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Chemical & Process

Our comprehensive simulation capabilities include pressure vessel analysis and fluid flow troubleshooting of process equipment, helping clients determine structural integrity, improve efficiency, increase throughput and reduce downtime. Our  complementary technical safety and reliability services have been engaged throughout the world by chemical, LNG, CHP and other processing plants.

The integrity of process equipment can be assessed by our experienced structural mechanics engineers or through the supply of Ansys software and training. Projects have included pressure vessel assessment to PD5500 / ASME VIII Div 2 and thermal & dynamic pipe stressing, with typical deliverables involving stress linearisation, analysis-to-code and fatigue checks. We also have specialised fracture mechanics capabilities.

Steam pipe/branch intersection analysis including weld details
Steam pipe/branch intersection analysis including weld details
Courtesy: Micro Matic Ltd
Structural analysis of tap and valve (Courtesy: Micro Matic Ltd)
FEA of gas holder (Courtesy: Motherwell Bridge Ltd Clayton Walker Gasholders)
FEA of gas holder (Courtesy: Motherwell Bridge Ltd Clayton Walker Gasholders)

 

Safety assessment, standards compliance, troubleshooting and up-scaling of capacity is also supported by computational fluid dynamics (CFD). We make extensive use of industy-leading Ansys CFX / FLUENT simulation software to help process engineers reduce energy consumption,  increase plant efficiency and understand the implications of changes in scale. In particular, we have expertise in pumps, valve & seal performance  and mixing & reactor design.

Industrial Process Mixing (Courtesy: Fillworth (UK) Ltd)
Mixing simulation (Courtesy: Fillworth (UK) Ltd)
Courtesy: Chembridge Technologies Ltd
Cyclone analysis (Courtesy: Chembridge Technologies Ltd)

 

Our fluid dynamics team have also undertaken projects to simulate transient thermal-based manufacturing processes.

Modelling the infra-red pre-heating stage of coating curing (Courtesy: Glasscoat International Ltd)
Modelling the infra-red pre-heating stage of coating curing (Courtesy: Glasscoat International Ltd)

 

In water and waste water applications, we use CFD simulation to match retention, mixing, reaction or settling time requirements to actual residence time distribution, with significant experience in UV disinfection units.

CFD study into plant treatment and sewage
CFD study into plant treatment and sewage

 

Seawater filtration investigation including vortex-shedding prediction (Courtesy: MAHLE Industrial Filtration UK Ltd)
Seawater filtration investigation including vortex-shedding prediction (Courtesy: MAHLE Industrial Filtration UK Ltd)

Plant-level flow characterisation and equipment selection decisions, including the diagnosis of under-performing units and evaluation of alternative new or retrofits designs, can often be tackled most effectively using 1D flow models. Our Flownex thermo-fluid software is able to account for large fluid ranges including two-phase, slurries, gasses, liquids and gas mixtures, ideal for boiler, pipe/duct network, pump/compressor and even SCADA systems and control design. Integrated with 3D CFD as appropriate, we can provide process and equipment design engineers with both software tools and insight at all levels of operation.

flownex-process-industry

Through an experienced team of safety consultants, we have supported companies with IEC 61511 functional safety standards for more than 20 years. LOPA and SIL assessments, HAZOP chairing and Safety File compilation activities are undertaken while a wide range of training courses in Safety Instrumented Systems (SIS), Alarm Systems Management and specific topics are delivered.

We have considerable expertise and experience in providing safety consulting services at  gas storage sites for over a decade including Avonmouth, Glenmavis, Kirriemuir, Partington and Grain LNG. Our assignments have covered every aspect of process safety including work on construction projects.

Safety File written for 45MW combined heat and power site (Courtesy: SSE)
Safety File for 45MW combined heat and power site (Courtesy: SSE)

 

RAMS Analysis, including FMECAs, is offered through our reliability services team to identify potential system failures and help optimise production throughput.

Appropriate ReliaSoft Synthesis software tools, used by companies such as Dow, Dupont and Shell Chemicals, can also be installed at a client’s site with dedicated training. This enables process, quality and maintenance engineers to:

  • Effectively capture and organize plant-specific data that reflect the actual equipment failure frequencies and maintenance practices used to quantify the reliability of components and systems.
  • Generate a well-defined maintenance plan rather than an equipment failure-driven breakdown maintenance plan to reduce costs, increase operational availability and improve inventory control.

Clients

We have supplied software, training and consulting services to over 120 operators & product development companies, including: 

  • ABB
  • Alstom
  • AMEC
  • atg UV Technology
  • Centrica
  • Dragon LNG
  • Dow Chemicals
  • Edincare Pumped Drainage Systems
  • EDF Energy
  • Fillworth (UK) Ltd
  • Fluor
  • Givaudan UK Ltd
  • Glasscoat International
  • Health & Safety Executive (HSE)
  • Hydro Polymers
  • ITM Power
  • Johnson Matthey
  • K Home International
  • Micromatic
  • N G Bailey
  • National Power
  • Northern Gas Networks Ltd
  • Northvale Korting
  • PowerGen
  • Roche Chemicals
  • Scottish & Southern Energy (SSE)
  • Siemens Industrial Turbomachinery
  • United Utilities Water
  • Worley Parsons

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