Reinaldo Pinto
Global Sales Manager
Agenda
Product Applications
AFT products are being successfully applied to a broad range of
industrial systems:
Transient Analysis
AFT Impulse 5.0
According to Chicago Bridge Iron about Impulse:
AFT Impulse allowed the separation of "reality" from
"theoretical" to arrive at a true model of the existing system
Meeting design parameters Specs.: Pressure, Flow, Temperature, Energy Consumption, etc.
Dealing with Hydraulic Phenomena's:
1.
Cavitation (steady state and transient)
Valves erosion
Pumps erosion
Valves leak
Pipe Collapse ..\..\Seminar\Technical Topics\Collapse\Railroad tank car vacuum implosion.avi
Pipe flashing (vapor cavities)
2.
Overpressures
Pipe Rupture ..\..\Seminar\Technical Topics\Pipe failure - pump start-up\Sea Water Pump Explosion
_ Video _ Break.com_2.mp4
3.
Sonic Choking
3.
System Protection devices Failure to Control: Relief Systems, Equipment Protection devices, etc.
Relief Valve Cycling (Chattering) ..\..\Seminar\Technical Topics\Valve Chattering\Safety Valve Chattering.avi
Flow limitation
Code Compliance
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Customers
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Customers in India
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Cost calculations
Rheological data handling to support non-Newtonian fluids
Modules for:
Extended Time Simulation
Goal Seek & Control
Settling Slurries
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GSC
Automatically determines input variables that will yield specified
output values
Extends Fathoms control simulation capabilities to include
remote sensing
SSL
Simulates settling slurry behavior
Simulates pump performance degradation
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Includes modeling of
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CST
Supports cost databases for piping, fittings, valves, pumps and
other system components
Analyzes first and life cycle cost of piping/pump systems
Integrates system hydraulic design and cost
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AFT FATHOM
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AFT Fathom -
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AFT Fathom -
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AFT Fathom -
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Piping insulation
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Solution Techniques
AFT Fathom uses the Newton-Raphson Method to solve the
flow distribution in a pipe network
The Newton-Raphson Method for pipe networks is a matrix
method
AFT Fathom -
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1
2
1 + 12 + 1 = 2 + 22 + 2 +
The dynamic pressure and static pressure can be combined
into the stagnation (total) pressure, and the solution is then for
total pressure
Therefore, the momentum equation becomes
,1 + 1 = ,2 + 2 +
AFT Fathom -
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Law of Friction
Traditional method of friction loss calculation uses the DarcyWeisbach friction factor, f
1 2
=
9.35
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(Re < 2300)
AFT Fathom -
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AFT FATHOM
EXAMPLES
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3m
5m
AFT Fathom -
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AFT Fathom -
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Note:
Pump Head Rise = 93.4 m
This has 2 parts:
Elevation Rise = 57.0 m
Frictional Head = 36.4 m
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36.9m
System Curve
Head
Friction
Hf
93.9m
Total Dynamic
Head (TDH)
Static
Hs 57.0m
Flowrate
Operating
Flow Rate
AFT Fathom -
110.7 m3/hr
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3m
60m
295m
3m
5m
AFT Fathom -
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AFT Fathom -
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Note:
Pump Head Rise = 81.7 m
This has 2 parts:
Elevation Rise = 57.0 m
Frictional Head = 24.7 m
AFT Fathom -
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System Curve
Pump Curve
(VFD at 92.1% Speed)
Head
93.9m
Flowrate
36.9m Hf
Hf
24.7m
57.0m Hs
Hs
57.0m
No
Control
VFD
90 m3/hr
81.7m
No
Control
VFD
110.7 m3/hr
AFT Fathom -
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3m
60m
295m
3m
5m
AFT Fathom -
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AFT Fathom -
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AFT Fathom -
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Note:
Pump Head Rise = 97.7 m
This has 3 parts:
Elevation Rise = 57.0 m
Frictional Head = 24.7 m
Head Loss Across Control
Valve = 16.0 m (shown on
Valve Summary tab)
AFT Fathom -
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93.9m
Head Loss Across
Control Valve
Hcv 16.0m
Head
System Curve
Flowrate
97.7m
With
90 m3/hr Valve
36.9m Hf
Hf 24.7m
57.0m Hs
Hs 57.0m
Without
Valve 110.7 m3/hr
AFT Fathom -
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Pumps
Pumps
Variable speed pumps can be modeled by entering the pump
speed
Pump runout can be indentified
Viscosity corrections using Hydraulics Institute Standard can
be applied
Control to a flow rate, suction or discharge pressure can be
performed
Variable NPSH curves can be entered
Efficiency/power data can be entered
Fathom will determine power usage and proximity to BEP
Pump Summary
The Pump Summary report in the output window gathers all pump data into one
location for convenient review
Pump head and pressure rise
Pump horsepower - ideal if no efficiency curve data is provided or brake
horsepower if efficiency curve is provided
Pump speed
NPSHA and NPSHR
BEP and percent of BEP (if efficiency or power data is entered)
Viscosity correction constants CQ and CH (only if viscosity corrections are used)
This report is displayed by selection within the General Output tab of the Output
Control window then accessed using the Pump Summary tab of the Output window.
