FluidFlow3

FLUIDFLOW3

TRAINING MANUAL

www.accutech2000.com.au

June 2013

Accutech 2000 Pty Ltd (2013)

COPYRIGHT AND DISCLAIMER

Copyright

This Training Manual is copyrighted to Accutech 2000 Pty Ltd and may not be reproduced inany form without the written permission of Accutech 2000 Pty Ltd.

Disclaimer

Accutech 2000 Pty Ltd disclaims any responsibility for the contents of this training manualand its use by any other party.

FluidFlow3 is intended solely as an aid for pipe flow engineers and not as a replacement forother design and analysis methods including hand calculations and sound engineeringjudgement. All data generated with FluidFlow3 should be independently verified with otherengineering methods including appropriate peer review.

FluidFlow3 assumes that the user possesses a good general knowledge of engineering pipesystem hydraulics. Even the most advanced and easy-to-use software package cannotmake up for a lack of fundamental knowledge on the part of the user. The level of knowledgeassumed by FluidFlow3 is consistent with that obtained in a typical engineeringundergraduate course in fluid mechanics and complimented by appropriate post-graduatestudy and experience.

Every effort is made to ensure correct calculation results. Flite Software Ltd and Accutech2000 Pty Ltd do NOT guarantee calculation accuracy. The Quality Assurance statements inthe Help file apply.

Accutechs Terms and Conditions and Flites Softwares Licence Agreement apply to the useof FluidFlow3.

FluidFlow3 Training Manual Terminology_______________________________________________________________________________________

The following terminology is use in this training manual:

Component An equipment item whose hydraulic characteristics are saved inthe database and shown on the Component Toolbar.

Element Any component included in a model and displayed via its icon on theflowsheet. An element also describes a text box on the flowsheet.

Active or Activated An element on the flowsheet which is selected and consequentlysynchronised with the Data Palette.

Toggle This means select an alternative, viz show/hide, on/off.

/click/ left click./right click/ right click./2click/ double click./click/drag/glue/ left click on the flowsheet, hold, drag and click again and release.

Finger-point Cursor or pointer displays as a pointing finger use to activate anelement.

[Database] Square brackets mean use a menu option in this case thedatabase.

[Database][Pipes] Use sequence of menu options.

3-dot Click on a button.

F-key.

Use keyboard key.

Identifies an action to be performed , a design example step.

Describes the consequence of the user action.

Indicates a tab option.

Indicates a component selection to be included on the flowsheet,in this case a butterfly valve from the Valves component dataset.

{Butterfly Valve} An element on the flowsheet.

Calculation.FF3 File name.

...QA Compressible Flow\Choking Tests\path to the default examples files supplied with FluidFlow3.

FluidFlow3 Training Manual Contents_______________________________________________________________________________________

PAGECOPYRIGHT AND DISCLAIMERTERMINOLOGY

1.0 INTRODUCTION 1

1.1 THE FLUIDFLOW3 SCREEN LAYOUT GENERAL 11.2 FLOWSHEET PANE 3

1.2.1 Visible Properties 31.2.2 Flowsheet Toolbar 31.2.3 Pop-up Menu 41.2.4 Cursor 41.2.5 Guidelines 5

1.3 DATA PALETTE 51.4 COMPONENT PALETTE 71.5 THE HELP KEY 8

2.0 FIRST STEPS 9

2.1 DATA ENTRY 92.2 DISPLAY OF DATA ON THE FLOWSHEET 102.3 DEFAULT SETTINGS 112.4 WARNINGS AND HINTS 132.5 BOUNDARY ELEMENTS 142.6 BUILDING A MODEL 15

3.0 A SIMPLE MODEL 17

3.1 PRELIMINARY SETTINGS 173.2 LAYOUT THE MODEL 193.3 FITTINGS AND COMPONENTS 20

4.0 FLOWSHEET TECHNIQUES 22

4.1 THE SCHEMATIC 224.1.1 Moving Model Elements 224.1.2 Multi-Marking or Selecting a Group of Elements 224.1.3 Change Component Type 224.1.4 Cut/Copy/Paste 234.1.5 Isometric Display 24

4.2 TEXT 244.3 FLYBYs 244.4 THE DATA PALETTE 25

4.4.1 Results Inspector 254.4.2 List Inspector 25

5.0 ELEMENT TECHNIQUES 275.1 ELEMENT STATUS 275.2 PIPES 275.3 DIRECTIONAL ELEMENTS 285.4 JUNCTIONS 295.5 CONTROL VALVES 30

6.0 DESIGN EXERCISE 1: METHANOL TANKER OFFLOADING 31

6.1 STEP 1 316.2 STEP 2 336.3 AUTO BOOSTER 36

7.0 DATABASE 37

7.1 ADDING NEW DATA TO A DATASET 387.1.1 Adding a Valve to the Manual Valve Dataset 38

7.2 MANUFACTURERS DATASET 407.3 ADDING A PUMP AND MANUFACTURER TO THE DATABASE 407.4 EDITING DATA 427.5 PIPES DATASET 42

7.5.1 Adding a New Pipe Size 427.5.2 Adding a New Pipe Class 43

7.6 PIPE ROUGHNESS AND SCALING 437.5.3 Lined Pipes 44

8.0 DESIGN EXERCISE 2: ACETONE DELIVERY SYSTEM 46

8.1 ACETONE DESIGN PART 1 478.2 ACETONE DESIGN PART 2 48

9.0 DATA PALETTE 49

9.1 CHART INSPECTOR 499.2 LIST INSPECTOR 50

10.0 GENERAL RESISTANCES AND JUNCTIONS 51

10.1 GENERAL RESITANCES 5110.1.1 K Loss Coefficient Type Resistances 5110.1.2 User Defined Resistances 52

10.2 JUNCTIONS 54

11.0 PUMPED SYSTEMS 56

11.1 END SUCTION CENTRIFIGAL PUMPS 5611.1.1 Affinity Laws 5711.1.2 Viscosity Correction 5911.1.3 Pumps in Closed Circuits 59

11.2 POSITIVE DISPLACEMENT PUMPS 5911.2.1 Modelling PD Pumped Systems 61

12.0 CALCULATION OPTIONS 62

12.1 [OPTIONS][CALCULATION] 62

13.0 HEAT CHANGE AND FLUID MIXING 65

13.1 HEAT TRANSFER PIPES 6513.1.1 Buried Pipes 66

13.2 HEAT TRANSFER EQUIPMENT ITEMS 6613.2.1 Shell and Tube Heat Exchanges Definitions 68

13.3 MULTIPLE, COMBINING OR MIXING FLUIDS 6813.3.1 Dataset Fluid Mixtures 6810.3.2 Multiple Fluids in a Model 68

DESIGN EXERCISE 2: ACETONE DELIVERY SYSTEM - PART 3 69

14.0 REPORTING, EXPORTING AND CHECKING 70

14.1 REPORT PRINTING 7114.1.1 Printing Selected Elements 72

14.2 EXPORT 7214.2.1 Export to Excel 7214.2.2 Data Checking 72

15.0 ENVIRONMENT SETS 73

DESIGN EXERCISE 2: ACETONE DELIVERY SYSTEM - PART 4 59

12.3 VISCOSITY CORRECTION 6012.4 PUMPS IN CLOSED CIRCUITS 60

16.0 LARGE NETWORKS 74

16.1 SUB-MODLES 74

17.0 COMPRESSIBLE FLOW 76

17.1 THERMOPHYSICAL PROPERTIES 7717.2 HEAT CHANGE 7717.3 SONIC CHOKING 7717.4 COMRESSIBLE FLOW DESIGN EXERCISE 7817.5 CHOKED OR SONIC FLOW 82

18.00 TIPS AND TRICKS 83

18.1 THE BASICS 8318.2 MODEL CONVERGENCE 8418.3 COMPOSITE PLOTS 8418.4 ODDS AND ENDS 86

APPENDIX 1: MODELLING AND DESIGN NOTES

APPENDIX 2: GENERAL NOTES

FluidFlow3 Training Manual Chapter 1: Introduction

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1.0 INTRODUCTION

Open and solve these files in your Training Folder:4 Pumps in Parallel 3 Operating.FF3

Acrylic Acid Pumping.FF3

FluidFlow3 is a generic pipe network analysis program solving for flows and pressuresaround complex pipe networks and simulating the hydraulic performance of almost anytype of line equipment. FluidFlow3 also has many of the attributes of a more advancedprocess flow simulator viz:

Optional heat changed calculations: heat loss or gained through pipe walls or atequipment items such as heat exchangers.

The ability to simulate the mixing of fluids due to different fluid streams combining ata junction in a model.

The optional Scripting module which allows what if? and real-time calculations tobe performed.

The optional Slurry modules ability to simulate non-Newtonian/non-settling andsettling slurries and pulp and paper stock.

The optional 2-phase liquid/gas module.

1.1 THE FLUIDFLOW3 SCREEN LAYOUT - GENERAL

Image 1.1: The Workscreen

.


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The FluidFlow3 workscreen comprises two main panes, the flowsheet pane wherethe schematic layout of the piping network is developed or built and the datapalette where all input and output data are displayed via five separate tabbedinspectors (the sixth tab displays the calculation progress). These two panes aresized by dragging the centre boundary. /2click/ the title bar and the flowsheet fillsthe available work area.

Note: the [View] drop-down menu allows the various inspectors to be toggled (show/ hide) thereby increasing the available screen area for the flowsheet. Also/right click/ on the Data palette display a pop-up menu with the View options.

