Design PEL FLONET. User Guide 3BGB D0051

Transcription

1 IT Design PEL FLONET User Guide 3BGB D0051

2 About this document This guide is designed to assist the user in becoming quickly familiar with the capabilities of FLONET, its interface and how the program is used. It is valid for software releases up to and including version It has been produced to the recommendations of British Standard BS7649 Guide to the design and preparation of documentation for users of application software. Trademarks All trademarks acknowledged. Industrial IT Enabled This product has been certified by ABB Group as Industrial IT Enabled TM Information Level. All product information is supplied in interactive electronic format, based on ABB Aspect Object TM technology. The Industrial IT commitment from ABB ensures that every enterprise building block is equipped with the integral tools necessary to install, operate, and maintain it efficiently throughout the product lifecycle. Contacting PEL Support Services This program is developed, maintained and supported by PEL Support Services, ABB. We run a Hotline telephone and service to answer any queries about FLONET. Please let us have any suggestions on how you feel we could improve FLONET. You can contact us by any of the following routes: By Telephone: ++44 (0) By Fax: ++44 (0) By pel.support@gb.abb.com By Post: PEL Support Services ABB Ltd. Daresbury Park Daresbury Warrington Cheshire WA4 4BT United Kingdom. Owner: M. G. Pass, ABB. Approved By: M. G. Pass, ABB. Document Version / Issue Date: Version 1.2 / 10 October 2002 Last Amended Date: 10 October 2002 Last Amended By: M. G. Pass, ABB. Page 2 of 55 FLONET User Guide

3 ABB 2001 No part of this publication may be reproduced, transmitted, transcribed or stored in any retrieval system or translated into any human or computer language without the prior written permission of ABB. FLONET User Guide Page 3 of 55

4 Change history This table records the changes made to each new revision of this document. Changes to approved issues are indicated by a double revision bar on the outer margin next to the text. This is an example. Revision Date Description of change April 2000 First Approved Issue March 2001 Second Approved Issue comprising the following: New: ABB logo added. Amended: Section 2.8 (FLONET Toolbar) format revised October 2002 Third Approved Issue comprising the following: Amended: Industrial IT logo & paragraph added, Eutech removed, Front page modified. Page 4 of 55 FLONET User Guide

5 Contents 1. FLONET User Guide Introduction FLONET Network Properties FLONET Calculation Assumptions FLONET Network Configurations About this Guide The FLONET User Interface The FLONET start up screen The Piping Data Editor Piping Data Editor Autocomplete feature The Node Conditions Editor Flow Calculation Mode Pressure Calculation Mode Additional information on using the Node Conditions Editor Mixed flow and pressure calculations Initial Estimates External and Pendant Nodes The Pump Data Editor The Physical Properties Editor Handling Calculation Results Print Current Results Save Current Results Show Current Results Create a Report using Input and Results Data FLONET Menus File Menu Edit Menu Tools Menu Pipe Roughness Calculator K-value Calculator Pipe Inner Diameter Calculator Options menu Change Units Calculation Options Statistics Window menu Help menu The FLONET Toolbar FLONET Tutorial General Solving the Network Accessing FLONET Entering Data in the Piping Data Editor Defining the Inlet and Exit pressures and the direction of flow Defining the Pump Characteristics Defining Physical Properties Calculating the Network Solution Viewing Results Saving the Input file Saving Results Reports FLONET User Guide Page 5 of 55

6 Printing Results and Creating Reports Printing Results Creating a Report using Input and Results Data Tables Table 1 The FLONET Toolbar...33 Table 2 Values for tutorial example...35 Figures Figure 1 FLONET Start up screen showing Piping Data Editor...10 Figure 2 Piping Data Editor...11 Figure 3 Flow Calculation mode...13 Figure 4 Pressure Calculation mode...14 Figure 5 Pump Data Editor...17 Figure 6 Physical Properties Editor...18 Figure 7 Show Current Results...19 Figure 8 Results Report Generator...20 Figure 9 Pipe Roughness Calculator dialogue...23 Figure 10 Fittings Loss (K-value) Calculator dialogue...24 Figure 11 Pipe Inner Diameter Calculator dialogue...27 Figure 12 Set Network Units dialogue...28 Figure 13 The Calculations Option dialogue...29 Figure 14 Statistics dialogue...31 Figure 15 Node Diagram for FLONET tutorial example...34 Figure 16 FLONET tutorial example Pump Curve Graph...35 Figure 17 Piping Data Editor showing Pipe Inner Diameter Calculator selected...36 Figure 18 Pipe Inner Diameter Calculator dialogue selected...37 Figure 19 Pipe Roughness Calculator dialogue selected...37 Figure 20 Fittings Loss Calculator showing Bends dialogue selected...38 Figure 21 Fittings Loss Calculator showing Tee Junctions dialogue selected...38 Figure 22 Fittings Loss Calculator showing Summary tab selected...39 Figure 23 Completed Piping Data Editor...39 Figure 24 Node Conditions Editor selected...40 Figure 25 Pump Data Editor selected...41 Figure 26 Physical Properties Editor selected...42 Figure 27 Results of Calculation window...42 Figure 28 Viewing results of Selected Lines...43 Figure 29 Synchronise Results with Piping data view...43 Figure 30 Save Results dialogue...44 Figure 31 Results Report Generator showing columns selected...46 Figure 32 Choosing a Fluid Flow Program...52 Appendices Appendix A Creating a Physical Properties.FPF file...48 Appendix B In-cell Units Conversion...50 Appendix C Choosing a Fluid Flow Program...51 Appendix D Troubleshooting...53 Page 6 of 55 FLONET User Guide