DH2 = s a + s
2
s c
+s d
s
Q
Q 3
Q 4
DH2 = s2a + sbQ2 + cQ22 + d 2 + e 23
s
s
1 4
2 Q2
+s e
Head (ft)
15
80%
10
60%
5
0
0
50
100
Flow Rate (gpm)
150
200
For variable speed pumps Fathom can calculate the speed required to deliver a
specified discharge pressure/head or flow
You cannot simultaneously input the speed because that is what is being
calculated
Fathom disables the speed input field
The required speed is display in the Pump Summary of the Output window
Pump Configurations
Pump data can be entered for multiple configurations
The default is a single configuration.
Control Valves
Control Valves
Supply Tank
Pump
Valve (Lossless)
Tee (Simple)
Elbow (Standard)
When you try to run this model the reference pressure error is displayed
The error message identifies the following junctions as lacking a reference
pressure -
Tee (Simple)
Elbow (Standard)
FCV
This is analogous to a single pipe with specified flow, Q, at the inlet and outlet -
The solution to this modeling dilemma is to make one of the FCVs a PDCV
PDCV setting is the minimum deltaP needed across the control valve
To insure all control valves have at least the minimum deltaP, the hydraulically
most distant FCV is selected to be changed to a PDCV
Note that the GSC module offers a direct way of solving this issue without
resorting to the PDCV (see GSC Example scenario in model file)
Data is:
40 meters at 0 m3/hr
38 meters at 50 m3/hr
30 meters at 100 m3/hr
Pump
Valve
Tee (Simple)
FCV
Elbow (Standard)
Hint:
Morph the stop valve after the pump by dragging a control valve on
top of it while holding down the CTRL key, then set as PDCV at 0.7
bar
The user can assign different actions for each of these cases
AFT Fathom -
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AFT Fathom -
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AFT Fathom -
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Heat Exchanger
In AFT Fathom heat exchangers can be modeled:
as hydraulic only (e.g., a constant property model), or
as hydraulic and thermal
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Scenario Manager
Scenario Manager
The Scenario Manager allows you to keep variants of a model all with the same model
When changes are made to the base model, they are automatically passed downward
Changes at lower levels do not pass upwards
Current Workspace
scenario
Scenario tree
Notes can be added
for each Scenario
Rename, delete, clone,
promote & save
scenarios by clicking
here
Create a new
scenario by clicking
here
The Quick Access Panel provides convenient utilization of all of the features
of the Scenario Manager.
Types Of Changes
The types of changes that can be made are very broad
Junctions can be turned on and off to evaluate different
operating conditions
Pipe and junction data can be varied to parametrically evaluate
competing designs
You can build an existing system as your base model then add to
the system to evaluate expansion possibilities on the existing
system
You can easily evaluate different working fluids by setting them
up as different children scenarios
You can compare a newly-built clean system to one that has
been in service for a period of time with worn/corroded pipes,
etc.
