Engineering Projects
Case studies and project highlights from our consulting work.
Support Layout and Stress Assessment for GRE Piping: Field Inspection Insights
The installation of a new Glass Reinforced Epoxy (GRE) saltwater system at a chemical processing site required comprehensive support layout planning and stress assessment. This system included several extended piping lines, both above ground and buried, as well as multiple compact manifolds situated between tanks and pumps. The Dynaflow Research
Vibration Analysis of Hydrogen Cyanide (HCN) Line in Slug Flow Regime
A comprehensive vibration analysis was conducted on a water feed line operating in a slug flow regime. Slug flow, characterized by large intermittent fluid slugs within the pipeline, can exert significant dynamic forces on piping systems, potentially leading to structural failures. A recent leakage incident at an elbow joint highlighted
Vibration Level Assessment: Resonance Models and Fatigue Check
This case study focuses on the vibration assessment of a pentane line, specifically evaluating vibration stresses and the risk of fatigue issues at the nozzle/shell interfaces. Vibration measurement data provided by the client was analyzed. Initially, it was hypothesized that the vibration problem stemmed from a mechanical resonance phenomenon, implying
Noise and Vibration Analysis of a Metering Skid: An Acoustic and Mechanical Resonance Assessment
A gas metering skid is being designed for use in a flow station. DRG was commissioned by a client to conduct a comprehensive noise and vibration study of the metering skid to assess its vulnerability to fatigue failure. The potential for fatigue failure arises if the mechanical resonance modes of
Assessment of Vibrating Process Line: Fatigue Analysis and Recommendations
Large amplitude vibrations in a process line have resulted in damage to several pipe supports. DRG was engaged to identify the root cause of these vibrations, assess potential fatigue issues, and recommend remedial actions for the client. Analysis DRG performed a comprehensive visual inspection to determine the resonance modes being
LNG Bunkering System: Surge Analysis
Surge analysis in LNG bunkering systems is essential to ensure safe and efficient operations, particularly when fueling ferry ships. This analysis involves evaluating several worst-case scenarios to understand surge phenomena in a 600-meter long LNG bunkering line. The system utilizes a main pump and a booster pump to achieve flow,
Failure in a Branch Connection: Natural Mode Analysis
A branch connection linking to a high-pressure steam attemperator has experienced a failure, similar to a previous incident. Observations on-site indicate periodic movement of the connecting header housing equipment J-3103, suggesting a fatigue failure. The objective of this analysis is to propose a permanent solution to prevent future cracks in
Flue Gas Ducting Support Loads and Efficient Design
This project involves a feasibility study for designing a flue gas duct in a carbon capture and storage plant. The scope includes conceptualizing two large-diameter, thin-walled ducts that connect a heat exchanger to two boiler units. One of these ducts spans over an existing plant section, necessitating careful consideration of
Fiberglass Fire Water System: Stress Analysis
At an oil refinery plant in Saudi Arabia, a fiberglass-reinforced plastic (FRP) pipe fire water system has been installed, predominantly buried underground. Since its installation, the system has experienced several failures. DRG was tasked with conducting a comprehensive pipe stress analysis to assess the system’s integrity. This analysis focused on
Floating Head Heat Exchanger Fatigue Analysis
In a new industrial process, an existing floating head heat exchanger is being repurposed. The operational conditions involve cyclic loading, which were not originally considered during its design phase. To evaluate the impact of these cyclic loads on the heat exchanger, Dynaflow Research Group conducted a comprehensive fatigue analysis. Analysis
Gas Compressor Station Assessment
A gas compressor station, comprising five similar compressor units connected by an inlet and outlet header, is planned for offshore construction in Mexico. Each unit features three compressor stages that elevate the gas pressure from ambient levels to 95 bar. This substantial pressure increase is accompanied by a significant temperature
Pipe Stress Analysis for an Oil and Gas Extraction Facility
Dynaflow Research Group (DRG) conducted comprehensive pipe stress analyses for a large oil and gas extraction facility. This facility comprises three onshore flow stations, one offshore flow station, and a gas export compressor station. Crude oil and gas are transported from the wells to the flow stations, where the crude
Assessment of a Jetty Pipeline: Combined Pressure Surge and Dynamic Stress Analysis
A steel pipeline was under construction for offloading naphtha from ships arriving at a jetty. A surge analysis was conducted to evaluate the pipeline’s capability under various transient upset scenarios. Following this, a dynamic stress and flexibility study was performed based on the calculated pressure surges. Analysis A transient one-dimensional
Fire Water System on an LNG Plant: Stress and Surge Analysis
A comprehensive stress and surge analysis was performed for the firewater piping system of an LNG plant located in South America. The system, constructed using Glassfiber Reinforced Epoxy (GRE) pipes, underwent a dynamic response analysis to account for the largest and most critical unbalanced forces. Surge Analysis The existing firewater
Detailed Fatigue Analysis of an 8-Pass U-Tube Heat Exchanger in Refinery Operations
This case study examines the detailed fatigue stress analysis conducted on a heat exchanger used to heat Polyol before it entered a refinery reactor. The complex 8-pass, U-tube configuration with a flanged stationary tube sheet required thorough investigation to ensure operational integrity and longevity. Analysis Methodology Engineers identified and analyzed
Stress Analysis Review of Critical Fire Water System Sections
In this case study, a number of critical sections in an already installed fire water system were selected for review. At the time of the analysis, earlier on-site interventions had already been made, motivated by pipe failures. The analysis aimed to determine if additional interventions were necessary. Analysis Based on
Stress Analysis of a GRE Firewater Piping System
This case study describes the stress analysis performed on a firewater piping system located in the Middle East. The system was constructed using Glassfier Reinforced Epoxy (GRE) pipes. Most of the piping was buried underground and included several connections to above-ground steel piping, fire hydrants, and similar equipment. Analysis The
Mechanical Response of a Flow Station: Pulsation Analysis
Introduction At a Flow Station in Nigeria, vibration issues were observed in the suction and discharge headers, as well as the pump recirculation line. To address these concerns and identify potential underlying issues, DRG conducted a comprehensive pulsation analysis combined with a mechanical response assessment. Analysis A stress model was
Pulsation and Vibration Analysis of a Gas Compression Station
Introduction In this case study, we explored the pulsation and vibration phenomena at a gas compression station equipped with four centrifugal compressors. These compressors generate flow pulsations due to the action of the impellors, which can excite the system’s acoustic and mechanical natural frequencies. To understand and evaluate the system’s
Dynamic Stress And Vibration Analysis For A Gasoil Hydrofiner
Introduction During the start-up and normal operation phases of a Gasoil Hydrofiner system, significant vibrations were observed in its piping. These vibrations, described as “large amplitude,” were particularly concerning. The unit’s piping was divided across four separate pipelines. Analysis Upon examining the system under various process conditions, it was determined
Mitigating Pressure Surge Impact In A Process Line At BASF Antwerp
Pressure surges ocurr in piping systems whenever there are sudden changes in flow resistance from steady operation. Surges can cause significant damage, also at locations far removed from where they are initiated. For large or complex piping systems, this can make their impact challenging to predict without specialist analysis. Dynaflow