Optimising the planning of piping systems using CAE


Ulrich Feldhaus on how computer-aided engineering (CAE) programs allow reliability planning to be enhanced significantly.


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or complex chemical plants to survive in an extremely competitive market, failures can be the difference between profit and loss, or in the worst case an environmental disaster. Obtaining reliable statements on the behaviour of a plant requires


comprehensive and accurate information. To achieve this level of understanding, the use of computer-aided engineering (CAE) is continually increasing. The term ‘large-scale plant’ has changed its meaning over


the years. Traditionally methanol production would have a daily production rate of 2000 tons per day, today the production rate is typically 5000 tons per day and some up to a capacity of 10 000. The challenge is not only the rapidly increasing production rate for engineering departments, but the knowledge of how to get there. More and more often multi-stranded plants are substituted by single-stranded production lines. In such cases, faults can impact on the whole plant, therefore high reliability of processes is absolutely necessary. One of the enterprises that has a central position in the


market is the Frankfurt, Germany- based Lurgi GmbH. The company which employs 1450 people worldwide, 750 of them


16 www.engineerlive.com


in Germany, is engaged in the construction of plants for the production of petrochemical intermediates and final products as well as synthetic fuels and oleo chemistry. One of the main fields of activity for plants is gas production and treatment. Lurgi itself does not have a production line, but orders are given to contractors.


Simulation is essential Process technology requires highly accurate planning and outstanding engineering. The increasing complexities, even for experienced engineers, often mean experience alone is not enough for an efficient and stable solution. To simulate and analyse models which are unable to be


calculated manually, computer based simulation programs are often being used. Computer aided engineering (CAE) programs allow reliability planning to be enhanced significantly. Failures can be avoided or corrected before they cost additional time and money. The list of computational fluid dynamics (CFD) applications


used is comprehensive, including FEM analysis (Ansys) and process simulation (Aspen) as well as 3D CFD programs


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