The flowsheet and the data palette are always synchronised select an element onthe flowsheet and the data palette immediately displays the appropriate information;or from the List Inspector, select an element or elements and the same element orelements are immediately selected on the flowsheet.

At the top of the workscreen are two sets of operators:

Operator Set 1: Drop-down menus.Operator Set 2: A button bar mainly short-cuts to many of the menu options,

but also some more specific actions.

The tools on Operator Sets 1 & 2 include standard Windows options, but some areparticular to FluidFlow3.

Some of the drop down menu options are repeated on the button bar. Betweenthem, these two operator sets determine how FluidFlow3 works, eg filemanagement, database access, environment settings. Some of these features willbe described in detail later.

Two toolbars control the building and display of the flowsheet:

A Component Toolbar shown as a series of tab options from where equipmentitems can be selected to layout the model.

A Flowsheet Toolbar positioned along the left hand side of the screen. Optionshere determine how you view and utilise the flowsheet pane.

At the very bottom of the workscreen the status bar is displayed showing:

Flowsheet snap selection isometric, orthogonal or none. Friction loss correlations. Gas conditions standard or normal. Calculation status.


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1.2 FLOWSHEET PANE

To open a new flowsheet either

/click/ on the left-most button of Operator Set 2 (the Button Bar). [File][New]. .

Opening a new flowsheet will not affect flowsheets already open.

1.2.1 Visible Properties

Capabilities include:

As many flowsheets may be open as desired and whole or partschematics can be copied and pasted between them.

Multiple flowsheets may be displayed in tile or cascade format fromthe [Window] menu.

Flowsheets may be displayed in orthogonal, isometric or freehandformat.

Flowsheets may be annotated with text and individual elements candisplay their unique name and any user-selection of input and outputdata.

Element numbers can be displayed equipment items shown withoutsign; pipes shown (-ve).

FlyBys can be set to display any user-selection of input and outputdata by hovering the pointer over an element.

All the above visible properties can be toggled on or off, (ie show orhide).

The properties on the flowsheet are immediately updated after anychange, such as new calculation or change of units.

Icon size can be changed and the flowsheet zoomed.

1.2.2 Flowsheet Toolbar

The flowsheet toolbar controls the appearance of the flowsheet and how auser navigates around a model. Hover over the buttons to display thetooltips a shown.

Image 1.2: The Flowsheet Toolbar


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1.2.3 Pop-up Menu

/Right click/ on white space brings up the following pop-up menu:

Image 1.3: Pop-up Menu

A Pop-up menu is available from anywhere on the overall FluidFlow3 work-screen, its options changing depending on the location from where it wasactivated. For instance, /right click/ whilst hovering over the FlowsheetToolbar brings up options to toggle various toolbars or to customise them but only for the experienced user! The Pop-up for the List Inspector isdifferent and is described in Section 4.4.2.

1.2.4 Cursor

The cursor shape is intelligently synchronised with the toolbars, theflowsheet and the component palette. For example the cursor

Changes to an arrow pointer when hovered over any of the toolbars. Takes on the shape of an equipment item when selected from the

component palette but temporarily returns to a pointer when moved overthe data palette.

Returns to cross-hairs (orthogonal or isometric) when the selector tool is\clicked\

Cross-hairs change to a finger pointer when hovered over an elementon the flowsheet allowing the element to be selected.

The Paste cursor allows positioning of copied/pasted elements.


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1.2.5 Guidelines

Guidelines attach to the cursor once an element is selected. These allowelements to be appropriately positioned depending on whether orthogonal orisometric layout has been chosen.

[Options][Flowsheet] or and then allows the colour ofthe guidelines to be changed for greater clarity via:

Image 1.4: Colour Options

1.3 DATA PALETTE

The Data Palette comprises six tabs, five Inspectors with the sixth tab displayingthe progress of the calculation.

TAB DESCRIPTIONMessages Inspector Reports errors and warnings associated with the current

simulationInput Inspector Input data entered or editedResults Inspector Displays resultsChart Inspector Displays a graph of element performance if applicableList Inspector Lists groups of elementsWatch Shows progress of calculation

Each inspector on the data palette is synchronised with the flowsheet, so that if youactivate an element on the flowsheet, the data palette as a whole is refreshed todisplay the properties of the current selection and vice versa.

The Message Inspector provides a commentary on the development and calculationof the model. Messages may be:

Information such as affinity laws have been applied to a pump curve A warning for instance a pump is operating outside its set range A build error for instance component does not have a connecting pipe A fatal error such as pressure is calculated below absolute zero.


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The Messages Inspector comprises two panes, the upper pane listing all elementsfor which a message is displayed and a lower pane detailing the messages. Theupper and lower panes are synchronised with the selected element on theflowsheet.

Messages are intrinsically linked to [Options][Warnings and Hints] see Section2.4.

Messages provide advice to the user. Some messages are hard-coded into theprogram such as Unable to Control Flow for a control valve. Others can betoggled by the user such as Pipe Velocity is below the Warning Limit.

The Status Bar will indicate if the model has solved and, whether or not this is thecase, Messages may still be displayed.

The Image below shows the message associated with a control valve operatingbelow a user-defined minimum position.

Image 1.5: Message Inspector

The Input Inspector is where the characteristics of an element are defined. Data isone of three types:

Sourced from a database. Sourced from a pre-set Default settings via the Component Bar. User-defined directly into the Inspector.

Input data can be edited and changed at any time.


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The user has complete control over what is displayed in the Results Inspector via[Options][Environment][Visible Results] or .

Hint: To switch between the Input and Results Inspectors for a particular elementon the flowsheet use /click/ whilst finger-pointing to the active element.

The Chart Inspector graphs the hydraulic characteristic of the selected element ifappropriate.

The Watch Inspector displays the progress of a calculation.

The List Inspector is described in Section 4.4.2.

1.4 COMPONENT PALETTE

The twelve tabs shown on this operator group together, and control access to,twelve groups of similar fluid flow system components as described in the tablebelow. The tabs each display a suite of element icons, eg displays 14different types of pipes/pipe materials which can be utilised on a flowsheet. Eachelement icon (in this case each of the 14 pipes) can have its own default values andvisible properties pre-set. Each element icon consequently has its own entry in thedatabase.

Component TabsCOMPONENTS

Pipes Pipe schedules for steel, uPVC, poly and other pipematerials

Boundaries Locations or elements where fluid enters or leaves thenetwork often referred to a inlet/outlet (I/O) nodes.

Junctions Elbows, tees, wyes etcBoosters Pumps, fans and compressorsValves 16 types of manual valves from butterfly, gate to 3-wayControllers Pressure and flow control valvesCheck Valves 5 typesGeneral Resistances Filters, cyclones etc and user-defined resistances based on

standard K-type equationsSize Change Reducers, orifices and nozzlesRelief Devices Relief valve and bursting diskHeat Exchangers Shell & tube, plate, jacketed vessel, knock-out potAuto Simple elements which do not rely on actual performance

data pressure sustainer, pressure reducer, booster. Usethese components to achieve a particular set value, forinstance a set flowrate through a pump.


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Note: Available components will depend on activated modules.

Select various tabs and components, hover the cursor over the icons to displaydescriptions.

1.5 THE HELP KEY

FluidFlow3 contains full context sensitive help, activated as follows: (a) from [Help](b) the F1 key and (c) Help buttons

FluidFlow3 Training Manual Chapter 2: First Steps

9

2.0 FIRST STEPS

Open and solve the file: 4 Pumps in Parallel 3 Operating.FF3

We need to look first at some basic software functions which will assist in learning how todrive FluidFlow3. These are:

Data entry. Display of data on the flowsheet. Default settings. Warnings settings. Boundary elements.

2.1 DATA ENTRY

There are three main areas of data entry where information about components orelements is entered. These are:

Database Input Inspector Default Settings

The Input Inspector and the Default Settings dialogs are very similar the InputInspector for a steel pipe is shown on Image 2.1 below. (Database input is coveredin Chapter 7.0).

Image 2.1: Data Entry Fields

Note: Default Settings and the Input Inspector are intrinsically linked such thatwhen a component is first placed on the flowsheet, the Input Inspector copies itsdata from the Default Settings. This data can, of course, be edited at any time viathe Input Inspector.


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Data entry method is essentially the same in each case. Referring to Image 2.1, theleft-hand column (blue or dark shaded) describes or names the data entry fields, thecontents of which are selected/input and displayed in the right-hand column. Thereare three types of data entry field:

1. Discrete data - user-entered for data specific to the current model such aspipe length but may also be sourced from the default settings. (Alsoincludes text entry).

2. Selection field - an option choice from an in-built drop down list such asUse Database Size, Units selection or On/Off.

3. Database or other link - /clicking/ this field brings up a 3-dot buttonwhich links so somewhere else in the program.

Note: All other data entry dialogs operate in a similar way; some fields display onlyhelpful information or hints.

2.2 DISPLAY OF DATA ON THE FLOWSHEET

Any input and output (results) data associated with an element can be displayed onthe flowsheet (visible data). This is activated from the Properties on Flowsheetfield on the Input Inspector by selecting the Show option. This then activates threechoices:

1. Alignment of the text.2. The text font.3. The properties to be displayed.

Selecting Properties on Flowsheet and /clicking/ the button will display thefollowing dialog ...

The list displays both Inputand Results data.

Expand both Input andResults to display the full listof properties.

