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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 thermodynamic 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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Gas Turbine Start-up

Pressure regulators are to be employed at a gas-fired power station to reduce upstream gas pressures from a maximum of 15 MPa to approximately 3.5 MPa. Due to the Joule-Thompson effect, the resulting gas temperature drops could be in the region of 55 °C. The dew-point temperature of the hydrocarbons (gas) flowing through is -15 °C and the minimum ambient temperature of the area is -6 °C. Thus the regulators could potentially be subjected to gas at -61 °C at start-up. According to the valve manufacturer, temperatures as low as -20 °C can be tolerated for some time, provided that condensation does not occur.

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Gas Fired Heater Insulated Pipe

A client in the petrochemical industry sought help with regards to a fired heater employed on a plant. The client wished to perform thermal fatigue and stress analysis on the heater, especially during transient operating conditions such as start-up and on-off cyclic operations, where the possibility for large temperature gradients exists.

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Header Balancing

This case study demonstrates the capability of Flownex to determine the orifice sizes required to ensure balanced flow in several parallel pipes connected by two headers. In practice this system could represent the cooling flow through a simple radiator.

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Gas Fired Heater

A client in the petrochemical industry sought help with regards to a fired heater employed on a plant. The client wished to perform thermal fatigue and stress analysis on the heater, especially during transient operating conditions such as start-up and on-off cyclic operations, where the possibility for large temperature gradients exists.

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Combined Cycle Power Plant

This case study demonstrates the modeling of a Combined Cycle (CC) power plant of a High Temperature Gas-Cooled Reactor (HTGR). The nuclear reactor is not modeled in detail as the focus of this case study is not on the reactor but on the CC Power Conversion Unit (PCU).

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Boiler Header Cracking Investigation

This Case Study describes how Steinmüller used Flownex to dynamically simulate the flow and heat transfer over the platen evaporator and determine the possible reasons for header cracking.

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Boiler Fuel Oil Distribution

This Case Study demonstrates how Steinmüller used Flownex to simulate a fuel oil distribution network. The Flownex models served as a comparison study between the current fuel distribution network and proposed changes to the network. By implementing the proposed changes and accurately simulating the proposed changes, Steinmüller was able to make efficient design decisions and determine the possible cost implication due to the changes.

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Boiler Flow Distribution

This Case Study describes how Steinmüller was able to do what-if studies and to make decisions such as whether to remove the evaporative platens to optimize the plant in terms of reliability, plant availability and overall plant efficiency. Flownex proved valuable in the investigation by providing the new flow distribution in the water walls and super heaters based on design changes and also the steam condition that is provided to the turbines.

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Water Jacket Flow Balancing

This case study demonstrates the flow balancing that was investigated as part of the design of a water jacket. The water jacket is used to cool a cylindrical test section that forms part of a highly specialized experimental facility.

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