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Introduction
Flowmaster can take account of elevation by inputting level data at nodes. The level is from a fixed datum
point as shown below.
Example
Create a new network as below by using pipes, bends and pumps, using the values shown on the diagram.
Whilst inputting the data, select the analysis type to be Incompressible Steady State to show the data fields
which have to be completed. Note the negative figure on the flow source to highlight it is a demand.
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Pressure
Absolute Total Pressure =
Whereas Ptotal =
static +
static + ATM Pressure
Or Pat_node_level =
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static + Pdynamic
total -
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Easy Guide
Defining a Pressure
Loss Component
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Introduction
Flowmaster has a discrete loss component which allows engineers to model networks without a high
level of detail. This may be used to represent a series of pipes where it is not necessary to understand
the behaviours within the series, or where there are many branches of a pipe system and the user is only
concerned with what happens at one particular branch.
Application Example
Consider the example below as modelled in Flowmaster.
In this case, the engineer is trying to calculate the flow rate necessary to conform to the two known
pressure levels. Knowing the pipe diameter (and bend) remains constant at 1.6m, and it is not necessary to
understand other detail, this network can be defined as shown over.
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The discrete loss component is defined by cross sectional area and a Forward and Reverse Loss Coefficient.
Cross sectional area in this case is defined by r2 where r=0.8m. The Forward Loss Coefficient (k) is
calculated by
k=
k=
k=
2 x (200,000-150,000)
998 x 19.12
0.27
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business purposes only, provided that this entire notice appears in all copies. In accepting this document, the
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Application Example
Consider the network below
Liquid is being pumped from a reservoir through a pump and valve into a pipe. The pressure condition is
set at atmospheric (or 1 bar in this example). We would like to design the network and then control the
pump speed in order to understand the flow rate at the end of the pipe as the pump changes speed.
Analysis Type
In order for Flowmaster to analyse this example, you
must first change the analysis type. Flowmaster makes
it simple by only showing the data fields required for
the selected analysis.
For this example we are looking for pump performance
over time therefore a transient study. As this example
is looking at water, we need to input data for an
incompressible transient study. Choose the correct
study type from the drop down box halfway down the
data tab (see above right).
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Pumps
Next lets look at what data is required for the pump to be defined.
As with all Flowmaster components the pink fields are mandatory. Hopefully you will have a full set of
manufacturers data in order to define the pump when you come to run your own analysis. However,
some of the fields can be calculated.
Pump and Motor Inertia can be calculated from the following equations, ref Thorley (Fluid Transients in Pipeline Systems, 1991, ISBN 0-9517830-0-9):
Pump Inertia =
Motor Inertia =
Where W = Pump Power (kW), N = Pump Speed (r.p.m x 10-3), I = Inertia (kg/m2)
Pump Power (W) =
where = fluid density, = overall efficiency, g = gravity, H = Duty Head
Q = Duty flow rate
Frictional Torque
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Flowmaster Model
A simple network in Flowmaster as shown below:
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These results can be compared to those obtained from hand calculations. These hand calculations are
shown below:
Velocity
Q = Av
Where Q = 0.0010833 m3/s
A = D24
(D = 0.015 m)
This gives v = 6.14 m/s
Flowmaster gives v = 6.13 m/s
This corresponds to a 0.13% difference.
Reynolds Number
Re = vD
Where = 1000 kg/m3
v = 6.14 m/s
= 0.001002
This gives Re = 91916.2
Flowmaster gives Re = 91605.6
This corresponds to a 0.3% difference.
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Loss Coefficient
The loss coefficient can be worked out by first evaluating the friction factor. The relevant equations are
shown below:
Pressure Drop
These values can now be substituted into the following equation to work out the pressure difference:
P2 P1=K v22
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Gauge Template
Flow Rate Gauge
Gauge Template
Temperature Gauge
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Data Curve 1 is the Vapour Pressure v Temperature Curve for Glycol/Water (50/50) and is available in the
Performance Data > Materials> Incompressible library
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Data Curve 3 is the NPSHR Vs Flow Rate curve and is defined below
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Results
If the NPSHA is less then NPSHR then the controller outputs a result of 1 to record that the pump could
cavitate. If NPSHA is greater than NPSHR then the controller outputs a result of 0 to record that the pump
is not cavitating. The following graph shows a sample set of results for pump flow increasing (Blue Line),
suction pressure dropping (Red Line), and pump cavitation occurring at about 1.7secs (Green Line).
