless a diverging nozzle exists), the flow chokes
 When the flow chokes, a lowering of the downstream pressure
When the flow chokes a lowering of the downstream pressure
will not generate additional flow
 Flow can choke at three types of geometries
 A flow restriction (e.g., orifice)
 A flow expansion (area increase)
 Th d f i i i h
The end of a pipe as it exits the system (endpoint choking)
( d i h ki )
S i Ch ki O
Sonic Choking Overview (2)
i (2)
 Flow can choke in multiple locations in a system
 Pressure drop across shock wave is whatever it needs to be so
subsonic flow downstream of choke can meet the downstream
b i fl d t f h k t th d t
boundary condition
C l l i S i Ch ki
Calculating Sonic Choking
 Sonic choking depends on the local velocity which in turn
depends on the local flow area
 A convenient equation for calculating mass flow rate and choked
A i t ti f l l ti fl t d h k d
flow rate is given below
 To calculate choked flow, M = 1 should be substituted into the
second equation
Po
A
m f (M)
To
  1 2 1
    1 2
f ( M)  M 1  M 
ZR  2 
 AFT Arrow requires a choked flow area, called CdA, to be entered
for each component Toin which you want the choking calculation
Asonic  m

Po f ( M ) M 1
performed
f d
Th
Three Types of Sonic Choking
T f S i Ch ki
 The three types of sonic choking are shown graphically
Flow chokes at exit
into atmosphere
p or tank
Endpoint choking
Flow chokes at
expansion in pipe area
Expansion choking
This can also occur at a flow
splitter where the sum of the
two exit pipes exceeds the
supply pipe Flow chokes at
restriction
t i ti iin pipe
i
Restriction choking
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT A
AFT Arrow Agenda Details
A d D il
 AFT Arrow™: Compressible Pipe
Flow Modeling
 A1. Introduction to AFT Impulse
 A2. Hands‐on Training
 Steam relief system evaluation
 Compressed air system model
 Natural gas pipeline evaluation
g pp
 A3. Industry Application Examples
1 S
1. Steam Relief System Evaluation
R li f S E l i
 Size relief valve discharge line
 Pressure in vent stack cannot exceed 10% of supply pressure
 What size flow area is needed at relief valve to pass 20,000 kg/hr?
 Will 8 inch pipe be large enough?
D = 8 inch (20.3 cm) EL = 10 m
L = 8 m Vent Stack
D = 8 inch (20.3 cm), L = 8 m
20,000 kg/hr Elbow r/D = 1.5

minimum
EL = 2 m
D = 6 inch (15.4 cm), L = 2 m
P = 7 bar g
T = 200 C
EL = 0 m
1 S
1. Steam Relief System ‐
R li f S M d l
Model
 AFT Arrow model of relief piping
1 S
R li f S V l
Valve
 Valve flow area data
1 S
R li f S O
Output
 Vent stack pressure is 0.3 bar g which meets requirement
 Flow meets requirement, two sonic choking points
AFT A
A d D il
Flow Modeling
g pp
2 C
2. Compressed Air System Model
d Ai S M d l
 The machine tools are sensitive to temperature, but the
manufacturer says they can compensate for this if they know the
delivery temperature the tools will experience
 What is the (static) temperature at the tools?
 Hint : Look at pipes P6‐9 outlet temperatures
pp 9 p
P1 P2 P4 P4 P5
J1
2 inch 2 inch 2 inch 2 inch 2 inch
Atmosphere
(5.25 cm) (5.25 cm) J3 (5.25 cm) J4 (5.25 cm) J5 (5.25 cm) J6
18 C
T = -18
L=0.3 m L=8 m L=8 m L=8 m L=8 m
J2 P6 P7 P8 P9
Compressor 1 inch 1 inch 1 inch 1 inch
(2.7 cm) (2.7 cm) (2.7 cm) (2.7 cm)
L=3m L=3m L=3m L=3m
J7 J8 J9 J10
Tool #1 Tool #2 Tool #3 Tool #4
2 C
2. Compressed Air System ‐
d Ai S C
Compressor
2 C
2. Compressed Air System ‐
d Ai S V l
Valve
2. Compressed Air System
2. Compressed Air System – Pipe Heat
Pipe Heat
Transfer Data (All Pipes)
2. Compressed Air System
2. Compressed Air System – Pipe Heat
Pipe Heat
Transfer Data (All Pipes)
AFT A
A d D il
Flow Modeling
g pp
3 N
3. Natural Gas Pipeline Evaluation
l G Pi li E l i
 Evaluate 100 km natural gas pipeline for compressor
requirements
 Pi di b ti
Pipes are adiabatic
 Compressor is adiabatic
 Flow requirement is 160 000 kg/hr at 80% efficiency
Flow requirement is 160,000 kg/hr at 80% efficiency
 Supply and discharge are P = 10 bar (absolute) and T = 20 C
3 N
3. Natural Gas Pipeline –
l G Pi li G D fi i i
Gas Definition
3 N
3. Natural Gas Pipeline –
l G Pi li O
Output
Trey Walters, P.E.
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT A
AFT Arrow Applications (1)
A li i (1)
 Power
 Static
 Main steam system
M i t t and reheat system pressure drop calculation and
d h t t d l l ti d
flow distribution ‐ Stm system blowdown.aro
AFT A
A li i (2)
 Static
 Water treatment plant aeration system ‐
W t t t t l t ti t Aeration_Blower_Sizing.aro
A ti Bl Si i
 Chemical plant process nitrogen supply ‐ Nitrogen System in Chemical
Plant.aro
 Fuel gas flow ‐ Fuel_Gas_Letdown.aro
AFT A
A li i (3)
 Static
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
Cost Reduction Through Intelligent System
Cost Reduction Through Intelligent System
Sizing
M1 ‐ 1 AF T Seminar, India December, 2011
E i
Engineering Process Today
i P T d
 The Problem
 Engineers do not have the time or the tools to rigorously balance the
tradeoffs in pipe pump and energy costs
tradeoffs in pipe, pump and energy costs
 Even simple systems have billions of potential size combinations ‐
far too many to evaluate using traditional design methods
E i
Engineering Process Today (cont.)
i P T d ( )
 The Result
 Piping systems cost more than they
need
 Pumps are oversized and use much
more energy than is necessary
 The Need
 A technology that allows engineers to
id tif l t d i i ti l
identify low cost designs in a timely
manner
 The Solution
 Intelligent System Sizing
A l i
Analysis vs. Design
D i
Activity Input Output
Analysis Pipe sizes, pump data, Flowrate, velocity, pressure