7 FLONET User Guide Page 7 of 55

8 1. FLONET User Guide 1.1. Introduction FLONET is used to calculate pressure and flow data in liquid or low pressure gas networks where manual calculations would be too time consuming or impractical. It also enables the user to change parameters in the system (for example, the position of a control valve) and immediately see the effect on the network. Note. For high pressure gases use ADRIAN or PIPER. Use PIPER for liquid phase systems. FLONET performs two types of calculation: Pressure mode Flow mode Given the flows at the input and output nodes and one pressure in the system FLONET calculates all other flows and pressures. Given the pressures and flow direction at the input and output nodes FLONET calculates all the other flows and pressures. In this mode expert FLONET users can also use it to calculate systems given other valid combinations of flowrates and pressures. This document explains how to use FLONET to set up a FLONET model. It provides an example of how to use the capabilities of the program while pointing out suggestions for best practice in both constructing and validating a model FLONET Network Properties A FLONET network can contain: Compressible or incompressible fluids. Loops and tree-like structures. Pumps and non-return valves. Turbulent, transitional and laminar flow regimes. Pipes of any dimension and reasonable roughness. Pressure loss data due to fittings. Moderate temperature variations. Gravity heads due to sloping pipes FLONET Calculation Assumptions The following assumptions are made in FLONET Calculations: The flow/pressure equations in FLONET work on an isothermal basis. FLONET calculations are only valid for low Mach numbers, that is, around 0.2 Ma. At high Mach numbers the internal energy changes become important and the isothermal model is less valid. Page 8 of 55 FLONET User Guide

9 FLONET fittings are modelled using a single K-value. This represents all the fittings and no provision is made for the order in which fittings occur. The K-value calculator allows detailed information about the fittings in a pipe to be stored although a single value is used for calculations. The calculator stores the information that the K-value comprises, for example, three tight radius 90 bends, one long radius 180 bend and a 4 inch NB circular port plug valve. The network description is not directed (unlike the ADRIAN program). This means that, even though a particular pipe starts at node A and ends at node B, it does not follow that the fluid can only flow in the direction of A to B FLONET Network Configurations A FLONET network consists of: Nodes where pipes start and finish Pipes which run between nodes. The following information is required to specify a FLONET network: A name, length, bore, roughness, and mean temperature for each pipe. A label and height for each node. Details of pressure losses due to fittings in the form of K-values. Details of the capability of any pumps in the system in the form of Head (m) versus Flow (m 3 /s) characteristics. The pump curve can be defined using between 1 and 20 points (see Figure 16 for an example). Density and viscosity data for the fluid in the network (a value for Cp/Cv is required for gases). A datum pressure at some point in the network About this Guide This guide is designed to assist the user in becoming quickly familiar with the capabilities of FLONET, its interface and how the program is used. The chapters are organised as follows: Chapter 1 An introduction to FLONET. Chapter 2 Details the FLONET user interface. Chapter 3 A tutorial to guide the user through a typical FLONET session emphasising the commonly used features. It is recommended that the user should read this chapter while running the program. Appendices Detailed instructions for creating a physical properties.fpf file, hints, an explanation of in-cell unit conversion, choosing a fluid Flow program and troubleshooting hints. FLONET User Guide Page 9 of 55

10 2. The FLONET User Interface The FLONET user interface has special forms or Editors to allow easy definition of the system being modelled. It also offers many useful features including automatic units conversion and a calculator The FLONET start up screen FLONET consists of four Editors into which data is entered. These are the: Piping Data Editor Node Conditions Editor Pump Data Editor Physical Properties Editor. Only the Piping Data Editor is displayed at start up as shown in Figure 1: Figure 1 FLONET Start up screen showing Piping Data Editor The following sections in this chapter contain detailed information on these Editors. Page 10 of 55 FLONET User Guide

11 2.2. The Piping Data Editor The Piping Data Editor allows you to define all the pipes in the system. This editor is displayed as the default when FLONET is started. If the Editor is not displayed it can be activated by clicking on the toolbar button (see left). Each pipe has an inlet node and an outlet node. Nodes are points where pipes start and end and include inlets and outlets to the network as well as conventional junctions such as manifolds and T junctions. Nodes should be placed in the following locations: Inlets and outlets to the system. Pendant Nodes - these are nodes that belong to one pipe only. They should only be included if they have inlet or outlet flows. However, if there is no inlet or outlet flow a value of zero can be entered but it is recommended that the pipe and node are omitted completely (see section for more information on Nodes). Junctions - blanked off tee junctions should not be nodes as these are taken into account by the K-value calculator. Any point where there is a change in pipe diameter. Inlets and Outlets to process equipment. At any point where it is desired to know the pressure. This may be a point on plant where a pressure gauge exists so would be useful for model validation purposes. The editor provides special tools to help input data such as pipe diameters, roughness, fittings loss coefficients etc (see section for more information). Figure 2 Piping Data Editor Usage Pipe Name Inlet Node & Outlet Node Mandatory. A unique name must be supplied for each pipe in the network. Note. All names used in FLONET must be less than 20 characters in length. Mandatory. Each pipe starts and ends at a node identified by a four character name which you must specify. If you enter a name for a node that already exists then the pipe will be attached to that node. If the node does not exist then a new node will be created. FLONET User Guide Page 11 of 55

