FLUID CONTROL RESEARCH INSTITUTE

Kanjikode West, Palakkad. 678623. Kerala, INDIA

SOFTWARE ACTIVITIES Contents

Commercial Software Developed by FCRI
Software for Flowmeter Selection and Sizing Software for Control Valve Selection and Sizing Software for Safety Relief Valve Selection and Sizing... Software for Uncertainty Estimation and Plotting of Calibration Line.. Software for Hydraulic analysis of Water Distribution Networks.. Software for Unit Conversion. Software for Calculation of flowrate, beta and custody transfer properties for Natural Gas through an Orifice Plate..

Consultancy
Software for Surge Analysis Description Case studies Software for Finite Element Analysis for Static and dynamic Stresses, Vibration, Natural frequency response, etc Description Case studies Software for Computational Fluid Dynamics Problems using Finite Volume Method Description Case studies

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Commercial Software

I. Software for Flowmeter Selection and Sizing (FMSEL)

The FMSEL software has been developed with the aim of helping the Instrumentation Engineer on the selection of flowmeter and sizing of DP meters based on ISO / BS / AGA Standards. The software is suitable for liquid, gas, steam and natural gas. Accurate gas tables, steam tables, material properties, flange details etc. are included. Various correction factors for the compressibility of the gases, vent hole correction factors are also included. It is menu driven and user friendly. Extensive error tapping is done to catch the most likely input errors. The software supports all the system of units.

Flowmeter Selection :

The selection process begins with the decision on the type of fluid to be metered. Subsequently, the selection procedure should examine the following characteristics which are listed below. Performance considerations, which include meter rangeability, pressure loss, overall approximate error etc. Fluid property considerations, which include fluid type (liquid or gas), temperature, pressure, viscosity, density etc. Installation and maintenance considerations like the upstream straight length of the pipe required, maximum and minimum line size, service etc. Environmental considerations such as temperature effects, pressure effects. Economic considerations like relative prevailing cost, life expectancy, maintenance etc. Flowmeters that can be selected are 1. Conventional differential pressure types * Sharp edged concentric orifice, corner, flange, radius, pipe and vena contracta tapping. * Venturi tube Classical venturi tube Venturi nozzle * Flow Nozzle ISA 1932 Nozzle Long radius nozzle 2. Other differential types * Eccentric and segmental orifice * Annubar * Target meter * Conical entrance and quarter of circle orifice plate * Positive displacement types Positive displacement meter * Rotary turbine type meters Turbine meter * Fluid oscillating types Vortex meter * Electromagnetic types Magnetic meter * Ultrasonic types Ultrasonic meter * Direct and Indirect mass types Coriolis meter * Miscellaneous types Rotameter Pipe bend : 91 491 2566120/2566206/2566119

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Flowmeter Design : The software calculates pipe diameter (corrected to operating temperature), beta ratio, coefficient of discharge, Reynolds number, exact differential pressure, pressure drop, tolerance limit etc for liquids, gas, steam and natural gas applications. It also calculates the upstream and downstream straight length requirements. The different types of flowmeter covered for design are * Concentric square edge orifice with Flange tapping Radius tapping Corner tapping * Orifice with special entrance form Conical entrance orifice Quarter of circle orifice * Non concentric orifice Eccentric orifice plate Segmental orifice plate * Restriction orifice plate * Venturi tube Rectangular venturi tube Classical venturi tube * Nozzle ISA 1932 nozzle Long radius nozzle Venturi nozzle Critical flow venturi nozzle * Conical inlet * Pitot tube (flowrate) * Pipe bend (flowrate) System Requirements A PC with DOS version 3.0 or above and 640 KB RAM.

The software is used by Major industries like GAIL, IPCL, SAIL, BARC, IL etc.

