Advanced Engineering Solutions for the Chemical & Process Industry • Dynaflow Research Group

Dynaflow provides advanced fluid flow and structural analysis services that directly address the challenges faced by chemical and process industry operations. Facilities in this sector must reliably manage complex fluid behaviors, prevent equipment failures, optimize processes, and ensure compliance with rigorous safety standards.

Our solutions enable chemical plants, storage terminals, processing units, and related facilities to optimize fluid flow, reduce operational risks, minimize energy consumption, and significantly improve overall asset integrity. Leveraging extensive industry experience and advanced analytical tools—including BOSfluids, BOSpulse, ANSYS, OpenFOAM, HELYX, and structural analysis software—we help clients optimize processes, enhance safety, and comply with stringent industry standards such as ASME Boiler and Pressure Vessel Code, API standards, ISO guidelines, and other relevant international codes.

Addressing Industry Challenges

The chemical industry is a cornerstone of the global economy, responsible for producing a wide array of commodity chemicals essential for various sectors. From petrochemicals and polymers to pesticides and pharmaceuticals, the complexity of chemical production necessitates sophisticated piping systems for transporting raw materials and connecting equipment throughout the process.

At Dynaflow, we understand the diverse challenges faced by the chemical sector including:

SOLUTIONS

Process Design and Optimization

In chemical processing facilities, efficient and optimized equipment design is critical to achieving consistent product quality and minimizing operational costs. Typical challenges include poor mixing, uneven fluid distribution, bottlenecks, and excessive energy consumption.

Computational Fluid Dynamics

Dynaflow utilizes advanced CFD simulations to optimize fluid flow within storage tanks, pipelines, mixers, reactors, separators, and loading/unloading systems. Our expertise ensures that fluids behave as intended—improving mixing, reducing energy consumption, and enhancing overall operational efficiency. We have successfully conducted CFD analyses for a wide range of chemical processing equipment, ensuring consistent product quality, reducing bottlenecks, and lowering operational costs.

Pulsation Analysis

Pulsations from pumps and compressors can lead to excessive vibrations and premature equipment failure. Dynaflow performs detailed pulsation studies using our specialized software (BOSpulse) to accurately predict and mitigate harmful pulsations in fluid transfer systems. By recommending practical solutions, clients can reduce equipment stress, extend asset life, and improve overall reliability of chemical process operations.

Finite Element Analysis

Through structural simulations using proven FEA methods, Dynaflow helps chemical plants optimize the design of critical components such as storage tanks, piping systems, pressure vessels, and support structures. Our FEA solutions ensure structural integrity, verify compliance with industry standards (including ASME Section VIII Div. 1 & 2, API 653, EN 13445, and other relevant codes), optimize material usage, and reliably predict equipment behavior under various operational conditions, ultimately reducing costs and improving asset longevity.

Safety Systems and Risk Management

Chemical plants manage hazardous materials at high pressures and temperatures, making robust safety systems essential. Challenges include pressure surges (water hammer), pulsation-induced vibrations, transient flow events, and equipment failures that can lead to safety incidents and costly downtime.

Surge and Waterhammer Analysis

Pressure surges and waterhammer events in pipelines can cause catastrophic equipment failure and safety hazards. Dynaflow’s surge analyses (using BOSfluids) identify scenarios that lead to pressure transients, enabling the implementation of effective surge protection measures. By simulating rapid valve closures, pump trips, and other transient events, we help clients ensure safe operations, protect equipment integrity, and comply with industry safety requirements.

Vibration Analysis

Excessive vibrations in chemical process equipment—including compressors, pumps, and piping systems—can lead to fatigue failures and unsafe conditions. Dynaflow provides comprehensive vibration analyses to identify vibration sources, assess severity, and propose effective mitigation strategies. Our services help clients proactively manage risks, reduce maintenance costs, and significantly improve operational reliability and safety.

Root Cause Analysis for Failures

Dynaflow conducts detailed root cause analyses following equipment failures or operational incidents. By systematically investigating incidents using our expertise in fluid dynamics, structural mechanics, and failure modes, we accurately pinpoint underlying issues and recommend practical and effective corrective actions. Our RCA services help chemical facilities prevent issue recurrence, improve safety practices, and enhance overall system reliability.

Quality Control and Asset Integrity

Maintaining long-term asset reliability and integrity is essential to chemical industry operations. Equipment such as pipelines, storage tanks, reactors, and pressure vessels are frequently exposed to cyclic loads, vibrations, and corrosive environments, resulting in fatigue-related failures and structural deterioration over time.

Fatigue Analysis

Fatigue failures represent a significant risk for chemical processing equipment exposed to cyclic loading or pulsating flow. Dynaflow provides thorough fatigue assessments to evaluate equipment lifespan, identify vulnerable components, and recommend targeted inspection and maintenance strategies. Our fatigue studies help clients proactively address structural integrity concerns, optimize maintenance schedules, reduce downtime, and prolong asset life.