fittings, etc. drop, NPSH, etc.
Design Flowrate, velocity, pressure, Pipe sizes, selected pumps,

NPSH, etc. fittings, etc.
Wh i I lli
What is Intelligence System Sizing?
S Si i ?
 Intelligence System Sizing selects pipes, pumps and fittings
simultaneously as a unit
 Th b i f l ti b b d
The basis for selection can be based on:
 Monetary cost
 Weight
 Volume
 Others…
Wh i I lli
What is Intelligence System Sizing? (cont.)
S Si i ? ( )
 Intelligence System Sizing does this by:
 Perturbing the engineer’s design
 Repeatedly re‐analyzing the system
R dl l i h
hydraulically
 Defining the shape of the design space
g p g p
 Identifying combinations of design
parameters that reduce cost
C i ti th l t t ti t
 Communicating the lowest cost option to
the engineer
 We call this technology IntelliFlow
gy ®
AFT M
AFT Mercury: An Intelligent Design Tool
A I lli D i T l
 AFT Mercury™ utilizes IntelliFlow technology and provides the
final key ingredient: an advanced graphical user interface (GUI)
 Th H d li S l i id ti l t AFT F th
The Hydraulic Solver is identical to AFT Fathom
AFT Fathom
Graphical Interface
Input Output
Yes
Hydraulic
y Solver Converged?
g
No
Optimization Engine
AFT M
AFT Mercury C bili i
Capabilities
 Models and optimizes incompressible network pipe and duct
systems
 Automatically determines optimal pipe and component sizes
A t ti ll d t i ti l i d t i
 Engineering optimization ‐ minimize
 Weight
 Size (volume)
 Cost optimization ‐ minimize initial or life cycle cost
 Non‐recurring costs (materials and installation)
 Recurring costs (energy and maintenance) including time varying
AFT M
AFT Mercury A li i
Applications
 Concurrently size pump and piping system
 AFT Mercury identifies optimal tradeoff between pump costs and
pipe costs
 Quickly perform initial vs. life cycle cost comparison
 Compare optimal VFD vs
Compare optimal VFD vs. control valve system designs
control valve system designs
 Optimal system may not be the same for each
 Achieve pipe and duct system balancing by intelligent sizing
pp y g y g g
 Intelligent sizing over multiple design cases
 AFT Mercury ensures optimal system satisfies all off‐design cases
 Understand what drives your design
 AFT Mercury identifies active constraints which are the design
drivers
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
AFT M
AFT Mercury E
Example
l
 Find systems with minimal initial, life cycle and energy costs
S
System Parameters
P
 Fluid is water
 Pipe is steel, sch 40 for 4” & 6”, sch 20 from 8” thru 36”, 1/2” wall
ffabricated pipe from 38” thru 48”
b i t d i f 8” th 8”
 Constraints
 Minimum condenser flow = 15,000 gpm
Minimum condenser flow = 15 000 gpm
 Minimum lube oil cooler flow = 700 gpm
 Pipes are linked so that there are ten independent sizes
p p
 Pump design flow has been specified as 8,000 gpm, head is
variable, dependent on the pipe sizes selected
 Power is thus variable and is used to characterize pump cost vs..
Capacity
 Note – this system has over 40 quadrillion design possibilities
O i i dS
Optimized System Costs
C
 Costs for 10 Year Design
Cost in U.S. Dollars
Initial (Mat'l + Cost
Criteria Material Installation Operating Total Reduction
Inst)
Initial Design 409,000 676,000 1,085,000 2,752,000 3,837,000 -
Initial Cost Opt 361,000 494,000 855,000 5,163,000 6,017,000 21%
Life Cycle Opt 441,000 895,000 1,336,000 2,236,000 3,571,000 7%
Life Cycle for 419,000 690,000 1,079,000 2,615,000 3,694,000 5% energy
M Fi
Max Firstt C
Costt
S l
Selected Pipe Sizes
d Pi Si
M2 ‐4 AF T Seminar, India December, 2011
Fi di
Finding the "Sweet Spot"
h "S S "
 The pump sizing “Sweet Spot” can be identified
 This is the pump operating point which, when combined with the
optimized piping system yields the absolute lowest cost
optimized piping system, yields the absolute lowest cost
Power (hp)
125 150 175 200 225
5.0 This is the 10 year life
ons of Dollarss)
cycle case
Optimal design Original design