Make any selection from thelist and the selected valueswill be displayed on theflowsheet.

Image 2.2: Element Properties Dialog


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Exercise: Using the open flowsheet 4 Pumps in Parallel 3 Operating.FF3...

Select any pipe by pointing the cursor to it (the cursor should change to a fingerpointer) and /click/.

Return to the Input Inspector and toggle Properties on Flowsheet to Show. /click/ in the Properties on Flowsheet field and /click/ the button. From the Element Properties dialog select the following to be displayed on the

flowsheet: Input: Pipe Length, Nominal Size Results: Flow, Friction Loss

OK Return to the flowsheet.

Note: If the data does not display then toggle it on/off from the Show or Hide

Properties on Flowsheet button on the Flowsheet Toolbar.

Experiment with the Alignment and Font options.

2.3 DEFAULT SETTINGS

Whenever an element is added to a model, FluidFlow3 uses the pre-set defaultvalues or properties for that component. The default values can always be over-written via the Input Inspector but pre-setting the default values makes the enteringof data quicker and less likely to error.

For instance, if the next five pipes to be added to the model are all to be 4 schedule40, then prior to adding these pipes the default should be set accordingly. Existingpipe values will remain unchanged, but new pipes will reflect the default values.

[Options][Environment][Component Defaults] or brings up the dialog shownbelow. Note the similarity of data entry to the corresponding Input Inspector shownin image 2.1 above. The left-hand column lists the component groups - identical tothe tabs on the Component Toolbar.

Select any component group and the underlying elements are displayed. Selectan element and its defaults can be selected and set in the right hand column in asimilar way to that described in Section 2.1.

Initially it may seem daunting to set the defaults of every available component.However, its only required for those components to be used in the current modeland additionally, the default settings can be saved to an Environment see Chapter15.

Set your default values for steel pipes and {Known or Assigned Pressures} asshown in the images below. Well use these settings later.

/Click/ in the Properties field and then /click/ the button to display theElements Properties dialog. Select the following Input Data:

Pipes: Classification (95), Length (79) and Nominal Size (107){Known or Assigned Pressure}: Elevation (62)

Note: space limitations means that the actual property name is not displayed,just the underlying code number.


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Image 2.3a: Pipe Defaults

Image 2.3b: Boundary Defaults


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2.4 WARNINGS, HINTS AND MESSAGES

One of FluidFlow3s most useful functions is the feedback it provides after acalculation has been completed (or failed if fatal errors are encountered!). Thisfeedback may be in several forms, viz:

A flowsheet error such as an element, say a 3-way valve, has insufficientpipe connections.

A reminder. For instance notifying that a pump speed or impeller diameterhas been changed within the current mode.

A component unable to deliver the set conditions such as a flow controlvalve unable to deliver the set flowrate.

A range warning. The desired range within which some components arerequired to perform can be user-defined. Should the solution fall outside thisrange then a warning is enunciated. For example, pipe velocity upper andlower limits can be set.

If an element generates a message it will be flagged red on the flowsheet and themessage will be displayed in the Message Inspector.

User-control over Warnings and Hints is via [Options][Warnings and Hints] or the

right-most button on the button bar, which brings up the dialog shown below.

Image 2.4: Warnings and Hints

Set your pipe velocity and control valve opening limits as shown in the imageabove

Note: The Message Inspector is synchronised with the flowsheet and the red-flagging can be toggled on/off from the flowsheet toolbar button . Ranges can beset for some components in the database see Sections 7.1.1 and 7.3.


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2.5 BOUNDARY ELEMENTS

FluidFlow3 utilises the concept of an input/output (I/O) node in its analysis of a pipenetwork. An I/O node is a point at which fluid is considered to either enter or leavethe network. For instance, it could be the tank supplying water to the suction side ofa pump or the end of a pipe discharging to atmosphere. For each I/O node eitherthe pressure or the flow must be specified; the unknown quantity is then calculated.

FluidFlow3 has six available boundary elements shown below:

Image 2.3: Boundary Elements

A reservoir may have several pipes adjoining, their connections being above orbelow its set fluid level. The nozzle may discharge to atmosphere or to apressure above or below atmospheric pressure.

Notes:

1. An I/O node can be the actual physical limit of the pipe system or aconnection point to a downstream network of pipes, for instance the tie-inpoint to a downstream pipe system. If a demand flowrate is specified at thisposition, the software will calculate the associated pressure (orbackpressure) at this location or if a pressure is specified the softwarecalculates the associated flow. The two values then represent theflow/pressure availability for delivery of fluid to the downstream pipework.

2. You cannot specify both flow and pressure at a boundary element.3. A fluid is always defined at a {Known or Assigned Pressure} since prior to

calculation flow direction is not known. Flow may be into the network whenthe defined fluid is used or out of the network when the discharging fluid willbe a function of upstream conditions and not necessarily the fluid defined atthe {Known or Assigned Pressure}.


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4. Caution: Whilst its convenient to regard a {Known or Assigned Pressure}element as a tank containing a liquid with the liquid surface at thedesignated elevation above datum and a pressure (+/-) above that surface,this is not always the actual situation. As previously noted, it may be a tie-inpoint where there is no free surface, or with a gas, the concept of a surfaceelevation has no meaning. To simulate a tank with a floor level and liquiddepths above floor level, use a {Reservoir} boundary.

5. An Open Pipe has very specific properties. It represents discharge toatmosphere at standard conditions.

2.6 BUILDING A MODEL Open a new flowsheet [File][New] or /click/ the New Page tool on Button Bar .

When you first start FluidFlow3 you will be presented with a blank flowsheet window(Flowsheet 1). Ensure that you are working in orthogonal snap mode by toggling

the tool on the flowsheet toolbar (or ) to display flowsheet options. /2click/the title bar to fill the available workspace and set your zoom to 100%.

A piping network on the flowsheet comprises a sequence of elements each with itsown hydraulic characteristic. These may be equipment items such as valves,bends, pumps or pipes. Each element can have the status on, off or ignore.

An element is any piece of equipment or pipe shown on the flowsheet representedby its own unique icon with its underlying data stored in the database and/or definedin the Input Inspector. A block of text on the flowsheet is also referred to as anelement.

Exercise:

/click/ on and select a steel pipe (the left-most icon). Hover the cursor over the flowsheet window. Notice that the cursor has

changed to a pipe shape. The guidelines should also be displayed.

Hint: If the guidelines are not clear on your monitor then goto: and change the Highlight Colour, try fuchsia. (See also Section 3.1).

/click/drag/glue/ to rubber band a pipe onto the flowsheet.

The cursor remains unchanged until either the Selection or Area Markertools are selected or another component is selected hence you canuse other toolbars, other toolbar tools and the input inspector without de-activating the cursor.

The pipe terminates with an {Open Pipe} boundary and this is the selectedelement since it was the last one to be positioned.

Toggle-on pipe and node numbers from the flowsheet toolbar

Additional pipes can be added either by connecting to some midway point on theexisting pipe, or joining to one of the {Open Pipe} ends.


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Hover over the pipe. The cursor changes once again to a flange shape toindicate that an element may be connected. /click/drag/glue/ a secondpipe.

Hover over any pipe end (the cursor does not change in this case) and/click/drag/glue/ a third pipe.

A junction configures itself appropriately to the number of pipes joining, viz twopipes bend, three pipes tee or wye, four pipes cross. Four is themaximum. After that you need to use a {Connector} junction.

Activate the Selection Tool . Point to a pipe (the cursor changes to a finger-pointer) and /click/ to activate the

pipe.

The Input Inspector immediately displays the attributes of the selected element(these initially reflect the default values).

All inspectors are synchronised to the selected element. Experiment with amending the pipe data see Section 2.1 and Image 2.1.

Moving Elements

You can drag an element to a new position on the flowsheet.

De-activate the cursor use . Select a junction (not a pipe) hover, finger point and /click/ and hold. Drag. Note the adjoining pipe follows.

Continue to experiment with placing various components pumps, valves etc ontothe flowsheet and joining with pipes, then viewing the Input Inspector. Some pointsto look for

A component viz: {Known or Assigned Pressure} or {Known or

Assigned Flow} may have only one pipe adjoining but a {Reservoir}may have several. Explore the Pipe Connections for a Reservoir from theInput Inspector.

Elements are automatically and sequentially numbered. This numbering isused by FluidFlow3 to define directional components such as pumps andcontrol valves by orientating towards the downstream pipe number.

Note: Some elements are directional, in that the user has to specify the direction offlow through the element see Section 5.4.

FluidFlow Training Manual Chapter 3: Simple Model

17

3.0 A SIMPLE MODEL

Clear your flowsheet [Edit][Clear] or close without saving any flowsheets and/or open a new one.

Well reinforce some of the flowsheet techniques learnt in Chapter 2 to build a simplepipe network the classical 3-reservoir problem shown in Figure 3.1 below.

50.0m

30.0m

40.0m

20.0m

All pipes 4 Sch 40, 200m longFluid: water at 15 deg C

Figure 3.1: 3-Reservoir Problem

3.1 PRELIMINARY SETTINGS

FluidFlow3 allows a large number of settings to be established by the user prior tobuilding a model. These may be saved into an Environment for later re-use.

Flowsheet Settings

[Options][Flowsheet] or brings up the dialogs shown below:

Some of the selections from these two dialogs are available direct from the operatorsets, toolbars or Pop-up. Reset to the default settings on each dialog.

Snap OptionsSelects orthogonal, isometric ornone. This selection is alsoavailable on the Flowsheet

Toolbar .