12 Usage Pipe Length Pipe Bore Pipe Roughness Fittings Loss Coeff. Pipe Temperature Comment Mandatory. Enter a pipe length. Mandatory. Refer to the Pipe Inner Diameter Calculator (see section for more information) for entering data into this field. The result is automatically pasted into this cell. Mandatory. Refer to the Pipe Roughness Calculator (see section for more information) for entering data into this field. The result is automatically pasted into this cell. Note. This value is the relative roughness of the pipe. The value will change with the pipe diameter. Once a value has been entered for both the pipe bore and the relative roughness, FLONET automatically recalculates the value for relative roughness as the pipe bore is changed. FLONET assumes that the pipe absolute roughness remains unchanged when performing the calculation. Mandatory. Refer to the Fittings Loss Calculator (see section for more information) for entering data into this field. The result is automatically pasted into this cell. Note. Non-return valves can be modelled by making the K-value negative. Flow will only be allowed from the Inlet Node to the Outlet node using the absolute value of the given K-value. Mandatory. Enter the pipe temperature in C. Use this field to record any explanatory comments. Note. Pumps If a pump is to be placed in the network, its inlet and outlet nodes must be joined by a pipe so that FLONET can represent the flow through the pump Piping Data Editor Autocomplete feature There is often a large amount of information in a piping network definition which remains true for each pipe in the system. To avoid having to retype this data for each pipe, FLONET automatically enters some of the piping data using default information. The defaults are taken from the pipe that is immediately above the new pipe being defined in the Piping Data Editor. The default information is: Pipe length Pipe bore Pipe roughness Pipe temperature. Fitting loss data is never defaulted as it is expected to be different for each pipe. Page 12 of 55 FLONET User Guide

13 2.3. The Node Conditions Editor The Node Conditions Editor requires different input for each of the two calculation modes, that is: Flow Calculation Mode Pressure Calculation Mode. FLONET automatically enters the node names in the Node Editor as they are added to the Piping Data Editor. The editor dialogue is accessed by clicking on the Node Conditions Editor button (see left) on the toolbar Flow Calculation Mode In Flow calculation mode, the pressures and directions of the flows at all Inlet and Outlet nodes must be entered as shown in Figure 3. All other nodes are left blank. Figure 3 Flow Calculation mode Enter the direction of the flow in the following format: 1 = Flow into the system - 1 = Flow out of the system. Note. A value entered for flow will be used as the initial estimate. The node height is the height above some known reference. The best figures to use are the elevation levels from the piping isometrics. Note. Remember that the ground level may not be constant when using it as a datum. This is especially the case with networks spread over a large area. Expert users can find additional information on using the Node Conditions editor in section FLONET User Guide Page 13 of 55

14 Pressure Calculation Mode In Pressure calculation mode the flow into and out of pendant nodes must be specified along with one reference pressure anywhere in the system as in the following example: Figure 4 Pressure Calculation mode FLONET will automatically enter the node names as they are added to the Piping Data Editor. Remember that the direction of the flow is indicated as: Positive = Flow into the system Negative = Flow out of the system. and that the flows into and out of the system must balance. The node height is the height above some known reference. The best figures to use are the elevation levels from the piping isometrics. Note. Remember that the ground level may not be constant when using it as a datum. This is especially the case with networks spread over a large area. Expert users can find additional information on using the Node Conditions editor in section Page 14 of 55 FLONET User Guide

15 Additional information on using the Node Conditions Editor Mixed flow and pressure calculations In Flow Calculation mode, expert users can specify problems with greater flexibility: Pressures within the network may be specified instead of those at pendant nodes. A combination of flows and pressures may be specified. The user must ensure that a valid set of parameters is specified which allows the model to be solved - the number of settings must equal the number of degrees of freedom of the problem and care should be taken not to overspecify one part of a network while underspecifying another part. Any sufficient set of node pressures (internal or external) and external flows can be specified as fixed data. If any external flows are to be calculated then you must specify that a flow calculation is required. Pressure calculations should only be specified if all external flows are known and specified. Therefore, for a system with N external nodes, the following can now be specified as fixed: N external flows + any 1 pressure (Pressure calculation) As before or N-2 external flows + any 2 pressures (Flow calculation) or N-3 external flows + any 3 pressures (Flow calculation) or 1 external flows + any N-1 pressures (Flow calculation) or 0 external flows + any N pressures (Flow calculation) As before. Ensure that when node pressures are specified they are independent of each other which means that they must not be linked by branches through which the flow is fixed. In a pressure calculation, the external flows specified in the node conditions data are used as given. In a flow calculation, if they are not equal to +1 or -1, they are normally accepted as estimates to initialise the calculation. If an external flow is required to be fixed during a flow calculation, the specified pressure must be negative to indicate this fact to the solver. If the pressure is not specified at that node then it should be assigned a very small negative value (-1E-15), again to indicate that the flow has been specified and not estimated Initial Estimates When a Flow calculation is requested, FLONET accepts initial estimates for the external flow in place of just +1 or -1 if required: this does not guarantee convergence but it may help. If initial estimates are supplied, the user must ensure that they balance over the network. Alternatively, one or more of the external flows may be specified as +1 or -1 (at least one of them must be a -1) in which case the solver will estimate these flows as appropriate External and Pendant Nodes An External Node is one where fluid flows into or out of the system. Flows may only be specified (or estimated) at external nodes. A positive flow indicates flow into the system and a negative flow indicates flow out of the system. A Pendant Node is a node that is connected to only one other node. FLONET User Guide Page 15 of 55