4.5
(sweet spot) Energy reduced by
20%
m Cost (Millio
4.0
Results published in
Curve of optimal
p Chemical Processing
ptimal System
designs at any pump in 2002

3.5 head (not possible to
be below this curve and
satisfy
y requirements)
q )
Op
3.0
40 50 60 70 80
Head Rise (feet)
Seminar Agenda
Seminar Agenda
g
Flow Modeling
M1
I d
Industry Experience
E i
 DuPont used AFT Mercury to optimize four recently designed
systems for a wide variety of applications
 Tempered water supply: VFD vs. Control Valve
T d t l VFD C t l V l
 Wastewater transfer system
 Sulfuric acid unloading system
g y
 Molten sulfur transfer system
 First cost savings averaged 10%
 Life Cycle Savings exceeded 70% in one case, and averaged 50%
 Savings exceeded $100,000 in three of the four designs
 Results published at the 19th Pump Users Symposium in 2002
I d
Industry Experience (cont.)
E i ( )
 AFT Mercury was applied to a high pressure sea water pipeline
for oil field injection for a Saudi Aramco project
 O i i l j t d i
Original project design was $873 million
$8 illi
 First cost savings were $37 million (5%)
 Life Cycle Savings were $104 million (12%)
 Both first cost and energy cost was reduced
 Energy cost was reduced by $3 million
gy y 3
 Results published at the 24th Pump Users Symposium in 2008
I d
Industry Experience (cont.)
E i ( )
 AFT Mercury was applied to a recent ducting design by a major
commercial building contractor in Colorado
 They designed a ducting system using AFT Fathom
Th d i d d ti t i AFT F th
 The engineer spent four days sizing the system with Fathom
 The ducting system had a mixture of rectangular and round ducts
 With one day of effort, AFT Mercury was able to reduce the first
cost of the system by over 30%
 The savings for a 10 story building: about $150,000
AFT Tit 4.0 Capabilities

AFT Titan 4 0 C biliti
Arrow
 Models and optimizes compressible network pipe systems
M d l d ti i ibl t k i t
 Combines a powerful flow solver and flexible graphical interface
with an advanced optimization engine
i ( i l d i ll i )
( gy y g
cost (energy costs varying with time))
Summary
 IntelliFlow represents a new technology that offers tremendous
opportunity for cost reduction in pipe and duct system design,
construction and operation
 AFT Mercury and AFT Titan utilize this technology to provide a
pp , y
methodical approach to minimize first cost, life cycle cost or
energy cost in piping and ducting systems
Conclusions
 AFT’s software products are:
AFT s software products are:
 world leading
 used by many large engineering
organizations in the West and
around the world
 powerful for pipe system modeling
in industrial applications
 AFT’s partnership with Neon India
is helping India build…
 better
 safer
 and more economical systems
y

AFT Technology Seminar India Dec 2011

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AFT Technology Seminar India Dec 2011

Uploaded by

Copyright:

Available Formats

AFT Technology Seminar

Applied Flow Technology

 Chempak Viewer™ & Chempak Add‐in™ (for Excel)

 where P is the vector of pressures and JF is the Jacobian matrix of

Choose a pump with

Static Head (TDH)

Pump Curve (No Control)

System Curve 36.9m Hf Hf 24.7m

Flowrate With Without

PP  PA  a m P  m A   gzP  zA  fx

PP  PA  a m P  m A   gzP  zA  fx

two unknowns x=0 x = i-1 x=i x = i+1 x=L

Surface Elev. = 12 m Surface Elev. = 6 m

Time (sec) CdA (cm2)

* See AFT Arrow 4.0 User’s Guide , ChapterA1 ‐

* See AFT Arrow 4.0 User’s Guide , ChapterA1 ‐

20,000 kg/hr Elbow r/D = 1.5

Activity Input Output

Analysis Pipe sizes, pump data, Flowrate, velocity, pressure

Design Flowrate, velocity, pressure, Pipe sizes, selected pumps,

Optimal design Original design

designs at any pump in 2002

AFT Tit 4.0 Capabilities

You might also like