Split Pipe On Insertion:Ticked-On means that when anelement is connected midwayalong a pipe, the pipe will split intwo, each part with identicalcharacteristics to the originalexcept the length is halved.Ticked-Off means the originalpipe is retained and a new pipeadded, the characteristics of thenew pipe copied from the defaultsetting.

Image 3.2a: Flowsheet Settings


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Many of these selectionsare available from theflowsheet toolbar or theflowsheet pop-up window.

Image 3.2b: Flowsheet Settings

Element Default Characteristics Settings

These have already been set see Images 2.3a and 2.3 b.

Units Settings

[Options][Environment][ResultsUnits], or the Pop-up(/right click on white space/)brings up the units dialog asshown.

Set the units and decimalplaces to those shown on theleft.

Image 3.3: Units


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Comment:

Appropriate setting of default values can greatly assist in the construction of amodel. For instance, displaying pipe lengths and element elevations on theflowsheet will immediately provide feedback on the model values. Setting thedefault pipe lengths to 0.001mm will indicate that the proper pipe length has not yetbeen defined or elevations to 0.001m.

Warnings and Hints: [Options][Warnings and Hints]

These have already been set, see Image 2.4.

3.2 LAYOUT THE MODEL

Select {Known or Assigned Pressure} from and position it on theflowsheet window somewhere top left. The software automatically and sequentiallynumbers components junctions with a positive number, pipes with a negativenumber. To toggle component numbers use the Flowsheet Toolbar buttons

.

Move the cursor directly to the Input Inspector. (Note the default values previouslyset are displayed). Amend the elevation level to 50.0 m. Leave the (stagnation)pressure at 1 atmosphere (or 0.0 bar g).

Image 3.4: 3-Reservoir Model

Explanation: This input/output node in the piping network is now designated as aposition with a water surface elevation of 50.0 m above datum and with a stagnationpressure of atmospheric or 0.0 bar g above that surface. Flow will either enter orleave the network at this position depending on calculated pressures based on othercomponents, pipework and elevations.


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Move back to the flowsheet but note that the cursor is still activated with the {Knownor Assigned Pressure} icon. Place two more {Known or Assigned Pressures} inappropriate positions and amend their elevations accordingly.

Select a steel pipe and drag-and-glue a pipe from the {Known orAssigned Pressure} to some mid-point on the flowsheet window down to the right.The end of the pipe is now the active element as it was the last one placed on theflowsheet. Change its elevation to 30m via the Input Inspector.

Now activate the Selection Tool and finger-point to the pipe and /click/. TheInput Inspector immediately synchronises with the selected element and shows thepreviously entered default data for the pipe. Change the length to 200m.

Note the flowsheet immediately updates the visible data when a change is made.

Now complete the rest of the model as shown in Figure 3.4 by positioning the tworemaining tanks, entering the levels and then connecting with pipes. Solve.

Note: the junction has automatically configured to a tee. View its characteristics inthe Input Inspector by first /clicking/ the Nomenclature field. This describes theorientation of the three branches of a tee, ie the two branches making up thestraight channel (sometimes called the barrel) and the off-take or side branch.Orientation is changed by the Branch Pipe option field. Toggling the buttonchanges the branch as indicated by the red dot on the icon and by the pipe numbershown in the Branch Pipe field.

Use the Flowsheet Toolbar button to toggle pipe and junction numbers. Orientate the tee junction correction and re-solve. View the warnings.

3.3 FITTINGS AND COMPONENTS

Adding fittings to a pipe is simple. Simply select the appropriate component andthen /click/ to glue onto the pipe.

Try this with {Butterfly Valve} and position this at the outlet fromthe upper-most tank.

Hint: Hover over any of the equipment icons in the Component Palette to display itsdescription.

Note: When you place the valve on the upper pipe, it will split into two equal partsas a result of the Flowsheet setting Split Pipe On Insertion. Also its elevation willbe the default so amend this to 50m. Change the pipe length between the tank andthe pipe to 0.3m and return the downstream part of the pipe to 200m.

Use the Input Inspector to change the default butterfly valve to a Crane butterflyvalve 75% open.


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/click/ the button in the Valve Namefield to open the Valves dataset.

Organise by Manufacturer. Select the Crane valve. Key-in 75 in the % open field. Display on the flowsheet the visible

properties for the valve - % open, TotalPressure Loss and Calculated Flow.

Re-calc.

Comment: The total pressure loss acrossthe valve is minimal.

Progressively close the valve and viewhow the flow changes.

Create a folder called FluidFlow3 Training and save your reservoir model to a filecalled 3_Reservoir (the extension .FF3 will be automatically added). Save it withthe valve 75% open.

FluidFlow3 Training Manual Chapter 4: Flowsheet Techniques

22

4.0 FLOWSHEET TECHNIQUES Open your model 3_Reservoir.FF3. /click/ the Selection Tool .

The FluidFlow3 graphical interface has a number of features that make building, modifying,updating, interrogating and visualising a model and its data very effective.

4.1 THE SCHEMATIC

4.1.1 Moving Model Elements

Finger-point and hold on any element except a pipe and drag-and-glue.Note how the adjoining pipe(s) move as well.

Highlight a number of components. (Hold down the key at thesame time as you finger-point and /click/ each element) Now drag allthe highlighted components by finger-pointing and holding any one ofthe highlighted elements except a pipe. All the highlighted elements andadjoining pipes will move. (Remember and text box is also and elementand can be selected and moved as well).

4.1.2 Multi-Marking or Selecting a Group of Elements

There are several ways to mark or select a group of elements:

1. The area marker tools on the Flowsheet Toolbar .2. and finger-point as describe above.3. [Edit][Select]Whole Network, Nodes, Pipes, Text.4. The List Inspector see Section 4.4.2.

Area Marker Tools:

Select the rectangular area marker tool and /click/-drag-/click/ fromtop right to bottom left to enclose and select model elements

Select the random area marker tool and /click/-drag-/click/successively to outline a random area. /2click/ to close. Use forisometric flowsheets.

[Edit][Select]:

Try Whole Network and drag to a new position (Remember you mustfinger-point and hold on an junction element but not a pipe).

4.1.3 Change Component Type

Elements on the flowsheet can be individually changed or multiple numbersof the same element can be changed to a different element provided thechange is to a component commensurate with the original elementsfunction and pipe connections.

Select any junction element and then /right click/. The pop-up menupresents the Change Component option. /click/ Change Component todisplay the available components


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/right click/ on the 40m reservoir and change it to a {Known orAssigned Flow}

Image 4.1: Change Component Dialog

Note: If you wish to retain features of the original element such as elevationthen tick the Keep all common property values box.

From the Input Inspector change its properties to a flow of 10 l/s intothe network and solve.

Repeat the exercise with the tee-junction. Note you are presentedwith a very limited choice of replacement components; iecomponents commensurate with three pipes joining. Change to aConnector.

For a pipe element a new pipe material can be selected. The Keep allcommon property values box is not active in this case. The new pipe willreflect all the properties of its default setting except length, where theoriginal length will be retained.

4.1.4 Cut/Copy/Paste

You can cut/copy/paste to the same flowsheet or to a different one(its a good idea to set the receiving flowsheet to the same zoom asthe sending one).

Mark a block of components and Copy.Use [Edit]copy; or /right click/ on flowsheet white space anduse the pop-up menus; or use the copy button.

Paste. The paste button/cursor allows you to position thepasted elements.


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4.1.5 Isometric Display

Open a new flowsheet and change the display to isometric, either fromthe Flowsheet Toolbar or via .

Experiment with laying out pipes in iso format draw a simple model. Note how the iso guidelines help you position pipes correctly.

Experiment with different line thicknesses and colours Use the Mark any Area tool to outline parts of the model. Use the Resizing Tool to change the size of elements Display element numbers and experiment with font via .

Note: font, colour, line thickness etc operate on iso, ortho and freehandflowsheet displays.

4.2 TEXT

Select the text tool from the Flowsheet Toolbar and /click/ on white space.A text box displays on the flowsheet and a text editor field is activated on theInput Inspector. Short items of text can be entered directly into the text editorfield. Longer items of text can be word processed by /clicking/ to activatethe text editor.

Write a heading on your flowsheet in the text editor selecting a different font,size and colour from the default.

Save your model with the heading.

4.3 FLYBYs

Just as element properties can be selected for fixed display on the flowsheet, thesame facility exists to display data via FlyBys.

[Options][Environment][FlyBy Options] or brings the dialog shown below. Youcan select those properties you want displayed by FlyBys.

FlyBys are toggled from the Flowsheet Toolbar and display when the cursor ishovered over an element.

allows the FlyBy display transparancy to be toggled.


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Image 4.2: FlyBy Dialog

4.4 THE DATA PALETTE

4.4.1 Results Inspector

[Options][Environment][Visible Results] or displays a dialog similar toDefaults Setting. From here you can select those results fields you wish todisplay.

4.4.2 List Inspector

The List Inspector provides a very powerful method of selecting particulargroups of elements.

The image below left shows the two List Inspector panes, the upper paneshowing tick boxes for groups of elements (mirroring the ComponentToolbar tabs) and the lower pane showing the selected groups of elements in this case the pipes and boundaries from the model 3_Reservoir.FF3.

Hover over the lower window and /right click/. Sorting and Name displayoptions are available. Hover over the upper window and /right click/ and thePop-up displays.