16 It is important to remember the difference between the two types of node. Generally, a Pendant node is an external node, that is, one where fluid flows into or out of the system. However, there could be zero flow. It is feasible within FLONET for a node which is not pendant to still be an external node, that is, one where fluid enters or leaves the system (but not through a defined pipe/connector). If a specification or estimation of the flowrate is entered at a node, it is identified as an external node. This may be required to model leakage in or out of the system, flow into/from the network without creating a dummy node and connection or to switch off parts of the network. Note. Estimates may only be given for flows into or out of the system. They must not be given for internal flows. Page 16 of 55 FLONET User Guide

17 2.4. The Pump Data Editor The Pump Data Editor allows pumps to be added to a network (see section for an example of how this is performed). The editor dialogue is accessed by clicking on the Pump Data Editor button (see left) on the toolbar. Figure 5 Pump Data Editor Usage Maximum number of points on each pump characteristic Pump ID Comment Inlet Node & Outlet Node Head n Flow n Mandatory. The slider bar is used to select the number of points to be entered from the pump curve graph (see Figure 16 for an example). It is entered as a series of points (Range: 1 to 20). Mandatory. The Pump identifier. Optional. Use this field to record any explanatory comments. Mandatory. The two nodes specified must be connected by a pipe in the Pipe Data Editor as well as the pump. The pipe length may be specified as zero if there is no other pipe to be modelled. Mandatory. This value is taken from the Pump Curve graph (see Figure 16 for an example). Mandatory. This value is taken from the Pump Curve graph (see Figure 16 for an example). Note. Pumps must be placed into a pipe section. They cannot exist between two nodes without an associated pipe being present. In the example show in Figure 5 there must be a pipe in the Piping Data Editor which is defined as going between the two nodes A100 and A200. The pump is positioned in this piping section. FLONET User Guide Page 17 of 55

18 2.5. The Physical Properties Editor Three separate points for density and viscosity must be entered at three separate temperatures and three separate pressures. The editor dialogue is accessed by clicking on the Physical Properties Editor button (see left) on the toolbar. Figure 6 Physical Properties Editor For the best results the temperatures and pressures used to define the fluid properties should span the operating range within the pipe network. This allows FLONET to interpolate between these values to determine the operating conditions. Usage Network Fluid Type Physical Property ID Comment Mandatory. The ratio of the specific heats Cp/Cv must be entered if Gas is selected. Mandatory. The physical properties required are: Pressure Temperature Density Viscosity No two values should be equal (bar) No two values should be equal ( C) Corresponding to pressure and temperature (kg/m 3 ) Corresponding to pressure and temperature (CP). Optional. Use this field to record any explanatory comments. Note. Physical properties can be entered into FLONET manually or generated automatically using the PhysPack package then loaded as an.fpf file (see Appendix A for more information). Page 18 of 55 FLONET User Guide

19 2.6. Handling Calculation Results The four buttons grouped together at the right-hand side of the toolbar (see section Error! Reference source not found.) allow the user to handle results in the following manner: Print Current Results Save Current Results Show Current Results Create a report using input and results data Print Current Results This prints out all the results in a basic tabular form (see section for an example) Save Current Results This saves the results as a *.out file. This is a comma delimited text file which can be read by any spreadsheet. This is a useful format for presenting results if they are to be included in a report. The Results Report Generator can also be used if input data is required for a report (see section for more information) Show Current Results This displays the results editor on the screen. Figure 7 Show Current Results Usage Results: Synchronise results with Piping data view Warnings/Errors: Optional: It is possible for the Piping Data Editor to only display a selection of the pipes present, that is, just the inlet and outlet pipes (see section for more information). Checking this box allows only those selected pipes to be displayed when a simplified set of results (which are easier to view) are required. Displays a list of any warnings/errors detected during the calculation. FLONET User Guide Page 19 of 55

20 Create a Report using Input and Results Data This option allows a report to be created from input results and results data. The report is created dynamically as information is selected from the input data or the results to be included in the report. The report can be saved as either an Excel (.xls) or tab delimited text (.txt) file. Available columns to choose from Columns selected for this report An example of how the report will appear Figure 8 Results Report Generator Usage Columns available for display Displays all the possible columns available for selection. >> Copies any columns highlighted in the Columns available for display box to the Columns selected for this report box. Columns selected for this report Columns highlighted in the Columns available for display are transferred to the Columns selected for this report when the >> button is pressed. Page 20 of 55 FLONET User Guide

21 Usage Column Order Remove Column Print... Save... Clear Report Close Use the!/" arrows to change the order of highlighted columns. This change of order is shown on screen and immediately reflected in the Calculation Report. The example shown in Figure 8 has used the! arrow to move the position of the Flow Rate (kg/s) column from its original position after selection (above Reynolds Number ) to the position it is required in the report (below Fittings Loss Coeff ). Removes a highlighted column from the Columns selected for this report box. Displays the Page Setup dialogue. Click on OK to proceed to the Print dialogue. Displays the Save Results to file dialogue. Files can be saved in either an Excel (.xls) or tab delimited text (.txt) file format. Clears all the columns in the Columns selected for this report box. Exit the dialogue and return to the FLONET program. FLONET User Guide Page 21 of 55