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In general, we recommend that the default values are used as they are considered well suited for general
Flowmaster analyses. Our general advice if you do experience convergence problems, check and recheck
the input data.
If, after making these checks, you believe that solver control parameters require adjustment, then the
following information will be of use.
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Flowmaster Tolerances
Flowmaster checks total pressure and temperature tolerances at every node. Mass flow rate tolerances are
checked at every branch and mass flow continuity is checked at every node to a tolerance of 1/10th of the
branch mass flow tolerance. These sequences of checks are shown diagrammatically in the figure at the
end of this paper.
The default percentage pressure tolerance is set at 0.05% and has proven satisfactory for a wide range of
applications when used in conjunction with the standard weighting factor (see below). In some situations
(high absolute pressure values and small pressure differentials) a tighter tolerance may be appropriate.
But in compressible flows, with coupling of pressure with the mass flow solution through the density
term, these tighter tolerances may be too severe.
The absolute pressure tolerance should be well below the minimum pressure of interest. The default of
1 Nm-2 (1 Pa) is usually appropriate. Its main purpose is to prevent the percentage tolerance test from
becoming too severe when pressures are very close to zero.
The default percentage mass flow rate tolerance is set to 0.05% and has proven satisfactory for a wide
range of applications, when used in conjunction with the standard weighting factor.
The absolute mass flow tolerance should be well below the minimum mass flow rate of interest. It is
intended to prevent the percentage test from being too severe when flows are very close to zero e.g. in a
branch with a closed end or shut valve. The default value of 0.5gms-1 can be too high if low flow rates are
being used (e.g. grams per second).
The default weighting factor (or relaxation) is set to 0.5 and should be used in preference to a lower value
unless convergence problems are encountered. The default value should be appropriate for most stable
networks. If it proves necessary to reduce the weighting factor, then tighter pressure and mass flow
rate tolerances are required to achieve a similar level of accuracy. As a rule of thumb the pressure and
mass flow rate tolerances should be halved for each 0.1 reduction in weighting factor. (For example, use
tolerances of about 0.0125 % for a weighting factor of 0.3).
In transient analyses, increasing weighting factor, to say 0.7, can help with rapid events. However, do not
increase tolerances in transient analysis to improve convergence; it usually does the reverse.
Nodal temperature tolerance checks work in the same way as for pressure. But unless the network
comprises of closed loop systems (where an equilibrium temperature must be found) the calculated
temperatures will follow directly from the mass flow and pressure solutions. If improved temperature
accuracy is required it will often be better to tighten the mass flow tolerance - there is usually a better
feel for reasonable values for this quantity.
The minimum heat flow tolerance is only used by solid components (bars, bridges, temperature, heat
sources etc.).
The following flowchart shows how Flowmaster checks for convergence.
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business purposes only, provided that this entire notice appears in all copies. In accepting this document, the
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Example
A simple network has been constructed to validate the following relationship
Av = 28 x 10-06 Kv, where Av=Flow Coefficient (m2) and Kv=European Flow Coefficient (m3/h)
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Density <kg/m3> results:
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gives
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recipient agrees to make every reasonable effort to prevent unauthorized use of this information. All trademarks
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L
at
Example
This example demonstrates how a simple network can be modified in order to optimise computational
effort while still meeting the S criteria
The above pipes are 1000m and 675m long, applying the equation for S to this network gives
Schedule of Pipes
t1 =
0.1s
t2 =
0.02s
L (m)
a (m/s)
L/a (s)
S1
S2
Pipe 1
1000
1000
10
50
Pipe 2
675
1250
0.54
5.4
27
t = 0.02 s satisfies the criterion for S. This solution gives a large number of internal reach lengths and
combined with the 3000 time-steps required to run the simulation for 60 seconds requires considerable
computational effort.