II. Software for Control Valve Selection and Sizing (AUTOVALV)

AUTOVALV is a very user-friendly software in which the user is able to select the appropriate valve which meets the technical performance specifications, by just some keystrokes. Very little help is required to run the program, however a complete instruction manual is included. Inputs are through easy pull-down or popup Menus. Error traps are provided to ensure validity of data. AUTOVALV has two options, one for selecting and sizing a valve, another for sizing a selected valve. Sizing is simple and quick as it uses the equations provided in the ISA standard 75.01. Selection, chooses a valve from a database of 21 valves given below based on the input conditions. 1. Single seated wing guided globe 2. Single seated V skirt globe 3. Single seated contoured globe 4. Single seated V plug globe 5. Single seated cage globe 6. Double seated wing guided globe 7. Double seated contoured globe 8. Double seated V skirt globe 9. Double seated V plug globe 10. Standard bore ball Web site: www.fcriindia.com E-mail : customercare@fcriindia.com : 91 491 2566120/2566206/2566119 3

11. Characterized ball 12. Butterfly 60 deg. open 13. Butterfly 90 deg. open 14. Full port contour Angle 15. Angle cage 16. Angle venturi 17. Rotary eccentric plug 18. Restricted contour Angle 19. 2:1 Tapered Angle 20. Butterfly 90 deg. Offset 21. Butterfly fluted vane All the above valves except V skirt globes, Restricted contour angle and 2:1 Tapered angle are considered for choking and cavitation in sizing also. Selection supports 6 body materials, which are listed below 1. A216A Cast Iron 2. A395 Ductile Iron 3. B62 Bronze 4. A216 WCB Carbon steel 5. A351 CF8M Stainless steel 6. A351 CF8 Stainless steel AUTOVALV supports around 27 fluids for which a valve can be selected or sized just by specifying the inlet temperature of the fluid. Autovalv respectively would find the viscosity and specific gravity or specific gravity and compressibility factor of the liquid or the gas for these 27 fluids. For other liquids the user is to specify the specific gravity and viscosity. Besides liquids and gases AUTOVALV also supports dry saturated steam. The fluids supported are 1. Acetyline 2. Benzene 3. Carbon tetra chloride 4. Ethanol 5. Water 6. Air 7. Ammonia 8. Argon 9. Bromine 10. Butane 11. Carbon di-oxide 12.Carbon monoxide 13. Chlorine 14. Ethane 15. Ethylene 16. Helium 17. Hydrogen 18.Hydrogen Chloride 19. Hydrogen sulphide 20. Iso-butane 21. Methane 22. Nitrogen 23. Nitrous oxide 24. Oxygen 25. Propane 26.Propylene 27. Sulphur di-oxide Autovalv also provides a range of unit choices that are readily available by pressing a hot key during data entry. The various units are Flow rate (weight) - lb/hr, kg/hr Flow rate ( volume) - gal/min, sm3/hr, l/hr, ft3/hr,nm3/hr Pressure - lb/in2, bar, atm, mm.Hg, Pascal,Kg/cm2 Temperature - deg R, deg C, deg F, deg K Length - inch, mm, cm, meter Online help is also provided wherever necessary by usage of another hot key. Provision is also made to store the results in a file on the disk or to print it. Selection is an option mainly used to select and size a valve for the specified input conditions from the database of 21 valves. It can also be used to view the properties of valves in the database or modify the database by appending or deleting valves. The parameters considered for selection of the valve are temperature, ANSI class, leakage class, fluid characteristic and purpose. Based on these parameters a list of valves from the database is short listed as selected valves. Depending on the input conditions and service, suitable body material is selected. Other

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parameters like gasket, packing material and bonnet type is chosen based on temperature. The inner diameter and the thickness of the line is obtained from in-built data files once the line size and a schedule is chosen. For these valves sizing is performed checking for cavitation and choking. Those valves found cavitating or choking is discarded from the selection list. For the selected list noise calculation is performed and the noise level along with the respective valve is displayed for the user to make his choice based on cost consideration and the noise level desired. Sizing calculates valve coefficient and valve size besides checking for cavitation and choking. It also performs noise calculations for the valve specified. It can be used to calculate flow rate or differential pressure of the valve depending on the parameters known. Sizing is based on the equations given in the ISA standard 75.01.Representative values are used for various parameters like Fl, Xt etc. For exact results use those given in the manufacturers' catalogues. System Requirements A PC with DOS version 3.0 or above and 640 KB RAM.

The software is used by Major industries like IPCL, Hindusthan Newsprint, etc.