22 2.7. FLONET Menus This section lists the various menus and their options that can be selected. Keyboard shortcuts are shown in brackets File Menu The File menu allows you to access the following options: Menu Option New Open Merge Save Save As Import.FPF File Definition Creates a new file. Opens an existing file. Merges two existing files. Saves the file (FLONET files are saved with a.flo extension). Saves the file as a new name. Imports an.fpf file generated using the PhysPack package (see Appendix A for more information). This allows physical properties information about a fluid to be transferred directly from PhysPack into FLONET Edit Menu The Edit menu can be accessed by clicking on Edit or the right-hand mouse button while any of the four input Editors are activated. Some of the Edit options will be greyed out depending on the Editor selected. Menu Option Show selected pipes only (F11) Show all pipes (F12) Cut (Ctrl-X) Copy (Ctrl-C) Paste (Ctrl-V) Insert new row (Ctrl-Ins) Delete selected pipes Definition Enables only the selected pipes to be viewed. Select the pipes using the mouse while holding the Ctrl key down. This allows the most important pipes in a large network to be viewed. Reverts back to the normal view Cuts, copies and pastes whole pipes. It is not possible to copy single cells. Inserts a new pipe above the one currently selected. Removes selected pipes from the network. Select multiple pipes using the mouse while holding the Ctrl key down Tools Menu The Tools menu allows the following to be accessed when the Piping Data Editor window is active: Menu Option Pipe Roughness Calculator (Ctrl-R) K-value Calculator (Ctrl-K) Pipe Inner Diameter Calculator (Ctrl-D) Definition Displays the Pipe Roughness Calculator dialogue. Displays the K-value Calculator dialogue. Displays the Pipe Inner Diameter Calculator dialogue. Each of these calculators automatically paste their results into the correct position in the currently selected pipe. These calculators are detailed in the following sections. Page 22 of 55 FLONET User Guide

23 Pipe Roughness Calculator This calculator is used to select a Surface Type and Absolute Roughness. Clicking on OK then adds the selection to the calculation by pasting the selected value into the cell that was active when the calculator was called. FLONET uses the pipe bore from the pipe selected when the Roughness Calculator was called and uses the value to calculate the relative roughness value. Figure 9 Pipe Roughness Calculator dialogue FLONET User Guide Page 23 of 55

24 K-value Calculator The Fittings Loss (K-value) calculator consists of a number of sections where the fittings details of a pipe are built up. Although a single K-value is used in the calculations for each pipe, the K-value calculator retains a record of what the value consists of. The record of how many Tees, bends, valves, expansions etc. is saved together with the FLONET file when the program is exited. The front sheet of the dialogue contains a summary of the following data entered for each type of fitting recognised by FLONET: Tee Junctions Bends Valves Expansions/Contractions User Defined (Process Equipment) Manual Adjustment. Figure 10 Fittings Loss (K-value) Calculator dialogue The following selections can be made from this dialogue: Usage Summary Tab: - Sub Total Outputs the sub total before a manual adjustment is added. - Manual Adjustment The manual adjustment field is for entering miscellaneous fittings. It is also used for manually adjusting the model in the validation stage or for studying the effect of changes, for example, changing a control valve position. - Reason for Adjustment Text describing the reason for adjustment can be entered in this field. - Overall Total Outputs the overall total combining the sub total and the manual adjustment to produce the fittings loss value for the pipe. Page 24 of 55 FLONET User Guide

25 Usage Tee Junctions Tab: The Tee Junctions calculation takes into account any blanked off junctions. This can also be a line where the dead leg is isolated at a valve further downstream. Bends Tab: Add a Tee Junction: Select a Tee Junction Type, enter the Quantity and click on Add. The entry is added to the list at the bottom of the sheet. Remove a Tee Junction: Select the Tee Junction then click on Delete. An example of a typical Tee Junction tab display is shown below: Valves Tab: Valves are entered by selecting a valve type then double-clicking to display more details about that type of valve. For example, double-clicking on Globe Valve gives the option of selecting either Cast Valves or Forged Valves. Select the nominal bore of the value you require, enter a quantity and use the Add button to add the fitting to the pipe. An example of a typical Valves tab display is shown below: FLONET User Guide Page 25 of 55

26 Usage Contractions/Expansions Tab: Select either the Expansion or Contraction radio button then follow the same method as for Tee Junctions. For exit losses select an expansion with a small/large area ratio of zero. For entry losses select a contraction with a small/large area ratio of zero. A node is required where there is a change of cross-section so Expansion/Contraction data is not required. An example of a typical Contractions/Expansions tab display is shown below: User Defined (Process Equipment) Tab: The easiest way to model process equipment (for example, heat exchangers and filters) is as a section of pipe with a fittings loss coefficient. The pipe length needs to be short so that the pressure drop is solely due to the fittings (therefore, 1m is generally used). The values for mass flow, pressure drop etc. can be obtained from the process datasheet. Static head changes between inlet and outlet should not be taken into account as the node information will deal with this. An example of a typical User Defined (Process Equipment) tab display is shown below: Note. The K-values quoted in the K-value calculator, together with those commonly quoted in reference texts, assume that the flow in the pipe is turbulent. Although FLONET performs calculations that feature Laminar (or transitional) flow regimes, the user must enter their own K-value data for this situation. K-values for fittings losses under Laminar flow conditions are typically much higher than equivalent K-values for turbulent conditions. The K-value is automatically posted into the cell that is currently active when the K-value dialogue is closed. This value is pasted to the clipboard if the cell does not accept the value. Page 26 of 55 FLONET User Guide

