Hydraulic Modeling

Hydraulic Modeling

A software based representation of a pipe network

PCE develops up-to-date hydraulic simulation models that represent the current operating performance of each system.   We develop multiple scenario models ensuring that recommendations to system deficiencies will result in desired performance.  Our ability to precisely tune simulation models to represent current day operations sets us apart as the industry leader in simulation analysis.

We develop detailed hydraulic simulation models of any firewater, cooling water, steam, condensate, compressed air, process, etc. and validate these models against field data. With these detailed simulation models, PCE can quantify the root causes of reduced throughput and determine the lowest cost solutions.

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Hydraulic Modeling Benefits

Identify and correct imbalances within each steam pressure level to avoid any unnecessary steam exhaust or letdown from a higher pressure, saving $7,000,000 at one plant.
Developed the additional information needed for more accurate scoping of utility systems to serve the proposed process expansion, resulting in capital cost avoidance of $10,000,000.
Cooling Water Systems Balance flows by reducing identified system build-ups, reconfiguring piping, and restoring identified pump degradation.
Reduce plugging by lowering high exit temperature on the cooling water side of plant heat exchangers.

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Model Can Be Used To:

  • Determine current system conditions
  • Simulate future improvements and/or expansions
  • Preliminary design
  • Simulate operational changes (pumps on/off, exchangers on/off, valuing changes, etc.
  • Identify and correct imbalances within each steam pressure level to avoid any unnecessary steam exhaust or letdown from a higher pressure, saving $7,000,000 at one plant
  • Developed the additional information needed for more accurate scoping of utility systems to serve the proposed process expansion, resulting in capital cost avoidance of $10,000,000

Fire Protection Engineering Services:

  • Fire Protection Engineering
  • Hydraulic, Surge, Radiation, Blast, and Explosion Modeling
  • Risk Management Consulting
  • Process Safety Consulting
  • Emergency Response Consulting
  • HSE Consulting
  • Design/Procurement/Construction Management

Process Safety Engineering Services:

  • PSM Compliance Audit/Program Support (OSHA 29 CFR 1910.119)
  • RMP Compliance Audit/Program Support (OSHA 40 CFR Part 68)
  •  ALARP Assessment
  • Human Factors Analysis
  • Facility Siting Analysis
  • Layers of Protection Analysis (LOPA)
  • SIL Determination
  • Process Hazard Analysis (PHA) and HAZOP (PHA Pro 8 Software)
  • Offshore Case Studies
  • Code Consulting (OSHA)

HSE/Industrial Hygiene Engineering Services:

  • Accident Investigation
  • Sampling, Data Collection, and Analysis
  • Guidance on Regulation, Industry Standards, and Code Compliance
  • Air Permitting –PSD, NNSR, Title V
  • Air Reporting –Emission Inventories, Excess Emission Reports, and Deviation Reports
  • Water –NPDES, Storm Water, Pollution Prevention Plans, and SPCC
  • Waste Characterization and Reporting –SARA, TRI, and Tier II
  • Auditing –Air, Water, Waste
  • Safety and Environmental Auditing
  • Agent Remediation Design and Guidance
  • Biological Agents (i.e. Mold, Legionella, Bacterial Contamination)
  • Chemical Agents (i.e. Asbestos, Lead, VOCs)
  • Contaminant Control thru Ventilation
  • Indoor and Outdoor Air Quality
  • Environmental Site Assessments
  • Non-Ionizing Radiation
  • Noise and Vibration
  • Exposure Monitoring
  • General Hazard and Risk

Emergency Response Engineering Services:

  • Physical, theoretical (classroom), and online training
  • Development and review of emergency response scenarios (fire, HAZMAT, leak, etc.)
  • Development and review of emergency response pre-plans
  • Physical audits of emergency response documentation, training grounds, personnel, procedures, and equipment
  • Development of emergency response plans and contingency plans
  • Fire brigade planning and dimensioning
  • Emergency response equipment dimensioning and procurement services
  • Development of emergency response philosophy and basis of design documents
  • Development of fire-fighting strategy and tactics documents and field cards
  • Design of permanent and mobile emergency operations centers

Cooling Water Engineering and Optimization Services:

  • Reduce Cooling Tower VOC’s by increasing water velocities through leaking heat exchangers
  • Balance flows by reducing identified system build-ups, reconfiguring piping, and restoring identified pump degradation
  • Reduce plugging by lowering high exit temperature on the cooling water side of plant heat exchangers
  • improve the cooling water flowrate and heat transfer in critical product column condensers and increase product quality
  • Increase LPG recovery and wet gas loading by increasing flow to exchangers at FCC.
  • Increase the time between turn-arounds to improve overall plant throughput and production
  • Ensure Cooling Tower can meet hydraulic & thermal loadsUsing performance surveys & analysis