Selections from the list in the lower pane can be made utilising the normalWindows techniques of /click/ and /click/.


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/right click/ in theupper pane todisplay this dropdown menu

/right click/ in thelower pane todisplay this dialog.

Image 4.3: List Inspector

Notes:

1. The List Inspector is synchronised with the flowsheet so that selecteditems in the list will be highlighted on the flowsheet and vice-versa.

2. Use the List Inspector to make global updates to elements or to developfocussed reports on specific parts or elements in a model especiallyfor the development of model checking reports see Section 15.3

FluidFlow3 Training Manual Chapter 5: Element Techniques

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5.0 ELEMENT TECHNIQUES

Open your model 3_Reservoir.FF3

Elements on the flowsheet schematic can be manipulated in a number of ways to controlthe simulation. Well explore some of these in this section.

5.1 ELEMENT STATUS AND QUANTITY

All elements can be specified: On Off or Closed Ignore Pressure Loss

Consequently individual elements such as a pump can be switched off (say whensimulating one or two pumps in parallel) or whole sections of a network can beisolated by switching off (closing) a valve.

Note: the Option Ignore Pressure Loss for a pump simply removes the pump fromthe network it does not turn the pump off. If this option is selected flow may takeplace through the pump depending on system conditions.

An element quantity can be defined via the Input Inspector so that, for example,instead of showing 6 separate elbows in a pipe run, all six can be represented byone element icon.

5.2 PIPES

The Input Inspector allows for a number of choices as shown on the image below

Image 5.1: Input Inspector - Pipes


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Experiment with the various Input Inspector options for pipes, viz Geometry Database sizing and classification - Yes/No Friction model Database roughness Yes/No Roughness Scaling (note scaling really means a % reduction in pipe inner diameter

any associated change to the roughness of the pipe would need to beentered via roughness

5.3 DIRECTIONAL ELEMENTS

Some fittings are directional in that the direction of flow has to be specified.These are:

Boosters pumps and fans. Check valves. Tees, wyes and crosses (not so much to define flow direction but barrel

and branch). Controllers.

Elements need to be orientated from the Input Inspector, see the image below right.

Exercise

Add a non-return valve to the pipe leading from the 40m elevation reservoir onyour model 3_Reservoir and explore the result with the two orientation options.

Image 5.2: Input Inspector Component Orientation

Note: the red dot indicates the direction of flow or Discharge Pipe.


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5.4 JUNCTIONS

FluidFlow3s Junction dataset contains the following five types:

1. Bends or elbows2. Crosses3. Mitres4. Symmetric wyes5. Sharp edged tees

The hydraulic characteristics of the junctions are based upon four sources

Crane (Flow of Fluids Through Valves, Fitting and Pipe, CranePublication 410).

Idelchick (Handbook of Hydraulic Resistance by IE Idelchik). Miller SAE (gas flow only)

In terms of Junctions, Crane assumes that each branch is the same diameter sothat if a Crane junction is used with unequal pipe diameters joining, the calculatedhead loss may not be precise. Crane also assumes a 90 deg angle for a bend ortee.

Idelchick (Ik) allows for unequal pipe diameters joining, user defined angles anduser-specification of barrel and branch directions for tees and wyes. Idelchik alsocalculates velocity head recovery across junctions where this occurs.

Note: The orientation of tees and crosses needs to be specified via the button

For more details see Chapter 10 and Appendix Design Note 02.

Exercise

Open a new flowsheet.

Place on the flowsheet one of each of the junction icons and connect theappropriate number of pipes to each. From the Input Inspector explore thevarious junction options.

For Idelchik view the Nomenclature field for a full explanation of junctionorientation.

For junctions with more than four pipes joining you must use a {Connector NoResistance} and note that this type of junction does not calculate a pressuredrop.


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5.5 CONTROL VALVES

FluidFlow3 allows control valves (pressure reducing, pressure sustaining and flow)to be modelled. Desired flow or pressure must be specified and the software willdetermine the opening of the valve and its Cv value. If the valve cannot control tothe set values it defaults fully open and a warning is enunciated.

Hint: Before using a control valve attempt to simulate the desired conditions usingan orifice plate. The software finds the orifice plate algorithm easier to solve.Having sized an office plate it is simple to convert this to an appropriately sizedcontrol valve. For pressure control valves use a Simple Valve from the AutoComponent Tab.

Exercise

Load the example model Acrylic Acid Pumping.FF3. Solve. Review the Inputand Results Inspectors for each of the flow control valves.

Set the flowsheet visible properties for the control valves to show the followingresults

Calculated Cv Flow In Total Pressure Total Pressure Loss Out Total Pressure Valve Opening

Note: Multi-select the two control valves and then set the visible properties.

Set Warnings, Liquid Limits, Min and Max Control Valve % to 30 and 80respectively.

Increase the set flow on the upper valve to 15.3 m3/hr view the WarningsInspector. Decrease the flow to 10 m3/hr, then 5.0 m3/hr view the WarningsInspector.

FluidFlow3 Training Manual Chapter 6: Design Exercise 1

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6.0 DESIGN EXERCISE 1. METHANOL TANKER OFFLOADING Open a new flowsheet

It is required to design a system to offload methanol from a rail car. The railcar holds 30m3of methanol and an offload in a time of no more than 15 minutes per car is required. Thepreliminary design flow will therefore be 30*4 = 120 m3/hr.

The delivery line from the rail dock to the tank farm will be approx 42 m long and contains 2isolation globe valves at the pump and a non-return valve. The elevation difference from thepump sited at the rail dock to the entry nozzle at the top of the storage tank is 10m.

Lets approach the design goals in two steps.

1. We will supply the system from a {Known or Assigned Flow} boundary andsize the pipe.

2. Based on Step 1, we will select a centrifugal pump by using the calculated pressurerequired at the supply node. In this step we will also model the pump suction lineand check that NPSH requirements are met.

6.1 STEP 1

At this point you might select a saved environment or set units and defaultsspecifically for this design. Well make the following changes to our pre-sets

Set the Defaults {Known or Assigned Flow} Elevation: 0.0m

Flow Direction: Into NetworkFlow: 120m/hrTemperature: 15degFluid: MethanolFluid Type: NewtonianProperties on Flowsheet: ShowFont: DefaultProperties: As shown on Image 6.1

{Known or Assigned Pressure} Elevation: 10.0mPressure: 0.0 bargFluid: Water !!!Fluid Type: NewtonianProperties on Flowsheet: ShowFont: DefaultProperties: As shown on Image 6.1

Steel Pipe Length: 0.1m2 inch Sch 40Friction model: MoodyUse Database Roughness: Clean or newScaling 0%Heat Loss Model: IgnoreProperties on Flowsheet: Length

Units m3/hr; m fluidWarnings Pipe maximum velocity 4.0m/s.


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Explanation:

1. At the {Known or Assigned Flow} we have defined both the fluid and itstemperature. Unless we select a heat loss model for any of the elements inthe model, this temperature will propagate through the rest of the system.Therefore the physical properties of the fluid will also remain constant.

2. The {Known or Assigned Pressure} fluid definition is immaterial here, sothe default water can be left, although it might add clarity use methanol.Remember, the {Known or Assigned Pressure} is not really a tank, but anI/O node where a certain elevation and pressure is defined in this case10.0m and atmospheric.

Note: If the discharge was to two tankers at different elevations, then the fluiddefinition would have to be methanol, otherwise FluidFlow3s fluid mixingcapability could be activated with water flowing from one {Known or AssignedPressure} to another and mixing with the methanol. This concept is illustrated inChapter 8.0, Design Exercise No. 2.

3. We did not set defaults for the valves and junctions so these values will becopied from whatever was previously set. We must set their valuesaccordingly.

Build the Model

Set up the flowsheet as shown in Image 6.1, (orthogonal) by first placing the nodeson the flowsheet and then connecting pipes. Edit the pipe lengths to show the samelengths as shown.

Image 6.1: Methanol Tanker Offloading - Step 1


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Results

Calculate. A pipe warning will be enunciated (toggle the pipe warning tool on theflowsheet toolbar or view Messages). This is hardly surprising since the defaultpipe size is 2 and is clearly too small for this volume of flow.

Note: The ability to show element properties (input data or calculated results) onthe flowsheet is very powerful feature of FluidFlow3. The flowsheet updates theseproperties instantly a change is made to the flowsheet, either after data entry, unitschange or calculation. So display relevant data on your flowsheet.

Multi-select all pipes and add velocity to the flowsheet display.

View the pipe results for any pipe and observe the Exact Economic Pipe Sizerecommended by FluidFlow3. From this we can see that the Exact Economic Sizeis ~ 175mm approximately 7.

Note: The economic size is a guide for pipe sizes based on 365 operating days peryear and in this design the system will only be operated only every few weeks.Based on this information we will select a pipe size of 4. To do this, multi-select allpipes and then change the pipe size from the Input Inspector to 4.

Recalculate and the warnings will disappear. Pipe sizing is complete so we willfocus on the pressure required at the supply node in order to obtain our design flowof 120m3/h. Check in your system the pressure should be around 22.5 m fluid g.

We now have a duty point for our pump, namely 120 m3/h @ 21 m if we allow a littleextra for suction line losses.

6.2 STEP 2

At this stage you would source a suitable pump from a pump supplier, key the pumpperformance curves into FluidFlow3s database (see Chapter 7) and then amendthe model accordingly. However, in this case we will use a pump already in thedatabase.