27 Pipe Inner Diameter Calculator This dialogue is used to calculate the pipe inner diameter. Select a standard pipe size then the available schedules for that pipe size. The details for that combination are displayed at the bottom of the dialogue box. Figure 11 Pipe Inner Diameter Calculator dialogue The following selections can be made from this dialogue: Usage Standard Pipe Sizes Lists the pipe sizes available from 1/8 to 36. Schedules Available Inner Diameter Wall Thickness Outside Diameter Return OK Lists the pipe schedules available for the pipe size selected. Displays the Inner Diameter of the selected pipe. Displays the Wall Thickness of the selected pipe. Displays the Outside Diameter of the selected pipe. Use the radio button to indicate which selection is to be returned to the program. The default is Inner Diameter. Pressing the OK button returns the chosen value to the program. The value is pasted into the cell that was highlighted when the Pipe Inner Diameter Calculator was selected. FLONET User Guide Page 27 of 55

28 Options menu The Options menu allows you to select the following dialogues: Change Units Calculation Options Statistics Change Units The Change Units (Set Network Units) dialogue allows you to specify the units used for the network. Figure 12 Set Network Units dialogue Usage Practical SI Units Basic SI Units British User Defined Set Units Selects Practical SI Units such as m 3 /s, bar, C, cp etc. Selects Basic SI Units such as m 3 /s, N/m 2, K, N.s/m 2, etc. Selects British units such as ft 3 /s, psia, F, lbf.s/ft 2 etc. Clicking this radio button highlights the Set Units button. The following units can be defined: - Length - Bore - Temperature - Flow - Pressure - Height - Flow Volume - Density - Viscosity - Velocity. Page 28 of 55 FLONET User Guide

29 Calculation Options The is option allows varying levels of accuracy to be set when calculations are performed. Note. It is recommended that changing most of these settings should only be attempted by the advanced user. It can lead to a considerable increase in calculation time if mistakes are made. Figure 13 The Calculations Option dialogue Usage Calculation Title Monitoring Level Calculation Accuracy Mandatory. Enter a title of up to 50 characters. Optional. A sliding bar that governs the amount of monitor output included in the results. It is unlikely that this will need to be changed by the user as the output information is usually only used by software developers and support personnel. (Range: 0 to 9). Optional. A sliding bar that defines the accuracy to which final results are to be calculated as a percentage. Identical results for 0.05% and 0.01% indicate adequate convergence. (Range: 0.01% to 1.0%). FLONET User Guide Page 29 of 55

30 Usage T Junctions Damping Factor Calculation Mode Maximum Iterations Optional. Calculates any T Junction losses (if present in the network). If this option is switched off, FLONET assumes that there is no pressure drop across branching modes within the network. If this option is switched on, FLONET makes assumptions about the configuration of the T junction at that node based on pipe diameters and flow directions and will calculate the pressure drop/recovery accordingly. Calculating T junction losses in cases where the flow direction may reverse can cause problems. Optional. The Damping Factor applied to the recalculation of pipe resistance at each step. This parameter can be changed if a calculation is proving difficult to converge. It is useful when losses are very significant as small changes in flow can produce disproportionate changes in the pressure profile. The damping factor reduces the change the solving algorithm would otherwise attempt to apply. Zero (no damping) is usually suitable as a default. A value between 20% to 50% should be sufficient if damping is required. (Range: 0% to 100%). Mandatory - Select either: Flow: Given the flows at the input and output nodes and one pressure in the system FLONET calculates all other flows and pressures. Pressure: Given the pressures and flow direction at the input and output nodes FLONET calculates all the other flows and pressures. In this mode expert FLONET users can also use it to calculate systems given other valid combinations of flowrates and pressures. Optional only relevant for flow calculations. The number of iterations will determine the number of recalculations of the network. The number of iterations for one recalculation is approximately equal to the number of unknown external flows and pressures. Ten recalculations are usually sufficient so it is recommended that the number of iterations is set to 10x the number of unknown external flows and pressures but this can be increased for a model that is proving difficult to converge. Page 30 of 55 FLONET User Guide

31 Statistics This dialogue displays a statistical breakdown of the network properties. Figure 14 Statistics dialogue Window menu This menu consists of the standard Windows options, that is, Cascade, Tile (horizontal and vertical) and Arrange Icons. It also provides another way of moving between the various editors Help menu On-line help is not yet available. FLONET User Guide Page 31 of 55

32 2.8. The FLONET Toolbar The buttons on the toolbar allow the following options to be selected: Button Purpose Create New FLONET file Creates a new FLONET file. Equivalent File menu item New Open FLONET File Opens an existing FLONET file. Equivalent File menu item Open Save FLONET File Saves the FLONET file that is currently open. Equivalent File menu item Save Piping Data Editor Activates the Piping Data Editor window. N/A Pipe Section Editor Activates the Piping Section Editor window. N/A Pump Editor Activates the Pump Editor window. N/A Physical Properties Editor Activates the Physical Properties Editor window. N/A Calculate Current Network Calculate results of the current network. N/A Network Statistics Displays the Network Statistics dialogue. Equivalent Options menu item Network Statistics Validate Network Checks that all the required input data is present before a calculation is performed. N/A Print Current Results Prints the results of the current calculation in tabular format. N/A Page 32 of 55 FLONET User Guide

33 Button Purpose Save Current Results Saves the results in a comma separated text format as a *.out file. N/A Open File Network Displays the results editor on the screen. N/A Create a report using input and results data Displays the Results Report Generator dialogue. N/A Table 1 The FLONET Toolbar FLONET User Guide Page 33 of 55

