Engineering Projects
Case studies and project highlights from our consulting work.
Vibration Analysis of Ultra-High-Pressure Pipework in Offshore Platform Design
The offshore oil and gas industry encounters distinctive challenges in managing high-pressure piping systems, where the repercussions of failure can be dire. Therefore, ensuring the structural integrity of these piping systems is paramount. This case study examines a critical investigation conducted during the Detailed Design Phase of an Offshore Topside
Asset Integrity Review of Fiberglass Piping in Cooling Water Network
A petrochemical facility has been experiencing recurring failures in its fiberglass piping Cooling Water (CW) network. With seven failures reported up to 2014 and a recent failure in November 2023, the integrity of the system has come under scrutiny. As the fiberglass piping approaches its 20-year design lifetime, a comprehensive
Surge Analysis of a Fiberglass Gas Pipeline
A fiberglass gas pipeline is being implemented to supply gas from a compressor station to a delivery point. As the pipeline approaches completion, ensuring its operational safety and integrity is paramount. This case study examines the surge analysis conducted on the buried portion of the pipeline to identify potential vulnerabilities
Design Review of Cooling Water Systems for Ammonia Plant
An ammonia plant in Australia has experienced recurring failures in its cooling water systems since its commissioning in the mid-2000s. The plant utilizes two primary cooling systems: a Sea Cooling Water (SCW) system and a Fresh Cooling Water (FCW) system. The SCW system, with a high capacity, consists of multiple
Fatigue Analysis of Industrial Pressure Vessel
This case study examines the structural integrity of an industrial pressure vessel subjected to cyclic thermal and pressure loading. In processes where such vessels experience significant temperature and pressure fluctuations, ensuring the longevity and safety of these critical components is paramount. The primary objective of this study is to assess
Thermal Stress Analysis of Air Cooler Heat Exchanger Header Box
This case study examines the structural integrity of header boxes in an industrial air cooler heat exchanger subjected to cyclic thermal loading and static pressure. In processes where heat exchangers experience significant temperature fluctuations, ensuring the longevity and safety of critical components is paramount. The primary objective of this study
Pulsation and Vibration Analysis of FPSO Compressor System
Floating Production Storage and Offloading (FPSO) units play a crucial role in offshore oil and gas production. A critical component of these systems is the compressor skid, which compresses natural gas for processing or export. This case study focuses on the pulsation and vibration analysis of a three-stage reciprocating compressor
Pulsation Analysis and Optimization of a Compressor System
This case study examines a reciprocating compressor system operated by a leading energy company, used for compressing natural gas. The system consists of three identical compressor units, each with two stages (suction and discharge pulsation suppression devices and connected piping), supplying gas to a common header. This system had been
Mitigating Water Hammer Effects in Jetty Fire Protection Systems
This case study examines the cooling water and foam systems located in two jetties (Jetty A and Jetty B) of a major industrial facility. These systems, critical for fire protection, have experienced significant issues related to water hammer effects and structural integrity. The primary objectives of this study are to
Stress and surge analysis on the GRE seawater cooling piping for an ammonia plant
The client is operating multiple ammonia plants with similar cooling water systems made of GRE. Last year, failures were discovered in buried GRE components—specifically, an elbow and a tee—at one of the older plants. A surge analysis conducted by Dynaflow Research Group revealed that these failures were due to an
Surge analysis for firewater system for Green Hydrogen Facility
A new firewater (FW) system is being designed for a Green Hydrogen Elements facility. The plant spans a large area of approx. 2 x 1.5 km and contains multiple critical areas. The piping material is Fiber Reinforced Plastic (FRP). The main firewater ring is of DN250 and DN300 piping. The
Surge and Stress Analysis for a Firewater System
A client designed a foam piping system that covers the three tanks in a tank pit in the harbor. The firewater system is directly connected to the general water supply. The main pipeline passes through the foam house where the water is mixed with foam. A manifold divides the mixture
Pulsation damper sizing according to API 619
A manufacturer of pulsation dampers requested Dynaflow Research Group to verify the performance of one of its discharge silencer designs in combination with a double rotary lobe gas blower by means of a pulsation study. The scope of the study consisted of a connecting straight pipe spool and the silencer
Fatigue Analysis For A Reactor Feed Pressurization Drum
A fatigue analysis has been done for a reactor feed pressurization drum. The vessel operates under cyclic pressure ranging from 25 psig to 200 psig (1.7 – 13.8 bar), with a design life of more than 5 million cycles. Additionally, it is subjected to 200 full-range cycles from atmospheric pressure
GRE Fire Water Header on a Jetty: Static Stress and Seismic Load Analysis
A Glass Reinforced Epoxy (GRE) fire water header, installed on a Liquefied Natural Gas (LNG) jetty, comprises DN700 pipes and is subjected to seismic accelerations. Due to the jetty’s structure, the seismic accelerations provided by the client vary significantly along its length. The fire water header must be evaluated for
Seawater Supply Header: Static Stress Analysis
The above-ground seawater supply header is designed to transport seawater from two tie-ins in a discharge manifold of the seawater pumps to AGA. A comprehensive static stress analysis was necessary to determine the stress levels within the Glass Reinforced Epoxy (GRE) line. Additionally, it was crucial to define a support
Incident Analysis for Plastically Deformed Line Due to Settlement
At an LNG terminal, an unexpected settlement of 12 inches of soil, containing several sections of Vacuum Insulated Piping (VIP), occurred. Because the above-ground pipe supports were unaffected by the settlement, the differential displacement between the above-ground supports and the underground soil resulted in plastic deformation of some of the
Verification of a Continuous Steam Generation System (SGS): Static Stress Assessment
This case study explores the static stress assessment of a continuous steam generation system (SGS) using finite element method analysis. The focus is on a small-diameter plant that utilizes molten salt to generate steam in a heat exchanger at a solar plant facility. The plant includes four sequential components: an
Gasholder Sizing Review: An Analytical Case Study
This case study presents a comprehensive review of gasholder sizing within a cokes gas network. The primary objective is to evaluate the impact of adjusting the gasholder size on reducing annual flaring volumes and providing a buffer for short-term discrepancies between cokes gas production and consumption. The study explores various
Sulphur Recovery Burners Assessment: Stress Analysis
DRG was engaged to conduct a stress analysis for two sulphur recovery burners, adhering to ASME VIII Division 1 Boiler and Pressure Vessel Code. This analysis involved traditional Division 1 calculations complemented by Finite Element Analysis (FEA) to evaluate the impact of nozzle loads on critical junctions. Additionally, an assessment
Finite Element Analysis of Filament Wound Pipe Coupler
This case study focuses on the finite element analysis (FEA) conducted for a filament wound coupler designed for 42-inch centrifugal cast fiberglass pipes. The objective was to evaluate the performance of the fiberglass coupler under various conditions to ensure it meets the required specifications. Analysis The filament wound couplers (FWC)