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Length adjustment
Pipe 2 is split into a 650 m elastic pipe and a 25 m rigid pipe.
t1 =
0.1s
Schedule of Pipes
L (m)
a (m/s)
L/a (s)
S1
Pipe 1
1000
1000
10
Pipe 2a
650
1250
0.52
5.2
Pipe 2b
25
RIGID
t = 0.1 s satisfies the criterion for S. The loss in accuracy of considering pipe 2 in two sections, one rigid
and one elastic is within the overall accuracy of the method. Computational effort is reduced with fewer
internal reach Iengths and 600 time-steps being required.
Schedule of Pipes
L (m)
a (m/s)
L/a (s)
S1
Pipe 1
1000
1000
10
Pipe 2
675
1300
0.519
5.19
t = 0.1 s satisfies the criterion for S. The loss in accuracy of considering the wave speed in pipe 2 to be
4% greater than that estimated is within the accuracy of wave speed prediction and the overall accuracy
of the method. Computational effort is about equal to the length adjustment method.
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business purposes only, provided that this entire notice appears in all copies. In accepting this document, the
recipient agrees to make every reasonable effort to prevent unauthorized use of this information. All trademarks
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Example
In order to size a centrifugal pump for a given network, it is necessary to simulate it over a range of flow
rates. To do this, create a curve which encompasses the range of interest in this case we know that the
system in question will never have to deal with flows greater than 6 cubic metres a second
Run the network for 60 seconds to cover the range of possible flow rates for the system. To create a
system curve, select the flow rate results for the valve and click X axis for plotting
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In the example below, two pumps are plotted along with the system curve (the purple line). The
intersection of the system curve with each pump curve represents the point at which the energy
provided by the pump matches that required by the system.
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By selecting the valve arm 2 flow rate result (select x axis for plotting as before) and the upstream node
pressure, a pump curve showing the drop in back pressure with increasing flow rate can be achieved.
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Easy Guide
Flow Balancing
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Application Example
In the Fire Protection System above, water is pumped from a constant head reservoir by the fire water pump
through a control valve and into a branched network of sprinkler nozzles. The required analysis is to calculate
the orifice plate diameters that will achieve a specified flow rate through each sprinkler nozzle.
Example Data
The example network data are shown in the tables below. In this example, the sprinkler nozzles are
represented by a Discrete Loss and Constant Head Reservoir. The required flow rate through the nozzles is 7
litres per second (0.007m3/s).
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Cross-sectional Area
0.03m
Pipe Diameter
0.025m
0m
0m
Pipe components
All pipes
Diameter: 0.2m
Radial Pump
Rated Flow
0.25m3/s
Rated Head
80m
Rated Speed
1450rpm
Rated Power
200kW
Initial Speed
1450rpm
0.2m
5m
-20m
Pipe 1, 11
Length: 20m
Pipe 2-3
Length: 10m
Pipes 4-10
Length: 2m
Ball Valves
0.2m
Valve
opening
0 ratio (closed)
Orifice Plates
Valve opening
1 ratio (open)
0.03m2
Pressure Source
Pipe Diameter
0.2m
Orifice Diameter
Not Set
0.007m3/s
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0.2m
Discrete Loss
Diameter
Total pressure
1 bar
As with all Flowmaster components the pink fields are mandatory. To size the orifice plate using Flow Balancing
we need to enter the pipe diameter and the required Volumetric Flow Rate, in this case 0.2m and 0.007m3/s
respectively. The value for the Orifice Diameter is left as Not Set as it will be calculated in the analysis.
Analysis Type
Once the model is complete, select the simulation tab
and change the analysis type to Incompressible Flow
Balancing by selecting from the drop down menu.
Then click run. Once completed, select the results tab
and double click the result file you have just created.