34 3. FLONET Tutorial 3.1. General This chapter demonstrates how the internal node pressures and flows are calculated for three external nodes A100, A215 and A225 with a pump situated between A100 and A200. The pipes between A200 to A210 and A200 to A220 slope upwards by five metres. Pressures are supplied at all external nodes. These are: A100 = 1.0 bar A215 = 0.4 bar A225 = 0.6 bar Note. A200 is assumed to be at reference height. The first step is to create a Node diagram for the network example which is shown in Figure 15. A210 P4 A bar P2 A220 P5 A bar A100 A200 P3 1.0 bar P1 Figure 15 Node Diagram for FLONET tutorial example The Node diagram is a simplified drawing of the process and is the basis of the model. It is worth careful consideration about where to put nodes before entering data into FLONET. Nodes should be placed in the following locations. Inlets/outlets to the system - these are referred to as external nodes. Junctions - blanked off tee junctions should not be nodes as these are taken into account by the K-value calculator. Any point where there is a change in pipe diameter. Inlets and Outlets to process equipment. At any point where it is desired to know the pressure. This may be a point on plant where a pressure gauge exists so would be useful for model validation purposes. Nodes can be given names up to four characters long. It is often useful to use a combination of letters and numbers to create a key, particularly with large networks. Page 34 of 55 FLONET User Guide

35 The values for the Node diagram in Figure 15 are shown in the table below: Pipe Nodes Length (m) Bore Fittings Temp o C P1 A100 A x 90 o Bends (radius 500mm) 40 1 x T-Junction Type 2 P2 A200 A x 1 Globe Valve - cast 40 P3 A200 A x 1 Globe Valve - forged 40 P4 A210 A x 90 o Bends (radius 300mm) 30 P5 A220 A x T-Junction Type 3 30 Table 2 Values for tutorial example Note. All pipes are Schedule 40, mild steel and slightly corroded. The following Pump Curve graph contains data that is used for calculations in section later in this example: Head [m] Flow [m 3 /s] Figure 16 FLONET tutorial example Pump Curve Graph Proceed to the next section where FLONET is used to solve the network. FLONET User Guide Page 35 of 55

36 3.2. Solving the Network The procedure to solve the network involves the following steps: Accessing FLONET Entering data in the Piping Data Editor Defining the inlet and outlet pressures and the direction of flow Defining the Pump characteristics Defining Physical Properties Solving the network. The results can be viewed, printed and saved after the network has been solved Accessing FLONET 1. Access FLONET by selecting Start Programs PEL then click on the FLONET icon. 2. A splash screen showing the program name and version number appears briefly before the start up screen (see Figure 1) showing the Piping Data Editor window is displayed. 3. Click on the Options menu and select Calculation Options. 4. Click on the Flow radio button in the Calculation Mode panel (see Figure 13) then click on OK Entering Data in the Piping Data Editor The Piping Data Editor window is used to specify the piping network. Procedure 1. In the Piping Data Editor, click the first cell under the Pipe Name column and enter P1. 2. Use the Tab key to move to the Inlet Node cell and enter A Tab to the next Outlet Node cell and enter A Tab to the Pipe Length cell and enter Tab to the Pipe Bore cell. Place the mouse over this highlighted cell then click on the right mouse button. Figure 17 Piping Data Editor showing Pipe Inner Diameter Calculator selected Page 36 of 55 FLONET User Guide

37 6. Select the Pipe Inner Diameter Calculator from the pop-up menu (this can also be selected from the Tools menu). 7. Select a 2 and Schedule 40 pipe. The following screen is displayed: Figure 18 Pipe Inner Diameter Calculator dialogue selected 8. Click on OK. The result is pasted into the Piping Data Editor cell. 9. Tab to the Pipe Roughness cell. Place the mouse over this highlighted cell, click on the right mouse button and select Roughness Calculator (this can also be selected from the Tools menu). Notice that the pipe bore is automatically displayed at the top of the dialogue. Figure 19 Pipe Roughness Calculator dialogue selected 10. Select Mild Steel (slightly corroded) then click on OK. The result is pasted into the cell. Note. The relative roughness is automatically updated whenever the bore is changed. 11. Tab to the Fittings Loss Coeff cell. 12. Place the mouse over this highlighted cell, click on the right mouse button and select K-Value Calculator (this can also be selected from the Tools menu). FLONET User Guide Page 37 of 55

38 13. When the calculator window appears, click on the Bends tab. Enter 500 in the radius box, 4 in the Quantity box then click on Add. The following screen is displayed: Figure 20 Fittings Loss Calculator showing Bends dialogue selected 14. Click on the Tee Junctions tab. 15. Click the down-arrow next to the Tee Junction Type box and select T-Junction Type Enter 1 in the Quantity box then click on Add. The following figure is displayed: Figure 21 Fittings Loss Calculator showing Tee Junctions dialogue selected Page 38 of 55 FLONET User Guide

39 17. Click on the Summary tab to display the K-Values summary. The following figure is displayed: Figure 22 Fittings Loss Calculator showing Summary tab selected 18. Click on OK. The result is pasted into the cell on the Piping Data Editor. 19. Click on the Pipe Temperature cell and enter the value The data for the first pipe is now complete. Add the data for the other four pipes in the same way using the information supplied in Table 2. Note. Remember to double-click on the valves in the K-Value Calculator to display the required options. The completed Piping Data Editor now looks like this: Figure 23 Completed Piping Data Editor 21. It is recommended that the data should be saved at this point in the procedure. Click on the Save button on the toolbar and save the data as FLONET.FLO on your disk drive. FLONET User Guide Page 39 of 55

