INDUSTRY

FOSSIL FUEL POWER GENERATION

Fossil Fuels still play an important role in power generation around the world, so energy producers are being tasked with reducing emissions and increasing efficiency. System-level thermal-fluid simulation with Flownex should be one of the tools engineers use to upgrade and improve their plants. 

OVERVIEW

Fossil Fuel power generation involves a myriad of interconnected thermal-fluid systems, from cooling to boilers, and from feedwater to steam turbines.  Flownex’s broad list of capabilities, speed, and ease of use make it uniquely qualified to model both subsystems and the entire plant. 

Typical uses include:

  • ANALYSIS
    • Simulation.
    • Performance assessment
    • Modification assessment
    • Fault root cause assessment
  • DESIGN
    • System sizing
    • Component sizing
    • Determining operating ranges
    • Flow, temperature, pressure, power consumption, etc.
    • Testing of control approaches
  •  
  • TRAINING
    • System behavior examination
    • Performing basic flow and
      heat transfer calculations
    • Thermo hydraulic principles
      and properties referencing

POWER GENERATION PLANTS

Every system in your plan has a unique set of thermal-fluid simulation needs. That is why engineers use Flownex to model each subsystem with the focus it needs. 

Typical applications include:

FEED WATER

  • Pipeline, valve and pump sizing
  • Cavitation, flashing and condensing detection
  • Pump performance and NPSH
  • Feedwater heater performance and tube leaks
  • Flash tank behavior

COOLING WATER CIRCUITS

  • Pipeline, valve and pump sizing
  • Water hammer
  • Cooling tower response
  • Heat exchanger sizing
  • Water reticulation flow balancing & energy efficiency

ASH SLURRY

  • Pump and pipe sizing
  • Plant expansion
  • Slurry settling and blockage

CONDENSERS

  • Air leak detection
  • Condenser level following
  • Wet and dry condenser heat exchange

BOILER STEAM SYSTEMS

  • Once-through and reheat boilers
  • Temperature calculation an change rates
  • Boiling stability & boiling regime examination
  • Detection of boiling oscillations (Ledinegg,
    density wave, pressure drop-type)
  • Recirculation rate and steam production
  • Natural circulation boiler
  • Attemperation system.
    Dry out prediction
  • Load changes

STEAM TURBINE & SUPPORTING SYSTEMS

  • Start-up, shutdown, and load following operation
  • Turbine trip control
  • Gland steam systems
  • Lubrication systems
  • Generator hydrogen and lubrication systems

COMBINED CYCLE PLANTS

Many facilities are combining multiple ways to generate power into a single plant. Flownex’s flexibility and large component library make it easy to balance often conflicting needs from each part of your system. 

Typical applications include:

  • High-level analysis and design of the complete
  • Combined thermodynamic cycle
  • Transient analysis of load change scenarios
  • Cycle efficiency analysis under different
    ambient conditions
  • Root cause analysis for fault finding

BOILER AUXILIARY SYSTEMS

Flownex helps engineers focus beyond the core systems to get efficiency and reliability improvements out of supporting systems like the boiler auxiliary systems.  

Key uses include:

  • Start-up fuel oil or gas systems
    • Flow balancing in branching networks
    • Pipe heat loss estimation
    • Pump sizing and viscosity adjustment
    • Control philosophy testing
    • Pump/pipe/injector matching
  • Draught group/Flue gas systems:
    • Calculation of ID or PA fan capacity margin as a function of loss characteristics
    • Pulverisers
    • Air heater seal leakage
    • Flue gas ducts
    • Precipitators
    • Flow regulator vanes
    • Flue gas desulphurization units (FGD)

HEAT RECOVERY STEAM GENERATOR & BOILER SIMULATIONS

One way that plants are increasing their efficiency and decreasing their environmental impact is through the use of heat recovery systems.  Flownex is the ideal tool for balancing such systems and realizing the full potential of your facility. 

Typical applications include:

STEADY STATE DESIGN

  • Analysis of natural circulation boiling sections
  • Modeling and design of the heat transfer between the gas and steam side of a heat exchanger
  • Modeling of the complete system, including superheaters, economizers, evaporators, pumps, turbines, etc
  • Adaptable modeling approach according to the required level of detail
  • Assists in proper and economical
    design for the expected operational
    conditions
 

TRANSIENT ANALYSIS

  • Determine rates of change in material temperatures
  • Evaluate control philosophy
  • Determine plant power ramp rates
  • Detection of unwanted operating
    conditions involving:
    • Boiling oscillations.
      Departure of Nucleate Boiling (DNB)
    • Evaluation of off-design
      or accident scenarios
  • Evaluation of temperature gradient during start-up
  • Evaluation of start-up, shut down and load changes
  • Flow stability analysis
  • Flow distribution
  • Balancing of flow in
    parallel paths

Testimonials

“Engineering productivity for the design and analysis of complex thermofluid systems such as those found in large coal-fired power plants is vastly improved by modeling in Flownex®. In addition, the system knowledge and understanding gained by the modeler is invaluable in subsequent activities. “

– Gary de Klerk, Pr. Eng.
   Chief Engineer, Plant engineer
   Turbine Process Group Technology
   ESKOM

Meet and exceed the unique requirements of fossil fuel power generation with PADT and Flownex

Getting the most out of fossil fuels as a power source and reducing the impact on the environment is a difficult and serious engineering problem. PADT has the experience, and Flownex has the capability to provide a powerful simulation platform to meet those goals. 

If you are ready to make Flownex part of your simulation workflow, reach out today at info@padtinc.com 

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