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The December 2003 issue of the Engineered Software Fluid Flow Newsletter describes how PIPE-FLO is being used at operating plants. PIPE-FLO provides a piping schematic of the piping system just like a flow diagram or P&ID. Unlike a static drawing, PIPE-FLO shows you how the piping system actually operates. Many of our customers use their PIPE-FLO piping system models as design documents making them available to everyone it the plant. This newsletter provides a series of example of how PIPE-FLO provides a clear picture of how fluid piping system operate.

In 1982 when PIPE-FLO was first released our customers used the software to design new piping systems. Over the years, owners and operators of plant piping systems use their PIPE-FLO models to simulate the operation of existing piping systems.

Using a piping system model, they get a clear picture of how the systems operate under a variety of expected conditions. This month’s newsletter demonstrates how PIPE-FLO is used by different groups in a plant.

SEE PIPE-FLO IN OPERATION

If you would like to see PIPE-FLO in operation, why not sign up for a Web Presentation. All you need is 45 minutes, a computer with an Internet connection, and a phone. One of our application engineers will demonstrate PIPE-FLO, and you’ll be able to see the program in operation and get your questions answered. It’s quick, it’s free, and it’s an excellent way to see how PIPE-FLO can help you get a clear picture of your next piping system.

To sign up for a free PIPE-FLO Web presentation call toll free 800-786-8545 or log onto http://www.eng-software.com/demo and sign up for the Web Demo.

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One of our customers at a chemical plant was evaluating her Demineralized water distribution system. Her plant was scheduled to go through a major system expansion, the project engineer wanted to see how the increased DI water requirements would affect the system.

The first step was to model the existing DI water system with PIPE-FLO. After modeling the existing system, she compared the calculated results with the observed plant values. With a close correlation between the PIPE-FLO model, and the operation of the DI water system she was able to determine the model was accurate.

She then added the new loads onto the existing model and set the flow rates to the new DI water requirements. While reviewing the results she discovered the existing DI water system would not meet the future capacity needs. After reviewing the piping system model, she discovered a section of the main DI water distribution header had a very large pressure drops. She then added a new pipeline in parallel to the choke point in the DI water system. After reviewing the results of the proposed changes, she was able to get the DI water system changes included in the capitol budget for the plant expansion.

The clear advantage of using PIPE-FLO was to identify the problem areas on the existing system and getting the modifications made prior to bringing the new loads online.

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One of our PIPE-FLO customers was faced with an unexpected and ongoing problem with a series of catastrophic pump failures. The pumps never lasted more than two months before failing. After examining the pumps, the failures always consisted of severe caviation damage and actual component mechanical breakage.

The initial assumption was the pump was operating around it’s design point, and the there were physical problems within the pump. After modeling the entire piping system with PIPE-FLO, they were able to determine the flow rate through the pump was well below the manufacturers minimum flow rate. The low flow rate was caused by the way the piping system was operated. As a result, the pump failure was due to caviation damage that occurred at the low flow rate and not a design problem with the pump.

You can find out more about how PIPE-FLO provided a clear picture by going to the following link: http://www.eng-software.com/customers/envirotech/default.htm.

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Operating plants have a variety of utility systems providing cooling water, compressed air, waste collection and treatment systems to name a few. In addition, the utility group is looking for ways to minimize pumping cost. PIPE-FLO is an excellent tool for these types of piping systems.

During a recent visit to a customer’s agro chemical plant, the utility engineer told me about a compressed air system he evaluated using PIPE-FLO.

The installed compressors were not sharing the load equally and he wanted to balance the compressor loads. Running the air compressors cost the plant $500,000 per year in energy cost so there was a strong interest to reducing operating costs.

After modeling the compressed air piping system with PIPE-FLO, he discovered that under different plant operating conditions, the loads swung between the compressors. By evaluating the compressors with different compressor set points, he was able to determine the compressor set points needed to stage the compressors so the most efficient compressor ran all the time. The less efficient compressors run as needed for swings in the load.

After analyzing the compressed air system with PIPE-FLO he said he was able to stage the compressors thus saving over $40,000 per year in electricity cost. In addition, he discovered he had an excess of 6 psi at the most remote air load. This allowed a further reduction in the compressor set points resulting in an additional 4% reduction in the energy consumption.  

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Safety is a paramount concern in any plant, and PIPE-FLO is doing its part. With PIPE-FLO the safety engineers can evaluate piping systems under a variety of expected operating conditions. We recently got a support call from a safety engineer at a process plant. He needed to know if the overflow line on a tank was large enough.

He created a lineup to simulate the system when the flow control valve into a tank failed to open. PIPE-FLO then calculated the maximum flow rate into the tank.

He then modeled the overflow piping and using the flow rate into the tank, he discovered the overflow piping and collection system was sized properly. The PIPE-FLO reports documented all the calculations.

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Operators of piping systems use PIPE-FLO to see if the system is operating as designed. One of our customers runs a winter ski resort, and they modeled the water and compressed air piping systems feeding their snow making machines.

By pumping water to a nozzle and mixing the water with compressed air, the snow making machine turns the water and air mixture to snow. If there is insufficient water pressure or air pressure at the snow making machine, the mixture does not freeze quickly and causes a sheet of ice to form on the ski run. If the water or air pressure is too high the mixture turns to snow, but more energy is consumed than needed.

Using the lineup feature of PIPE-FLO the snow operators are able to open and close the water and air supply to the snow making machines. If a nozzle in the PIPE-FLO model turns red, it indicates the pressure is too high. The operator knows they can turn on additional snow making machines. If the nozzle on the FLO-Sheet turns green, it indicates the pressure at the snow making machines is too low and it should be turned off.

Using the PIPE-FLO model the snow machine operators can be assured of having sufficient pressure for quality snow, while saving operating cost for compressed air and water systems.  

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