Change the {Known or Assigned Flow} component to a centrifugal pump. Thepump will be copied from the default setting. From the Input Inspector go to theBoosters Database.

Image 6.2: Access the Booster Database


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Note the Booster Database is organised as shown:

Image 6.3: Booster Database

Sort by Manufacturer and select Centrfugal Pump. Scroll down to Peerlessand select the 6AE11.

Set the Suction lines 6. Complete the model with the methanol source being a {Known or

Assigned Pressure}. Calculate. Save the model to Methanol.FF3.


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Image 6.4: Methanol Tanker Offloading - Step 2

Comments:

1. Duty flow is greater than 120m3/hr and velocity is above our 4.0m/s maximum.2. The duty point for this pump is not particularly appropriate, operating well below

BEP. Try the same pump with the originally suggested 5 line. The pumpoperates more efficiently, but would this greater efficiently offset the additionalcost of 5 pipework and valves? Velocity and flowrate are still high.

3. Since the efficiency and NPSH curves were entered into the Pump database,the solution also shows NPSH available and required and calculated power.

4. Try a reduced pump impeller diameter with 4 pipes:

Image 6.5: Pump Impeller Diameter Change


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6.3 AUTO BOOSTER

Open Methanol.FF3.

Instead of using a {Known or Assigned Flow} for our initial determination of pipesizes we could have used an Auto Booster.

Change your pump icon to an Auto Booster:

Image 6.6: Select Auto Booster

Orientate correctly. Set the flow to 120 m3/hr. Solve and observer the calculated duty point for the pump.

FluidFlow3 Training Manual Chapter 7: Database

37

7.0 DATABASE

Open your model 3_Reservoi.FF3

FluidFlow3 comes standard with a comprehensive database comprising a number ofdatasets viz:

Thermo-physical properties of more than 1000 fluids. Pipe schedules. Equipment items (or components) such as valves, bends, pumps, control valves,

etc. Manufacturer names. and more as shown in the image below:

Image 7.1: Datasets

Component data (except pipes) in the datasets are organised by four options:

Component Kind. Manufacturer linked to the Manufacturer dataset. Material linked to the Material dataset. Application linked to the Application dataset.

These options support the future Equipment Auto Selections module.


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7.1 ADDING NEW DATA TO A DATASET

With all component datasets the method of data entry is similar.

Step 1. Select the appropriate dataset - [Database][Dataset name].Step 2. Select preferred method of organisation.

Step 3. Select sub-group such that the button becomes live.

Step 4. /click/Step 5. Enter a unique name for the component.Step 6. Enter the component data and save.

7.1.1 Adding a Valve to the Manual Valve Dataset

We will add the new gate valve shown below to the Valves dataset

Select [Datasets][Valves]. Organise by Component Kind. Highlight the Gate Valve sub-group.

Enter the name My Gate Valve

The dialog will appear as the image below:

Image 7.2a: Gate Valve Data Entry

Leave Manufacturer, Materials and Applications Unspecified but set theother options as shown.


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The Defined By field determines how the head loss characteristic for thevalve is to be determined. There are a number of options

For an explanation of the head lossoptions see Software Application Note01 in the Appendix and the HydraulicsRefresher Course.

Image 7.2b: Valve Coefficient Definitions

With Positioning allows the selected characteristic to be tabulated against% open. Then, from the Input Inspector, the valve position can be changed.

No Positioning simply allows one characteristic value to be entered (usuallyat 100% open) and this cannot be changed from the Input Inspector.

Choose Kf with positioning and select...

Enter the data as shown in the image below.

Image 7.2c: Gate Valve Data Entry

Hint: Enter all the data in one column at a time, using the down arrow key tocreate a new row for each entry. You must hit to lock in the last rownumbers.

Note the Curve Fit Type and Equation Order options. You can zoom the curve by using the left mouse button held

down then move to mark a rectangular area and when yourelease the left mouse button the chart will zoom to the selectedarea. To undo this mark a rectangular are from bottom right totop left. A right mouse held down will also let you scroll the plotarea.


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Note: Minimum and Maximum operational limits can be defined. If a modelsolves with the equipment item operating outside these limits, the elementwill flag red on the flowsheet and a message will be enunciated. This is aparticularly useful feature for pumps.

Save. Change the existing valve on the 3_Reservoir model to {My Gate Valve}. Solve the model. Experiment with different valve closures as before.

7.2 MANUFACTURERS DATASET

In the above exercise we did not specify a manufacturer for our valve. We couldhave done so via two methods:

1. From the Manufacturer field in the data entry dialog shown in Image 7.2aabove.

2. Directly into the Manufacturers dataset.

Method 1 allows for either a new manufacturer to be added or an existing one to beselected; Method 2 allows direct entry of a new manufacturer.

Hint: Manufacturer simply refers to a sub-group name. It does not have to be anactual manufacturer it could be any descriptor such as spare pumps, or projectvalves.

The Materials and Applications datasets operate in the same way.

7.3 ADDING A PUMP AND MANUFACTURER TO THE DATABASE

Create a new manufacturer called the Archimedes Pump Company Open the Manufacturers dataset. Enter Archimedes Pump Company.

Now enter the Boosters dataset and organise by Component Kind. (Wecannot organise at this time by Manufacturer because the new manufacturergroup is empty and wont display)

Select / highlight any Centrifugal Pump eg ABS

Name the pump My Pump and Change the Manufacturer to Archimedes Pump Company. Enter the data shown in the table and Image 7.3 below.


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Archimedes Pump Company: My PumpNotes:

1. Data Operating Speed andImpeller Diameter refer to theentered curves. Maximum andminimum values define the limitsof change allowed from within theInput Inspector such that theaffinity laws are applied to theentered data (but do not changeit).

2. There is no requirement toenter efficiency or NPSH data; ifthese are not entered thenFluidFlow3 simply does notcalculate these values.

3. Pump Curve Extrapolation:FluidFlow3 will attempt toextrapolate the curve to the x-axis, ie H=0. Usually pumpcurves are not given to thisextent, but FluidFlow3 must plotdata completely within the firstquadrant. Rather than letFluidFlow3 estimate the zerohead position we stronglyrecommend that you developcoordinates to the right hand sideof the curve all the way to H=0. Inthis case enter a final coordinateQ=240 m3/hr, H=0.0m.

4. Min and Max Limit: Theselimits define the desiredoperational range of the pump.FluidFlow3 may solve anywherein the first quadrant but a pumpoperating outside the set limitswill be flagged red on theflowsheet and warningenunciated.

Save

Image 7.3: Capacity Curve Data Entry


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7.4 EDITING DATA

Once data have been saved to a dataset, they can be edited or changed. Simplyopen up the particular dataset, select the component and change the data fields.

Hint: We do not recommend that you rename manufacturers, components and pipeschedules unless absolutely necessary as extant models may not be able to find thecorrect data. Record the original name in case problems arise so that you canrevert back to the original name.

7.5 PIPES DATASET

The pipes dataset is organised on the following hierarchy:

MaterialSizeSchedule or Class

You cannot add new materials, but you can add new sizes and classes.

7.5.1 Adding a New Pipe Size

If pipe material is selected from the Pipes dataset editor as shown in Image7.5a below, then a new pipe size can be added. In fact this could also be acombined size/name such as 20 inch ERW.

Image 7.4a: Pipes Dataset Editor

The hierarchy described above remains, so the next step is to add the pipe classes.


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7.5.2 Adding a New Pipe Class

The button in the Pipe Data field brings up the following Pipe Data Editordialogue where class and pipe diameter can be entered.

Image 7.4b: Pipes Dataset Editor

Notes:

1. Additional rows can be added to the Pipe Data Editor by hitting thedown-arrow key.

2. Remember its the inside diameter value that FluidFlow3 uses in itscalculation of pipe friction loss.

7.6 PIPE ROUGHNESS AND SCALING

Data entered into the pipes dataset would normally be for new pipe. In practice,pipes could have a different roughness to new conditions or be scaled. The termscaled or scaling in FluidFlow3 means a % reduction in the value of the internaldiameter entered into the pipes dataset.

Additional datasets are provided for roughness and scaling, both operating in asimilar fashion. Pipe material is selected from the drop down combo box and thenuser-defined values for roughness and scaling can be entered. These values canthen be selected from the Input Inspector as shown in the image below:


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Image 7.5: Roughness Dataset

7.6.1 Lined Pipes

Simulating lined pipes presents some problems. The material ofconstruction of a pipe is fundamental to any calculation of heat loss (see thedataset Pipe Materials Thermal Conductivity) and FluidFlow3 cannotproperly calculate heat transfer though a multi-material pipe wall.

However in terms of friction loss calculation, only the internal diameter andthe pipe wall roughness are required so this type of pipe can be simulated.Values could be entered into the Pipes dataset, for instance a concrete linedsteel pipe might be entered as follows:

Material: SteelUnique Name (size): Concrete Lined 600 mmClass: Text as appropriateInside Diameter x mm

And an appropriate roughness and description entered into the PipeRoughness Dataset...

Image 7.6: Pipe Roughness Editor


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Or they could be entered via the Input Inspector as shown in Image below...

Image 7.7 Direct Entry of Pipe Data via the Input Inspector


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8.0 DESIGN EXERCISE 2: ACETONE DELIVERY SYSTEM

Open a new flowsheet.

Design the simple pumped system shown below such that it complies with the operationalrequirements.