III. Software for Safety Relief Valve Selection and Sizing (SAFEVALV)
Safevalv is a user-friendly software using which the user is able to select the appropriate valve, which meets technical performance specifications. Very little help is required to run the program, however a complete instruction manual is included. Inputs are through easy pull-down or popup Menus. Error traps are provided to ensure validity of data. The Valve sizing is based on American Petroleum Institute (API) standard RP 520 Part I. The software supports nearly 60 liquids like Acetaldehyde, Acetic acid, Acetone, fresh water, sea water, O-Xylene, etc., and steam. The properties of the above fluids like viscosity / specific gravity / compressibility factor / molecular weight etc. are stored in a database. Option is available for sizing other liquids, gases or vapors also. Safevalv provides a range of choices for the units used and they are readily available by pressing a hot key during data entry. Provision is there to store results in a file on a disk or to print it. The output of the software gives computed valve orifice area, selected valve from the database and its characteristics. System Requirements A PC with DOS version 3.0 or above and 640 KB RAM.

The software is used by Industries like Asian Industrial Valves.

IV. Software for Uncertainty Estimation and Plotting of Calibration Line (CALLINE)
Calline is a DOS based software developed in C language designed to help you plot a calibration graph, determine the equation for the best fit line and estimate total uncertainty for your calibration data. Input details The following data are required. - Name of test equipment - Make of test equipment - Identification number of test equipment - Full scale reading of the test equipment - X-axis title - Y-axis title - Date of test - Number of test data

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Test meter reading, reference meter reading and the systematic uncertainty of the reference meter. (This data can be entered from an ASCII file or entered through keyboard.) Output The following output are obtained - Uncertainty Estimation for the input data - Equation for the best fit line - Calibration graph The output can be printed to a printer or stored on to a file. System Requirements A PC with DOS version 3.0 or above and 640 KB RAM. Limitations Any input value should not be zero. Minimum 5 number of test data is to be entered. The equations used for uncertainty estimation hold good for cases where X and Y are both varying linearly. The values of X or Y should not be constant. The calibration graph screen is shown .

The software is used by Industries like MTL Instruments.

V. Software for hydraulic analysis of water distribution networks (FLOWNET)

Hydraulic analysis of a water distribution network requires a computer and efficient software along with reliable data. This software is developed using Newton Raphson method. This general-purpose analysis software can be used for various applications like simulation study, identification of problems in the existing system, evaluation of various alternative solutions, design of new system etc. At present, it is capable of handling 600 lines and 600 nodes, which is quite sufficient to handle most of the municipal water supply systems. Input System Data Line data Node data : : : Source nodes, peak factor, permissible error limits, etc. Diameter, length, C-value(Hazen Williams), connectivity, line no., etc. Ground level, trial pressure, node demand, node no., etc.

Output The output includes, pressure at various nodes and flow, velocity and head-loss at each line in addition to the data. Summary of results includes total supply from the source nodes and overall error etc. Depending on the user-defined trial pressure, the model converges to the final solution rapidly. Studying each output of the above analysis is time consuming, as the printer output needs to be physically transferred to a network form. A separate software DRAW is developed to overcome this difficulty. This software reads the results of the analysis and node location data and gives an output in a network drawing form. As this drawing is presented in AUTOCAD software, other facilities like zoom, layers, color, plotting, etc. is also available. Lines having higher head-loss and nodes having Web site: www.fcriindia.com E-mail : customercare@fcriindia.com : 91 491 2566120/2566206/2566119 6

lower pressure than a user-prescribed value, are presented in a different layer / color. This helps the user to identify the problems in the network and compare various alternative solutions easily. The reduction in time to study each output enables the user to explore more solutions easily. The reduction in time to study each output enables the user to explore more possibilities to overcome the problems and arriving at the best solution in a reasonable time.