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Results
Double click on one of the Orifice Plates to view the calculation data.
In the Results view, the Flow Rate is shown as the required input value of
0.007m3/s, giving a calculated orifice diameter of 0.0169476m.
The calculated operational values for the balancing components can now
be updated in the Data tab view.
Volumetric flow rate can be specified in most components, but it is most
appropriate to components that can be set up to give the desired flow rate
at the pressure conditions prevailing in the network. The components
most suited to the use of balancing flows are control valves, orifices, pipes,
pumps, reservoirs and accumulators.
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Easy Guide
Incompressible Priming
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Application Example
In the Fire Protection System above, water is pumped from a constant head reservoir by the fire water
pump through a control valve and into a hose (Priming Pipe). The required analysis is to calculate how
long it will take the water to exit the hose end, i.e. how long it takes the water to fill the priming pipe.
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Example Data
The example network data are shown below.
Pipe components
All pipes Diameter
Absolute Roughness
Wave Speed
Pipes 8 & 10 Length
Pipe 7 Length
Pipes 5 Length
0.2m
0.05mm
1000m/s
2m
20m
100m
Radial Pump
Rated Flow
Rated Head
Rated Speed
Rated Power
Pump Inertia
Motor Inertia
Speed Ratio
Friction Torque
Initial Speed
0.25m3/s
80m
1450rpm
200kW
50kgm2
25kgm2
1
500Nm
1450rpm
0.2m
5m
-20m
Ball Valves
All Valves Diameter
Valve 9 Valve Opening
Valve 6 Valve Opening
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0.2m
1 ratio (open)
0 ratio (closed)
1 bar
Discrete Loss
Forward Loss Coefficient
Reverse Loss Coefficient
Cross Sectional Area
5
5
0.001m2
0s
0 ratio (closed)
2s
1 ratio (open)
1000 s
1 ratio (open)
Note: Nodes (8, 9 and 10) downstream of the opening valve should be set to compressible, i.e. all nodes in
the priming section of the network. Changes to the type of node can be done in the node data form.
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Analysis Type
Once the model is complete, select the
simulation tab and change the analysis type
to 7. Incompressible Priming by selecting
from the drop down menu.
Enter the following values for simulation time
and time step
Time step
0.0005 s
Simulation Start Time 0 s
Simulation End Time 10 s
Then click run. Once completed, select the
results tab and double click the result file you
have just created.
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Results
In Results mode double click on component 8 Pipe: Cylindrical Elastic
to view Results form.
In the Results view, highlight Liquid Length, click Inspect... and select
plot.
The resulting plot will show you how the priming pipe filled and how
long it took to achieve this.
The components that can be primed include Discrete Losses, Orifices, Pipes, Pressure Sources and Control
Valves.
Those that can not include Accumulators, Heat Exchangers, Bends, Diaphragms, Junctions, Transitions,
Pumps, Reservoirs, Flow Sources, Flow v Pressure Sources, Check Valves and Weirs
Many of the components that cannot be primed can still be used in the liquid section of the system.
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Easy Guide
Defining a Fluid
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Fluid Properties
- Fluid Density (kg/m3)
Cp - Constant pressure specific heat (J/(kg K)
Cv - Constant volume specific heat (J/(kg K)
- Ratio of specific heat (Cp/Cv)
Z - Fluid compressibility factor
- Dynamic viscosity (N s/m2)
k - Thermal conductivity (W/m K)
R - Gas constant (J/kg K)
Deduced properties
c
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There are three methods to defining a fluid within Flowmaster, they are as follows;
1. For an Isothermal analysis, the fluid can be defined at a single temperature.
Data for the following properties is required
Reference temperature
Vapour Pressure
Reference Dynamic Viscosity
Reference Density
Bulk Modulus
2. For a temperature varying analysis, the fluid can be defined using fluid
property versus temperature curves or equations.