Figure 8.1: Acetone Delivery System

The objective is to design a system (shown above) where the pump delivers acetone at 10deg C from an underground storage sump to two header tanks. The maximum flowrate toeither tank is to be 15.0 l/s with a minimum not less than 10.0 l/s.

Supply can be to either one tank at a time or to both tanks.

We will use the previously entered pump, My Pump. Initially all pipes, suction anddischarge, are estimated to be 4 schedule 40 steel.

Design constraints are:

(1) Pump to operate within set minimum and maximum flow limits.(2) Pipe velocities not to exceed approximately 4.0m/s.

L=8.0m

El=10.0m

Globe lift check

All pipes Sch 40: 4Fluid: acetone at 10 deg C.All valves 100% openAll dimensions m

Lower Tank

Upper Tank

L=5.0m

L=0.3m

Ball Valves

L=20m L=20.0m

6 Ik Bends

L=50.0mL=0.3

L=0.3L=10.0m

Fluid Surface El= -2.0m

El=15.0m

Gate Valve

El= 2.0m

L=9.5m

Riser L=7.5m

Ground El= 0.0m

L=0.3m

El= 19.5m

Spring Loaded Global Lift Check

L=5.5m

Ground elevation 0.0m

L=2.0m


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8.1 ACETONE DESIGN - PART 1

Set the following defaultsAssigned Pressure Elevation - 0.001m

Pressure - 0.0 bar gFluid - acetoneTemperature - 10 deg C

Pipe Schedule 40, 4, L=0.001mBall Valve Crane Ball, fully open, elevation - 0.001mGate Valve Generic Miller, elevation 0.001mSpring loaded check valve Generic Globe Lift Check - elevation - 0.001mPump My Pump (previously saved see Ch 7), elevation 0.001m

Set tabular units - (3 decimal places)Flow l/sPressure m fluid g; m fluidAll other units Metric / SI

Build the model; amend all pipe lengths and node elevations. Set the fluid toacetone remember the fluid and initial temperatures are attributes of theboundaries. Solve the model and activate the Results Inspector.

Note: In this simulation we must specify acetone at both upper tanks (compareto Design Exercise No.1 where we specified the outlet fluid as water, eventhough the pumped fluid was methanol). The reason is that in this case, if wespecified water in the upper tanks, we could get fluid flow from the higher tankto the lower (density of water is greater than that of acetone), with fluid mixingoccurring at the tee junction.

Save this file as Acetone_01.FF3 to your training folder. (Remember,FluidFlow3 will add the extension .FF3)

With all pipes 4 and supply to both tanks we meet a number of problems:

Acetone Design: Part 1 ResultsCASE

STUDYSYSTEM DESIGN

PROBLEM(S)COMMENT

1 4 deliverypipesthroughout

Supply rate toeach tankoutside desiredrange.

Velocity of flow inthe 4 main linewell abovemaximum.

Pump operatingbeyond end ofset limit.

There are several options available tocontrol flow to the header tanks to withinthe desired 10.0-15.0l/s and consequentlyreduce pipe velocity and perhaps bring thepump into its desired operational range.They are:

(1) Reducing the size of the upper leveldelivery pipes downstream of the teejunction with an emphasis on achievingclose to the desired 15 l/s flowrate to bothtanks simultaneously.

(2) You could also vary the opening of themanually operated ball valves.

(3) Combination of both.

Try these experimenting with supply toeither one or two tanks.

View the Messages Inspector Save to Acetone 02.FFL


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8.2 ACETONE DESIGN - PART 2

Open your design file Acetone_01. All data should be as shown in Figure 8.1.The design has the following problems:

Supply rate to each tank outside desired range. Velocity of flow in the 4 main line well above maximum. Pump operating beyond end of set limit.

We have already experimented with reducing the pipe diameters and adjusting theball valves downstream of the tee junction but these methods do not provide thesame solution for supply to either one or both tanks. Perhaps control valves wouldbe an option? Normally, a control valve is one size smaller than the pipe into whichit is installed, so use a Keystone 3 butterfly flow control valve.

It might also be good design to increase the suction pipe diameter to one size largerthan the delivery pipe.

Acetone Design: Part 2 ResultsCASE

STUDYSYSTEM DESIGN PROBLEM(S) COMMENT

2 Increase suctionline to 6.

Replace ball valveswith Keystone 3Flow Control Valve.

Set the controlvalves to providethe desiredminimum andmaximum flowswith one or twotanks operating

Pump?

Remember - control valvesare directional, so when youreplace the ball valves withcontrol valves you MUSTset the correct orientationvia the Input Inspector.

What is the smallestpossible control valve whichsatisfies the three designrequirements, ie flow to onetank or the other or to bothtanks.

Good design would havethe FCV one size smallerthan the pipe and the FCVopen in the range say 40%to 75%. Valves arecurrently closed to about35% so there is anopportunity to use a smallercheaper valve (which wouldopen wider) and at thesame time maintain a pipeone size greater than thevalve.

Try a 2.0 inch valve with3inch lines downstream ofthe tee junction.

Check all flowcombinations.

Save this file asAcetone_03.FF3 in yourtraining folder.

FluidFlow3 Training Manual Chapter 9: Data Palette

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9.0 DATA PALETTE

Open and solve Methanol.FF3

The Data Palette comprises five Inspectors with the sixth option being a display of theprogress of the calculation. The Messages, Input, Result and Watch inspectors have beensufficiently explained in earlier chapters.

9.1 CHART INSPECTOR

The Chart Inspector graphs the hydraulic characteristic of the selected element ifappropriate. Some charting is specific to the active module, for instance Slurry or2-Phase. Well concentrate on the Pump Performance Chart shown below.

The button brings up the dialog above fromwhere the configuration of the chart can be set. Notethe tick box bottom left which will apply the settings toall equivalent elements on the same flowsheet.

The button takes you to the print capability.

The allows you to expand/contract thex-axis.

Image 9.1: Chart Inspector

FluidFlow3 Training Manual Chapter 9: Data Palette

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9.2 LIST INSPECTOR

/right click/ in the name field brings up the Pop-up dialog as shown below, enablingthe listed elements to be sorted. Sorting by Unique Name is extremely useful ifelements have been logically named. For instance, if a section of pipework is tohave its properties changed, each pipe component in that section could be giventhe same Unique Name, making it easy to multi-select.

Image 9.2: List Inspector

FluidFlow3 Training Manual Chapter 10: General Resistances and Junctions

51

10.0 GENERAL RESISTANCES AND JUNCTIONS

(See Design Notes 01 and 02)

10.1 GENERAL RESISTANCES

The Component Toolbar tab, General Resistances allows access to a number ofdifferent ways of defining the resistance of components which fall outside thegroupings of the other Component Toolbar tabs.

Some of these components are equipment- or industry-specific and their pressureloss relationship is pre-defined and selected only via the Input Inspector. Forinstance, a cyclone has a choice of four in-built methods of determining pressureloss. Other components such as a Fixed Pressure Loss or a User Defined Genericallow the user to specify or define the pressure loss relationship, again only via theInput Inspector. Filter properties can be entered only via the General Resistancesdataset.

Finally three general relationships, K, Kf and Kv are available, either via databaseentry or via the Input Inspector.

10.1.1 K Loss Coefficient Type Resistances

FluidFlow3 provides three different K methods of defining the lossrelationship for resistances. These are:

LOSS COEFF. DEFINING EQUATION COMMENTS

K dH = K (u2/2g)The head loss is defined by aconstant multiplied by the velocityhead.*This type of resistance coefficient isnot size scalable.

Kf dH = Kf fu2 / 2g

Where f is the fully turbulent frictionfactor and Kf= L/D is the equivalentlength of the resistance expressed inpipe diameters. FluidFlow3automatically determines f whenneeded and so the value that shouldbe entered into the Kf Value field isthe term L/D.

Kv

(A relationshiprather than acoefficient).

dP = (r/r)n-1(w/w)ndp

Where...dP is the pressure drop (orhead drop depending onentered units)r is densityw is mass flow refers to stored valuesn is usually 2

Defined as a flow coefficient.FluidFlow3 scales for flow changesfrom the entered conditionsaccording to a power law, normally 2.This type of resistance is not sizescalable.

Figure 10.1: Loss Coefficients


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Note: FluidFlow3 cannot accurately calculate the head loss across a fitting wherethe adjoining pipes are of unequal diameter except junctions defined by Idelchik orMiller.

Loss Coefficient K

This is the standard format for resistances such as entry and exit losses. This typeof resistance coefficient is not size scalable.

Loss Coefficient Kf

This is based on the method given in Flow of Fluids Through Valves, Resistanceand Pipes" Publication 410M, Crane. This type of resistance coefficient is sizescalable.

Loss Coefficient Kv

Data for this type of component would come from the manufacturer or possibly testresults. For a constant density liquid the relationship is equivalent HL = f(Q2), sothe Kv coefficient simply proportions the entered (database value) head lossaccording to the ratio of the calculated Q2 to the entered Q2 .

10.1.2 User Defined Resistances

Constant Head Loss Resistance

Head loss for this resistance is independent of flow and therefore pipediameter and velocity. As an example, it might be used to simulate a fixedhead loss for a filter where the condition is unknown but some loss must beincluded in the simulation.

User Defined Generic

This resistance is defined by a simple equation:

P = K + ABQn + CDQm

where the pressure and flow units, the exponents and the constants can beuser-defined.

A, B, C and D can have the following settings:

Fixed value Inlet density Inlet viscosity Inlet pressure K is a constant

with density, viscosity and pressure being determined at the time of solution.