Data Propagation
Changes to ancestors propagate to all descendants if the
descendant data has not been modified
Changes to descendents never propagates to ancestors
Diameter
Length
Base
25
Child #1
__
__
Gr. Child #1
__
__
Diameter
Length
Base
25
Child #1
__
Gr. Child #1
__
__
Diameter
Length
Base
25
Child #1
__
Gr. Child #1
__
__
Diameter
Length
Base
40
Child #1
__
Gr. Child #1
__
__
Diameter
Length
Base
25
Child #1
__
Gr. Child #1
__
Diameter
Length
Base
25
Child #1
__
Gr. Child #1
__
Diameter
Length
Base
25
Child #1
__
__
Gr. Child #1
__
__
Diameter = 2
Length = 25
Changes to Base Diameter will not affect
Diameter
Changes to Base Length will affect Length
Diameter = 2
Length = 15
Changes to Base Diameter will not affect
Diameter
Changes to Child #1 Diameter will affect
Diameter
Changes to Base Length or Child #1 Length
will not affect Length
Diameter
Length
Base
25
Child #1
__
Gr. Child #1
__
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Ancestral Data
Ancestral source of data can be viewed for all pipes and
junctions in Model Data
Links to Parent
A link to a parent may be re-established by returning the
attribute to the same value as that of its parent
This can be done manually be entering the value or selecting
Same As Parent from within a pipe or junction Property window,
Solution Control or System Properties.
You can make a pipe have the same attribute as its parent by choosing Copy Data
From Pipe: Parent Pipe Data
Junctions function similarly
Example Model
A piping system will be used to transport liquid methane, propane, and ethane at
cryogenic conditions
Supply is at -100 deg. C
The system will supply only one tank at a time
Pipe is Stainless Steel ANSI schedule 40S and is very well insulated (no heat
transfer)
Supply is pressurized to 35 barG and storage tanks to 30 barG
Both valves have Cv = 25
Using Fathom build all of these scenarios in a single model (cryo1 (SI).fth)
What is the flow rate for all cases?
Models\Fathom Models\cryo1.fth
Answers to Example
Flow rates to tanks using 12 inch (30.48 cm ID) pipe
Methane
Ethane
Propane
Methane
Ethane
Propane
Depending on how you arrange the scenarios, the Scenario Manager might look like
this:
Transient Analysis
AFT IMPULSE
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Waterhammer
Fluidhammer
Hydraulic Transients
Fluid Transients
Surge
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Types of Transient
Transient 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 Transient
Liquid acceleration caused by local phase change
2. Slug Transient
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 Transient
Caused by equipment or component operational changes
Pump trips, valves closed, etc.
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Instantaneous Transient
The magnitude of a transient is dependent on the wavespeed
of the liquid
The wavespeed () is dependent on the:
liquid acoustic velocity
pipe modulus of elasticity (E), wall thickness (t), and material
Poisson Ratio ()
pipe restraints
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Code Compliance
Once the overpressure is calculated, What should the designer do with
this value?
The answer to this question depends on the code being used.
AFT Impulse
Waterhammer Sequence
V= Vsteady
V=Vsteady
V=0
V=0
a
V= Vsteady
d
V= Vsteady
V=0
V=0
a
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DPinstantaneous
Psteady
x
V
Vsteady
x
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P
Psteady
DPinstantaneous
x
V
x
-Vsteady
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V= Vsteady
V=0
a
P
Psteady
DPinstantaneous
x
V
x
-Vsteady
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V=0
a
P
Psteady
DPinstantaneous
V
Vsteady
x
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Fundamental Equations
Mass / continuity equation
+
=0
2
Momentum equation
1
+
+ sin +
=0
2
Where :
a = wavespeed
V = velocity
x = distance along pipe
P = pressure
t = time
g = gravitational constant
a = slope of pipe
f = friction factor
D = diameter of pipe
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Method of Characteristics
By combining the mass and
momentum equations linearly and
substituting mass flow rate, , for
velocity, V, one obtains
t = 5 Dt
t = 4 Dt
t = 3 Dt
+ + +
= 0
22
t = 2 Dt
P
t = Dt
C+
C-
B
A
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 (Note: a similar equation can be written for the negative characteristic)
+
22
= 0
+ +
=0
22
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t = 5 Dt
t = 4 Dt
t = 3 Dt
Where:
A = cross sectional area
Resistance
t = 2 Dt
P
t = Dt
C+
=
22
t= 0
x=0
CB
A
x = i-1
x=i
x = i+1
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x=L
Pumps on or off
Valve open or closed
Check valves open or closed
Etc.