Data for the following properties is required
Bulk modulus (can also be defined as a Bulk Modulus v Temp & Pressure surface)
Vapour pressure v Temperature curve
Viscosity v Temperature curve
Density v Temperature curve
As an alternative to the curves the viscosity, density and specific heat capacity can be calculated by the
following means:
The viscosity can be calculated using the Walther Equation coefficients to effectively
calculate a temperature v viscosity curve. (see Reference help > fluid properties)
The variation of density with respect to temperature can be calculated using
the thermal expansion coefficient and the reference and actual temperatures.
The variation of specific heat capacity with respect to temperature can be
calculated using the coefficients A to F in place of a curve.
3. Eagle Database
Set the composition of the fluid using the eagle reference (maximum 5 different pure components), and also
set the following;
Equation of state
Vapour Pressure
Bulk Modulus
Mole Fractions of fluid components.
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Application Example
Consider the example above where all pipe diameters and valve diameters are to be the same. Rather than
enter each data value individually you can enter the diameter into one component and then copy this
value to all other selected components. First we must collect the components for which we want to enter a
common diameter.
Collecting components
When first building a network and a component is placed onto the schematic or a node is created, it is
automatically listed in the Data pane in the component collection.
When re-opening a network you can collect components and nodes in several ways;
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Data entry
To enter a common diameter for all components in the collection, first select one of the components and in
the lower pane click the Diameter entry field.
A drop down menu will automatically appear next to this cell allowing you to choose a unit for that value.
The default unit is the one that is selected as such for that unit set.
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Copying Data
To copy a value from one component to another, the first step is to tick the box next to the desired value in
the Copy column and then select the Copy icon in the top right of the lower pane.
This will open the Copy Features window where you can specify the copy function of your choice:
For example, if you want to copy the diameter from one pipe to the other, you can choose the Strict
matching (matches component type and data field name), but if you want to copy it over to both the pipe
and the valves, select Relaxed matching (only matches data field name).
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Composite Components
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Composite Components
Using Flowmaster V7, a design engineer can combine several standard Flowmaster components to model
complex geometries of individual components.
Application Example
The following example is taken from the automotive industry and represents a silencer model for an
automotive exhaust system.
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Accumulator Gas
This is the standard compressible accumulator component in
Flowmaster. For this application we will be using these components to
model the large volumes in the individual chambers of the silencer that
have perforations to account for the volume and mass accumulation.
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Example Data
The example network data are shown below.
Components 1 and 2: Pipe: Cylindrical Gas
Pipe Diameter
0.025 m
Pipe Length 1
0.1 m
Pipe Length 2
0.15 m
Absolute Roughness
0.025 mm
0.05 m
Pipe Diameter 2
0.05 m
Total Volume
0.001 m3
Polytropic Index 1
1.4
Polytropic Index 2
1.4
Pipe Diameter
0.03 m
Pipe Diameter
0.05 m
Orifice Diameter
0.02 m
Orifice Diameter
0.02 m
0.05 m
Minor Diameter
0.025 m
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0.015 m
0.02 m
Accumulator Volume
0.003 m3
Initial Temperature
80C
Polytropic Charge
1.4
Polytropic Discharge
1.4
Pstatic + Pdynamic
Or Pat_node_level =
Ptotal -
To validate the model, a pressure source is added at inlet and outlet and a Compressible Steady State
simulation performed.
Components 13 and 14: Pressure Source
Total Pressure 13
4 bar
Total Pressure 14
1 bar
Once our model is confirmed we are then ready to create our data form for the composite component.
There are several steps to doing this. These are listed below and we will discuss each step in detail.
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Assigning a Symbol
After you have created your network the next step is to assign a symbol to the composite. This is done from
the Connections tab in the Network View selecting the Symbol button.
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Absolute Roughness
0.025 mm
Polytropic Charge
1.4
Polytropic Discharge
1.4
Logic: Pressure and Temperature changes will not be significant enough to affect the Polytropic Index.
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0.05 m
Pipe Diameter 2
0.05 m
Logic: Using orifices and transitions to model the flow losses and velocity changes from 1 chamber to the next.