A User Defined Generic can be useful where a set of performance data isavailable such as that shown below flow versus head loss for the spraysystem in a cooling tower. Use Excel to generate an equation of theappropriate format.


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Figure 10.2: Generation of User Defined Generic Equation in Excel

Explore the various General Resistances tab and database.


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10.2 JUNCTIONS

FluidFlow3 determines head loss across junctions based on a choice of references,viz:

Crane: Flow of Fluids Through Valves, Fittings and Pipe, CranePublication 410.

Idelchick: Handbook of Hydraulic Resistance by IE Idelchik Miller: Internal Flow Systems, 2nd Edition, DS Miller,

Pub BHRA Information Services. ISBN 0-947711-77-5 SAE: (Source unknown)

Crane assumes for a bend or tee, that each branch is the same diameter and alsoassumes a 90 deg angle. Idelchik and Miller allow for unequal pipe diametersjoining, user defined angles and user specification of barrel and branch directionsfor tees and wyes.

A bend element may have a quantity assigned to it. The correct direction of a teeor wye must be specified using the red dot indicator.

Bends

Exercise:

Clear your screen and set up a simple model just two pipes with a junctionbetween. FluidFlow3 automatically defines the junction as a bend.

Use the Input Inspector to explore the various options of Definition, r/d andQuantity

Tees and Wyes

Add a third pipe to the junction and explore the tee and wye options especiallyusing the Nomenclature Explanation fields.

Caution on the use of Idelchik tees and wyes

Flite Software recommends the use of Idelchik junctions wherever possible, butAccutech advises caution.

The Idelchik method involves a number of significant qualifications, primarily basedon the ratios of the joining pipe diameters. If a junctions diameters falls outside thisrange a warning will be enunciated. Including Idelchik or Miller junctions significantlyincreases the number of iterations to solution.

Models with a large number of Idelchik (or Miller) tees sometimes fail to solve andthis arises out of two possible causes:

1. The software has determined a flow entering one branch and leavingsymmetrically through the other two and has unsuccessfully tried to change thisto a Diverging Wye (this may be flagged if the appropriate Warning is selected).

2. The settings of branches are all incorrect based on calculated flow directions.Whenever using or changing to Idelchik tees you MUST go though the entiremodel changing the direction of the tees appropriately.


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So are the Idelchik or Miller methods worth using? The answer is yes (andespecially for gas flow), but only if the appropriate conditions apply. Compared toCrane the result will be a slightly lower head loss and this may or may not besignificant in the overall design of the system.

Note: some conditions can results in pressure gain, rather than pressure lossacross a junction.

Flow Stability Across Tees (This section is copied from Miller)

Combining flow is a relatively stable process. Velocities increase through thejunction in many combining junctions. This aids flow stability reducing the tendencyfor transient movement, growth and decay of flow separation regions.

Dividing flows can lead to large flow instabilities that have caused structural failuresof large dividing tee junctions. These instabilities are associated with changes ifflow patterns within junctions with the size and location of flow separation regionschanging as the incoming flow is biased first towards one outlet leg and then theother. Instabilities can be at a maximum at or close to typical design operatingconditions, such as a 50/50 split in a symmetrical dividing tee junction. Underconditions of violently unsteady flow, head loses across a junction may be severaltimes the predicted values.

It is recommended that when head losses after a symmetrical tee junction do notexceed the junction loss by factor of 10 and flow distribution is important asymmetrical 180 deg tee junction should not be used. Symmetrical tee junctionsare best avoided in large systems, systems with high velocities and systems withflexible pipework.

Although Miller uses the term tee in this comment, he later also refers to instabilitiesin symmetrical wye junctions so it is assumed the comments apply to both.

FluidFlow3 Training Manual Chapter 11: Pumped Systems

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11.0 PUMPED SYSTEMS

Open Acetone02.FF3

11.1 END SUCTION CENTRIFUGAL PUMPS

Data Entry:

Insufficient data defining an end-suction centrifugal pump capacity, efficiency andNPSH curves can often lead to a model failing to converge.

FluidFlow3 makes no initial predictions on flows and pressures in the system andhence during its iterations can work to the far right hand side of the pump capacitycurve. Often, this is an area where the pump is not designed to operate and wherethe manufacturer does not supply any head/flow information. But the softwareneeds information in this zone.

The screen capture below shows a typical pump capacity curve and associateddata entered into the pump dataset.

Image 11.1: Pump Data Entry

Curve coordinates have been entered from Q=0 to H=0. Even if the manufacturerdoes not provide data points to the right hand side, these should be estimated andcoordinates down to zero head entered.

Maximum and Minimum Flows:

These values must be entered and define the recommended operational limits forthe pump. If the model solves with the pump operating outside these limits thepump will be flagged red on the flowsheet and a warning will be enunciated.

Note: This warning does not indicate an error merely that the pump is operatingoutside the manufacturers or user-defined limits.


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Maximum Head at a Flow Greater than Zero:

This type of curve can cause convergence problems for simulations operating atvery low flows. Textbooks often postulate a flat system curve that then passesthrough such a pump capacity curve at two points resulting in a huntingperformance of the pump.

For such a pump curve an obvious precaution would be to set the minimum flowvalue at something greater than that associated with maximum head. Any solutionwith a lower flow than this should be carefully analysed, not only in terms of theaccuracy of FluidFlow3s solution but also in terms of proper operation of the actualpump.

Alternatively, fudge the low flow coordinates such that the pump curve always hasa negative slope and then set the minimum flowrate to a value just greater than thepoint where the coordinates have been adjusted; any solution below this valuewould then not be accurate.

The following is a guide as to how pump data should be entered into the dataset:

A reasonable number of coordinates should be included for the capacitycurve throughout the entire first quadrant (ie from Q=0 to H=0). For theefficiency and NPSH curves it is not so important to have coordinatesentirely within the first quadrant but we advise the curves should extendto the set maximum and minimum flow values if possible. Data for theNPSH curve is often very limited and it is unwise rely on anyextrapolation beyond the limit of the manufacturers data. (Note: it is notobligatory to enter the efficiency and NPSH curves).

The impeller diameter and pump speed associated with the enteredpump curve must be defined.

Maximum and minimum flows must be input. If the final calculated dutypoint is outside the specified maximum and minimum, the pump will flagred on the flowsheet and a warning will be enunciated.

If it is intended to apply the affinity laws to the entered pump curve thena maximum and minimum operating speed and maximum and minimumimpeller diameter should be entered. (If the affinity laws are not to beused then make the maximum, minimum and operating values all thesame).

Note: Extending the NPSH curve to flow values lower than those supplied on thestandard pump curve is not recommended. NPSH required can rise significantly atlow flows and the manufacturers advice should be sought for these conditions.

11.1.1 Affinity Laws

FluidFlow will allow the performance of a pump to be adjusted within amodel for changes to impeller diameter or pump speed by applying theaffinity laws.

Two fields on the Pump Data Entry window, namely Impeller Diameter andOperating Speed allow the default values (ie the values stored in thedataset) to be over-ridden. Diameter and speed changes cannot be madeoutside the maximum/minimum limits set in the stored pump curve data.


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Image 11.2: Change Pump Speed or Impeller Diameter

Display the button in either field to access the change speed/diameterdialog. The software then applies the affinity laws to the entered pump curveto account for the change in impeller diameter or pump speed. This featuredoes not change the entered pump data, just modifies it for the currentmodel simulation.

DESIGN EXERCISE 2: ACETONE DELIVERY SYSTEM PART 4

Edit My Pump to include efficiency and NPSH data as shown below.

FLOW

m3/hr

HEADm

(water)

EFFICIENCY%

NPSHm

5 6230 63 40.060 62 64.2 3.5

112 55 77.4 4.1138 50 72.4 5.8155 45 65.0 7.0

Note: Do not extrapolate the efficiency and NPSH data use only the co-ordinates supplied. Since the minimum flow data for NPSH is 60m3/hr, itwould be logical to set this as the minimum value for all charts.

CASESTUDY

SYSTEM DESIGN PROBLEM(S) COMMENT

2

(As savedin Ch 8)

Pump at default speed, fluidtemperature 10 deg C andfluid level in undergroundtank 2.0m below groundlevel.

None at this stage. Viewthe pump performance especially NPSH. Alsosince the efficiency curvehas been entered you cansee the calculated pumppower.

To view pump graphs goto Chart on the DataPalette and select chartoptions from theConfigure button.

2 Make modest changes to thepump speed and impellerdiameter.Display the FCVs% Open and Flow.

Return the pump to defaultconditions

As the pump performancechanges, so the FCVopenings changed tocompensate.

What happens when youset extremes of change tothe pump?

5 Underground tank level fallsto near empty surface level5.0m.

NPSH available now lessthan required.

Options?

6 Tank level at 2.0m belowground level buttemperature of whole systemincreases to 35 deg C

NPSH available now lessthan required.

Options?


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11.1.2 Viscosity Correction

(See Design Note 03)

FluidFlow3 will correct or adjust a pump curve (always entered for water) toaccount for loss of performance when pumping a viscous fluid. This optioncan be turned on/off from Global Settings. The correction is basedon the Hydraulics Institute Method.

Build the model shown below.

Compare the results duty flow, head, efficiency and power - with theviscosity correction on and off. Note that changes in flow and head arerelatively small but the change in efficiency with the viscosity correctionon is significant, doubling the power required.

Note: Change the fluid to water with the correction on, and you will see t

FluidFlow3

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