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1
Surface Elev. = 12 m
Surface Pressure = 1.72 MPa(g)
Pipe Depth = 6 m
P2
L = 91 m
10 inch (25.5 cm ID)
P3
L = 46 m
10 inch (25.5 cm ID)
Abrupt Expansion
Elevation = 0 m
Ammonia at 24C
0 to 5 seconds
Model Cavitation
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4
Surface Elev. = 6 m
Surface Pressure = 1.72 MPa(g)
Pipe Depth = 1.5 m
Valve
Elevation = 0 m
t (sec)
Cv
0
1000
?
0
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Webinar Agenda
Q/A session
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CdA (cm2)
0
1.94
1.94
L=3 meters
1-1/2 inch
(4.1 cm ID)
L=3 meters
1-1/2 inch
(4.1 cm ID)
L=3 meters
1-1/2 inch
(4.1 cm ID)
L=3 meters
1-1/2 inch
(4.1 cm ID)
L=3 meters
1-1/2 inch
(4.1 cm ID)
L=3 meters
1-1/2 inch
(4.1 cm ID)
El = 3 meters
L=3 meters
1-1/2 inch
(4.1 cm ID)
4 inch
(10.2 cm ID)
L=3 m
El=0.3 meters
L=152 meters
8 inch
(20.3 cm ID)
El=0.3 meters
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El=0.3 meters
L=152 meters
8 inch
(20.3 cm ID)
L=0.5 m
1-1/2 inch
(4.1 cm ID)
Typical
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Nearest Supply
Farthest From
Supply
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Compressible Flow
AFT ARROW
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CST
Supports cost databases for piping, fittings, valves, pumps and
other system components
Analyzes first and life cycle cost of piping/pump systems
Integrates system hydraulic design and cost
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Solution Methods
AFT Arrow offers six solution methods
Two lumped methods
Four marching methods
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Database
AFT Arrow offers custom database for these type of data
Components
Fluid Properties
Pipe sizes
Insulation properties
Fitting and losses
Output configuration
Databases: local or network
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Typical Applications
Pipe and duct sizing
Compressor/Fan, control valve, relief valve: sizing and
selection
Simulating system operation and component interaction
Choked Flow calculations
Evaluating Heat Transfer in pipes and heat exchangers
Trouble shoot existing systems / cause of operational
problems
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Building a model
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Dynamic mixing
Assemble non-reacting mixtures (using Chempak Database)
Analyze dynamic mixtures resulting from intersecting flow streams
Models\Arrow Models\Mix1.aro
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US
PIPE UNITS
L= feet
J1
Methane
Process
200 psia, 300F
J2
Ethane
Process
200 psia, 300F
P1
L=50.
3 inch
schedule 40
J4
Bend
K=0.538
P2
L=25.
3 inch
schedule 40
J3
Propane
Process
200 psia, 300F
P3
L=50.
3 inch
schedule 40
J5
Tee or Wye
P4
L=25.
4 inch
schedule 40
P6
Main Relief Line
L=150
6 inch
schedule 40
P5
L=50.
3 inch
schedule 40
J6
Tee or Wye
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Models\Arrow Models\Test10.aro
A new emergency relief system at an oil refinery is being
considered and you have been called as a consultant to
evaluate the process calculations (model TEST10.ARO)
The system provides relief to processes for methane, propane
and ethane (use Chempak to specify three fluids at the same
time)
Each process is at 200 psia when the relief event occurs
The process engineer has evaluated the relief capacity at the
minimum process temperature of 300 F
The elbow is a standard elbow, and model the tees as
simplified
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