In various refinery plants, large burners are used to generate steam. These burners are supplied with air via a network of intake ducts. Airflow to the different burners is regulated using a complex system of valves and dampers. In practice, one or more burners may suddenly fail during plant startup or when operating settings are adjusted.
FlowMotion was commissioned to identify the cause of these disturbances. In the first phase of the study, flow velocities and static pressure distribution within individual components of the ducting system were determined. Particular attention was paid to the formation of flow vortices, as these negatively affect the homogeneity of the air supply to the burners. This analytical assessment was supported by simplified flow simulations of individual components. In parallel, pressure measurements were taken at significant positions in the duct system, allowing the initial results to be validated using experimental methods.
Through this combination of analytical, experimental, and numerical methods, sufficient information was gathered to predict flow effects when operating conditions change. Ultimately, this study led to improved tuning of the control system and a significant reduction in incidents, with minimal plant downtime.