40 Defining the Inlet and Exit pressures and the direction of flow Procedure 1. Select the Node Conditions Editor by clicking on the Node Conditions Editor button (see left) on the toolbar. The nodes that were entered in the Piping Data editor have been automatically generated here. 2. This is a flow calculation. FLONET requires the pressures and an indication of the flow direction at each pendant node. The following convention is used to show the flow direction: 1 = Flow into the system, that is, an inlet node. 1 = Flow out the system, that is, an outlet node. In the Flow Into Node column, enter 1 next to A100 to indicate flow into the network. 3. Enter 1 next to both A215 and A225 to indicate flows out of the network. 4. This inlet node is at a pressure of 1 bar. The two outlet nodes A215 and A225 are at pressures of 0.4 bar and 0.6 bar respectively. Perform the following steps to represent this: In the Pressure at Node column, type 1.0 next to A100, 0.4 next to A215 and 0.6 next to A In the Node Height column type 5 next to A210, A215, A220 and A225 to indicate that they are elevated by 5m. Type 0 as the node height for A100 and A200 to indicate that they are at the reference height. The following screen is displayed: Figure 24 Node Conditions Editor selected 6. Close the Node Conditions Editor window. Page 40 of 55 FLONET User Guide

41 Defining the Pump Characteristics Procedure 1. Select the Pump Data Editor by clicking on the Pump Data Editor button (see left) on the toolbar. 2. Move the scrollbar to the right to set the Maximum number of points to Enter PUMP1 for the Pump ID. The Inlet node is A100 and the Outlet Node is A Enter the following three pairs of Head and Flow values (these are taken from the graph shown in Figure 16): 25.0, , , The following screen is displayed: Figure 25 Pump Data Editor selected Note. Although the pump is defined as situated between two nodes, it is actually present in a pipe. For FLONET to work correctly, a pipe must be present in the Piping Data Editor which spans the two nodes shown in the Pump Editor. 5. Close the Pump Data Editor Defining Physical Properties The physical properties must be defined at this point in the procedure before solving the network. This data can be generated in PhysPack (see Appendix A for the procedure). Procedure 1. Select the Physical Properties Editor by clicking on the Physical Properties Editor button (see left) on the toolbar. 2. Enter the values given in Figure 26. Alternately, click on the File menu and select Import FPF File to import an existing property file from PhysPack. 3. Select FLONET.FPF from your disk drive and click on Open. FLONET User Guide Page 41 of 55

42 The values are pasted into the Physical Properties Editor cells as shown below. Figure 26 Physical Properties Editor selected Calculating the Network Solution Procedure 1. Click on the Calculate button (see left) on the toolbar. 2. The word Solving appears after FLONET on the caption of the main window. When the calculations are complete, Solving disappears and the results appear in the Results of calculation performed window as shown in Figure 27: Figure 27 Results of Calculation window Note. Always check to the Warnings/Errors tab to see if any warnings or errors were detected during the calculation. Page 42 of 55 FLONET User Guide

43 Viewing Results It is possible for the Piping Data Editor to display a selection of the pipes present. This is useful in large networks where only a small number of pipes may be of interest. Procedure In the Piping Data Editor: 1. Select multiple pipes by clicking on the pipes while holding down the Ctrl key. Just select the exit pipes P4 and P5. 2. Click on the right mouse button to display the Edit menu. 3. Select Show selected pipes only. The selected pipeline data is displayed: Figure 28 Viewing results of Selected Lines 4. In the Results Editor select the Synchronise results with Piping data view tick box to view only the pipes that were previously selected in the Piping Data Editor. Figure 29 Synchronise Results with Piping data view Saving the Input file Procedure 1. Select File then Save As 2. The data is saved as a *.flo file. This is used to save all the model input data. This also sets up a file *.flo.kvl which stores the breakdown of the K-values from the K-value calculator. Note. Ensure that when working on the model that the program is set to save as a *.flo file. Failure to do this results in the K-value data not being saved. FLONET User Guide Page 43 of 55

44 Saving Results Reports Procedure 1. Click on the Save Current Results button (see left). The Save Results dialogue is displayed. 2. This saves the results in a comma separated text format as a *.out file. This can then be edited using Lotus or any other spreadsheet or text editor. Figure 30 Save Results dialogue Printing Results and Creating Reports Results can be printed by using the following options from the toolbar: Printing Results Creating a Report using Input and Results Data. Page 44 of 55 FLONET User Guide

45 Printing Results This prints the data as displayed in the Results window. Procedure 1. Click on the Print Current Results button (see left). The Page Setup dialogue is displayed. 2. Make any required changes to the page setup and click on OK. 3. The Print dialogue is displayed. Click on OK. 4. The report that is produced is shown below: Flonet Calculation Results Inlet Node Outlet Node Inlet Node Pressure (bar) Outlet Node Pressure (bar) Flow Rate (kg/s) Mean velocity (m/s) Reynolds Number A100 A A200 A A200 A A210 A A220 A FLONET User Guide Page 45 of 55

46 Creating a Report using Input and Results Data This method is much more flexible than the simple Print Current Results process as it allows both input data from the Piping Data Editor and output data from the results screen to be included. Procedure 1. Click on the Creating a report using input and results data button (see left). The Results Report Generator dialogue is displayed. 2. Select the required items to display on the report from the Columns available for display list using the Ctrl key and the left-hand mouse button simultaneously. 3. Click on the >> button. The columns selected in the previous step are displayed in the Columns selected for this report window as shown in Figure 31. Use the up/down arrows to reorder the position of the columns on the report. Figure 31 Results Report Generator showing columns selected Printing the Report 4. Click on the Print button. The Page Setup dialogue is displayed. Make any changes required to the setup then click on OK. 5. The Print dialogue is displayed. Click on OK. Page 46 of 55 FLONET User Guide