VI. Software for Unit Conversion (UNICON)

Unicon is a user-friendly software using which the user is able to convert units from one system to another using very little keystrokes. Actions to be done are indicated in the self-explanatory user interface. Unicon supports 24 parameters like length, mass, volume, area, weight flowrate, volume flowrate, force, torque, energy, power, thermal conductivity, etc. It helps the user to convert a parameter from one system of units to another in precisely 5 keystrokes. The user can directly select the FROM system of units by pressing a hot key F8 and the TO system of units by pressing the hot key F7. General Utilities include finding the fluid properties like specific gravity and viscosity at a given temperature and pressure for a number of fluids, finding ANSI Class for a given temperature, pressure, service and material, finding the internal diameter, thickness and external diameter of a pipe given its nominal size and schedule are also included. System Requirements A PC with DOS version 3.0 or above and 640 KB RAM.

VI. Software for Calculation of flowrate, beta and custody transfer properties for Natural Gas through an Orifice Plate (FLOWTECH)
Flowtech is a windows based software developed to perform the following calculations for natural gas applications. 1. Calculation of mass and volumetric gas flow through a flange tapped and pipe tapped concentric orifice meter as per AGA report no.3 (1992) 2. Sizing of flange tapped concentric orificemeter as per Millers iterative procedure and formula substituted from AGA report no 3. 3. Calculations of compressibility factor and super compressibility factor of natural gas as per AGA report no. 8. 4. Calculation of Custody Transfer Properties of natural gas as per API MPMS 14.5 (1996). System Requirements A PC with WINDOWS 95 or above.

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Consultancy Software

Software for Surge Analysis Description

Surges are initiated whenever the steady state conditions are disturbed. Such disturbances may be caused by - opening, closing of valves in a pipeline - starting or stopping the pumps in the pumping main - Starting up a hydraulic turbine, accepting or rejecting load, etc. Transients caused by sudden power failure in pumping stations are usually severe and the pipeline should be designed to withstand positive and negative pressures caused by these operations. The general guidelines for choosing the protection devices in the pipeline due to water hammer effects are suggested by FCRI by using surge analysis software. The software has been used for water hammer studies in the following cases. 1. Water supply Mild steel / Pre-stressed cement concrete water supply mains having short and steep gradients. 2. Control valves in the delivery line of pumps. 3. Effluent Disposal system of thermal power plants. 4. Penstock failures in hydroelectric power stations. 5. Gravity mains. 6. Cooling water systems. 7. Cast iron sewage pumping mains. Projects executed in this area include the following Surge Analysis study for Water Pipeline System of Karnataka State (India) Urban Water Supply and Drainage Board for the following cities. (i) Belgaum (ii) Haliyal (iii) Kumta (iv) Bijapur Study of Air Influence on Hydraulic Transients on Fluid system with Air Valves. Time Series analysis of water-use data for a City (supplied by M.P. State Pollution Control Board).

Software for Finite Element Analysis for Static and dynamic stresses, Vibration, Natural frequency response, etc Description
FCRI undertakes work in FEM area mainly using software from ALGOR Inc. By using ALGOR we will be able to do linear stress analysis, buckling analysis, non linear stress analysis, model analysis, composite stress analysis, thermal analysis, piping analysis and from vibration point of view we can do mode shape analysis, response analysis, random vibration analysis and model analysis with load stiffening for any type of structures, from beam Maximum principal stress distribution element to three dimensional complicated on valve body subjected to moment in structures. N/m2

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Some of the work done by FCRI by using ALGOR are Stress analysis in gate valve, globe valve, butterfly valve, shells due to self-weight and internal pressure, thermal stress analysis in tubes, thermal mass flow meter, mode shape analysis in sparger tube, APT, response analysis in APT, stress analysis due to vibration. Recently FCRI has carried out a study by using ALGOR and compared the results with experiments as described below. In this case-study a 250mm control valve body was analyzed using Finite Element method and the experimental stress analysis the results were compared. For Finite Element Analysis, the software package ALGOR was used. The valve body was divided into different elements and suitable boundary conditions were given. By applying, various loads stress distribution plots were obtained. For experimental stress analysis, the strain gauge technique was used. An existing external valve loading setup available in FCRI is used for applying loads like moments, tension and compression. We have obtained good agreement between experiment and FEM. Experimental and FEM stresses were obtained in two loading conditions and the comparison between these two methods in five locations on the valve body are shown in tables 1 to 3. Stress distribution for a typical case is shown in figure. Sl. No Loading Type 1 2 Tension Moment Magnitude 206765 N 27993 Nm Maximum principle stress in N/m2 at locations A to E A 3.257 e+07 0.758 e+07 B 5.866 e+07 3.486 e+07 C 4.970 e+07 2.007 e+07 D 1.464 e+07 1.128 e+07 E 0.779 e+07 0.547 e+07

