Flownex Simulation Environment - Process Flow & Heat Transfer Engineering Systems Simulation Software

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Boiler System Solutions

Flownex is well suited to simulate fluid flow and heat transfer within boiler systems. Flownex's system approach to boilers allows engineers to truly understand their boiler behaviour, make informed engineering decisions when troubleshooting, ensure optimal operation and plan cost efficient maintenance schedules.

Flownex ability to model in real-time a combination of two-phase fluid (steam), heat transfer and transient simulation on a system level truly places it as a world leading boiler design and analysis tool.

Typical solution to Boiler Systems using Flownex:

  • Boiler tube failure root case analysis.
  • Temperature distribution analysis.
  • Header cracking root cause analysis.
  • Flow distribution, natural circulation.
  • Operator training.
  • Maintenance scheduling.
  • Boiler water circulation system simulation.
  • Mill shaft lubrication system simulation.
  • Boiler draught system simulation.
  • Boiler steam system simulation.

Solutions for the Boiler Steam System

  • Simulate attemperation control to evaluate system reaction to operational changes.
  • Calculate flow distribution in superheater/reheater in the event of a tube leak.
  • Calculate tube wall temperature change due to excessive fouling (inside and outside).

Solutions for the Boiler Water Circulation system

  • Design flow distribution through water walls (orifice sizing etc.).
  • Incorporate natural convection effects.
  • Calculate two phase flow in tubes and steam drum.
  • Track the level in the steam drum during dynamic transients such as blow downs.
  • Design forced convection flow distribution and pump sizes.
  • Determine heat transfer degradation due to water wall fouling (inside and outside). 

Solutions for the Boiler Draught System

  • Simulate dynamic adjustment of fan speed in order to find optimum control characteristics for efficient combustion.
  • Determine the effect of air heater performance degradation over time due to air in-leaks.
  • Determine overall system flow distribution and performance incorporating air in-leaks in to identify losses and performance reducing areas.
  • Determine system performance degradation over time due to bag filter fouling.
  • Simulate flow distribution and damper control for optimum primary and secondary fuel mixing in burner operation - NOx and SOreduction.
  • Design flow distribution between burners and Secondary Over fire Air (SOFA) in new or retrofitted plants.



THEME: Root Cause Analysis of System Performance Anomalies 

CASE STUDY: Two Phase Flow Regimes

This case study ‘Two-Phase Flow Regimes’, aims to demonstrate the capability of Flownex SE to carry out root cause analysis of a system to determine the cause of a system performance and safety issue. In addition to identifying the underlying cause, by using Flownex SE it is possible to deliver an optimized design solution in the simulation model, in order to remove the root cause issue and generate an improved design configuration.

The case study presents how Flownex SE was successfully employed in a Power Plant commissioning project where it quickly identified the cause of a system performance anomaly, optimized the system design to remove the anomaly and efficiently returned the system performance back within desired performance parameters.

One of the considerable benefits aside from identifying and rectifying the design issue was that by using Flownex SE, the analysis and optimization study was executed quickly and cost effectively keeping the commissioning schedule on track and mitigating the commercial impact on the project.


THEME: Flownex Interoperability and Investigative Analysis of Failures 

CASE STUDY: Boiler Tube Failure Thermo-Hydraulic Analysis

This case study ‘Boiler Tube Failure Thermo-Hydraulic Analysis’, aims to demonstrate the capability of Flownex SE to carry out investigative analysis of tube failure issues on a boiler, using Flownex to test various hypotheses which were considered to be the cause of tube failures. This case study also shows the versatility of Flownex to work in an interactive communicate manner with other modelling software in this case ANSYS structural analysis. 

The case study presents how Flownex SE was successfully employed in the investigation of boiler tube failures in a power plant setting. Having built a representative model of the boiler wall section in Flownex by importing geometric data from ANSYS it was possible to test all assumptions regarding the cause of the tube failures, related to the thermo-dynamic effects of operation in Flownex. Then the temperature distribution data from Flownex were fed back into ANSYS to analyse the structural effects on the boiler tube wall owing to the Flownex obtained temperature distribution data. 

The results from the model corresponded very well with the measured data from the plant, so this meant the Flownex model was an accurate simulation model of the existing plant performance. This enabled the model to be used for further data analysis for various other plant operating scenarios in the future.


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