Polytropic Index 1
1.4
Polytropic Index 2
1.4
Logic: Pressure and Temperature changes will not be significant enough to affect the Polytropic Index.
0.05 m
Logic: Set large to simulate significant difference in the flow area to properly model the velocity changes.
Components 8, 9, 10: Transition: Abrupt
Major Diameter
0.05 m
Logic: Set large to simulate significant difference in the flow area to properly model the velocity changes
Once these individual data items are set we are then ready to create our data form for the composite
component.
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Component
Data item
Same As
Component No.
Custom Field
Name
Length
Unique
Diameter
Pipe Diameter
Length
Unique
Internal Pipe
Length
Diameter
Pipe Diameter
3 Fixed Volume
Total Volume
Unique
Chamber 2 Volume
4 Fixed Volume
Total Volume
Unique
Chamber 3 Volume
5 Fixed Volume
Total Volume
Unique
Chamber 5 Volume
Orifice Diameter
Unique
Orifice Diameter
Unique
Exit Diameter
8 Transition: Abrupt
Minor Diameter
1, 2, 9, 10
Pipe Diameter
9 Transition: Abrupt
Minor Diameter
1, 2, 8, 10
Pipe Diameter
10 Transition: Abrupt
Minor Diameter
1, 2, 8, 9
Pipe Diameter
11 Accumulator: Gas
Pipe Diameter
Unique
11 Accumulator: Gas
Total Volume
Unique
Chamber 1 Volume
11 Accumulator: Gas
Initial Temperature
12
Initial Temperature
12 Accumulator: Gas
Pipe Diameter
Unique
12 Accumulator: Gas
Total Volume
Unique
Chamber 4 Volume
12 Accumulator: Gas
Initial Temperature
11
Initial Temperature
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Pipe Diameter
Chamber 1 Volume
Chamber 2 Volume
Chamber 3 Volume
Chamber 4 Volume
Chamber 5 Volume
Exit Diameter
Initial Temperature
Now that we have determined all of the inputs that will be required for our silencer we are ready to build the
data form.
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Note: there is not a default field type for Internal Pipe Length so we chose an Equivalent field simply named
Length.
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Component
Data item
Pipe Diameter
Diameter
Diameter
8 Transition: Abrupt
Minor Diameter
9 Transition: Abrupt
Minor Diameter
10 Transition: Abrupt
Minor Diameter
Length
Length
Chamber 1 Volume
11 Accumulator: Gas
Total Volume
Chamber 2 Volume
3 Fixed Volume
Total Volume
Chamber 3 Volume
4 Fixed Volume
Total Volume
Chamber 4 Volume
12 Accumulator: Gas
Total Volume
Chamber 5 Volume
5 Fixed Volume
Total Volume
11 Accumulator: Gas
Pipe Diameter
12 Accumulator: Gas
Pipe Diameter
Orifice Diameter
Exit Diameter
Orifice Diameter
Initial Temperature
11 Accumulator: Gas
Initial Temperature
12 Accumulator: Gas
Initial Temperature
The Figure below shows the proper mapping for the Inlet Pipe Length. We can see from the Table above
that the Length of component no. 1 is the proper field to map. So first, highlight Inlet Pipe Length in the
custom fields and then expand component 1 to show all the input fields.
Flowmaster applies a sorting logic and inactivates any field that could not match the data type that you
have chosen so it is easy to see that length is the only option for this component.
Check the box next to Length.
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Component
Data item
11 Accumulator: Gas
Gas Mass
Chamber 1 Pressure
11 Accumulator: Gas
Pressure
12 Accumulator: Gas
Gas Mass
Chamber 2 Pressure
12 Accumulator: Gas
Pressure
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1 Bar
4 Bar
Now run a compressible steady state analysis and compare the results for the Chamber 1 gas mass and
pressure with those same items for component 5 Accumulator: Gas and the results for Chamber 2 gas mass
and pressure with component 6 Accumulator: Gas.
If the composite is created correctly these results should match.
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