Table 1: FEM analysis stresses Sl. No Loading Type 1 2 Table Sl. No Type 1 2 Table Tension Moment Tension Moment Magnitude 206765 N 27993 Nm Maximum principle stress in N/m2 at locations A to E A 3.248e +07 0.744 e+07 B 5.805 e+07 3.517 e+07 C 5.005 e+07 2.057 e+07 D 1.492 e+07 1.143 e+07 E 0.757 e+07 0.535 e+07

2: Experimental stresses Loading Magnitude 206765 N 27993 Nm Percentage of variation between FEM and Experimental stresses A 0.3 1.9 B 1.1 -0.9 C -0.7 -2.5 D -1.9 -1.3 E 3.0 2.3

3: Comparison between experiment and FEM

Software for Computational Fluid Dynamics problems using Finite

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Software for Computational Fluid Dynamics problems using Finite Volume Method Description

The advent of high speed digital computer combined with the development of accurate numerical algorithms for solving physical problems on these computers has introduced the new approach of Computational Fluid Dynamics. It provides a new third approach in fluid dynamics. It nicely and synergistically compliments the other two approaches of pure theory and pure experiment. The future advancement of fluid dynamics will rest upon a proper balance of all the three approaches with computational fluid dynamics helping to interpret and understand the results of theory and experiment and vice versa. A general purpose CFD software Fluent-5 capable of handling complex flows ranging from incompressible (low subsonic) to mildly compressible (transonic) to highly compressible (supersonic & hypersonic) is being used by the Institute. The various modules available in the software addresses various modes of heat transfer, chemical species reaction, multiphase flows, phase change modeling, turbulent models with unstructured mesh flexibility and mesh adoption. Major woks done using this software are listed below. Modelling and Measurement of Airflow and Aerosol Particle Distribution in a Ventilated TwoZone Chamber. Numerical Model simulation of Pump-Intake Flow and Vortices. Turbulent flow and Heat Transfer in a Mixing Elbow. Transonic turbulent flow around an Airfoil. Periodic flow and Heat transfer in a Tube Bank. 3-D Film cooling using a Nonconformal Mesh. Nozzle flow for a Solid-Propellant Rocket. Two- and Three-dimensional Natural and mixed convection simulation using modular zonal models in Flow through steps of Labyrinth Seal buildings. Post processing for a 3-D chip cooling simulation. Combined Radiation and Natural Convection in a square Box (2-D) and a Cube (3-D). CFD Simulation for solid-liquid mixing flow in stirred tanks. CFD Simulation for liquid-gas mixing in a Static Mixer. Chemical Mixing and Gaseous Combustion. Liquid Fuel Combustion. Pulverized Coal combustion in a 2-D furnace. Chemical Vapor deposition. Water and Air in a Spinning Bowl. Cavitating flow around a Hydrofoil. Flow in a Co-Rotating Disk cavity system. Simulation of flow through a Centrifugal Blower. Turbulent through a Fan. Rotor-Stator Interaction using Sliding meshes. Prediction of Pressure distribution in a 2-D Static Labyrinth Seal. Flow through Heat Exchanger Numerical Simulation for Laminar Forced convection through an Eccentric Annuli. Flow modeling and design improvement for multiple orifice meter Flow pattern in a multi-tube Intermediate Heat Exchanger Modeling of Cone Flowmeter
7.57e+05 6.80e+05 6.04e+05 5.27e+05 4.50e+05 3.73e+05 2.96e+05 2.19e+05 1.43e+05 6.58e+04 -1.11e+04

For any Software activity related to the above mentioned areas, other flow related field problems and further details, please contact: The Director, Fluid Control Research Institute, Kanjikode West, Palakkad 678 623. Kerala.INDIA Web site: www.fcriindia.com E-mail : customercare@fcriindia.com : 91 491 2566120/2566206/2566119 10