Flowmaster V7 New User Training

Version 10

Notices
Flowmaster Limited reserves the right to make changes or improvement without notice to the software product described in this document. Flowmaster Limited has made every effort to ensure that the material contained in this document is accurate. Flowmaster Limited assumes no responsibility for any factual or typographical errors that may have occurred. The software product described in this document is supplied under a Flowmaster Software License Agreement. Copyright in the whole and every part of the software program belongs to Flowmaster Group BV (the owner) and may not be used, sold, licensed, transferred, copied or reproduced in whole or in part, in any manner or form, in or on any media to any person, other than in accordance with the terms of the owners license or otherwise without the prior consent of the owner. No responsibility is assumed for the use of software or hardware that is not supplied by Flowmaster Limited, or its affiliated companies. Flowmaster Limited makes no warranty, express or implied, as to the function or performance of the program described herein or the accuracy of the documentation provided. Flowmaster Limited specifically disclaims any liability for any special, consequential or incidental damages arising from the manufacture, sale or use of the program. Users of the program should make the final evaluation of the results presented and their usefulness in their own environment.

2007 Flowmaster Group BV. All rights reserved. The mark Flowmaster is a Community Trade Mark of Flowmaster Group BV and a Registered Trademark in the USA & Korea. US Government Licensees Restricted rights apply.

Table of Contents

CONTENTS Chapter 1:
1.1 1.2 1.3 2.1 2.2

Introduction ........................................................1

Chapter 2:
2.1.1

Who is Flowmaster Group?......................................................... 1 Flowmaster V7 .............................................................................. 2 Flowmaster V7 Key Strengths .................................................. 2

Flowmasters GUI ...............................................5

Starting Flowmaster ..................................................................... 5

Database Management Overview .................................................... 6

2.2.1 2.2.2 2.2.3 2.2.4

Project Views .............................................................................. 10

Networks ................................................................................................ 10 Catalogues ........................................................................................... 13 Users........................................................................................................ 13 Share ...................................................................................................... 15

2.3

2.3.1 2.3.2 2.3.3 2.3.4 2.3.5

Building a Network..................................................................... 16
Click, Drag and Drop........................................................................... 16 Connections.......................................................................................... 16 Toolbar Functionality ........................................................................... 17 Filter ........................................................................................................ 18 Palette.................................................................................................... 18

Exercise 1 ........................................................................................ 19 2.4 Network Views............................................................................ 20

2.4.1 2.4.2 2.4.3 2.4.4 2.4.5

Data Collection .................................................................................... 20 Data Input ............................................................................................. 22 Copying Data....................................................................................... 23 Selecting a Unit Set .............................................................................. 24 Curve Data ........................................................................................... 26

2.4.6 2.4.7 2.4.8

Exercise 2 ........................................................................................ 28 Exercise 3 ........................................................................................ 29

Surface Data......................................................................................... 29 Equation Editor ..................................................................................... 30

Exercise 4 ........................................................................................ 30
Simulation Type Filter............................................................................ 32 Simulation Types and Options ............................................................ 32

2.5

2.5.1 2.5.2

Running Simulations................................................................... 32
Errors and Warnings ............................................................................. 35

Exercise 5 ........................................................................................ 34 Viewing Results ........................................................................... 35

Viewing Component and Node Results........................................... 35 Drawing Results..................................................................................... 36 Plotting Results ...................................................................................... 38 Report Generation............................................................................... 38

2.6

2.6.1 2.6.2 2.6.3 2.6.4

Table of Contents

Chapter 3:
3.1
3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15 3.1.16 3.1.17

Steady State .....................................................41

Details of Each Component Family ........................................ 42

Chapter 4: Chapter 5:

Pipes ....................................................................................................... 42 Bends...................................................................................................... 43 Control Valves ...................................................................................... 44 Check Valves........................................................................................ 44 Directional Control Valves .................................................................. 46 Relief Valves .......................................................................................... 46 Junctions................................................................................................ 46 Transitions............................................................................................... 47 Orifices ................................................................................................... 47 Pumps..................................................................................................... 48 Motors..................................................................................................... 49 Reservoir ................................................................................................ 49 Accumulators ....................................................................................... 50 Sources................................................................................................... 51 Controllers ............................................................................................. 52 Cylinders ................................................................................................ 52 Loads...................................................................................................... 53

Steady State Examples ...................................55 Transient Simulation .........................................65

5.1 Causes of Severe Pressure Surge............................................. 65 5.2 Suppression of Fluid Transients ................................................. 65 5.3 Wave Propagation and Estimation of the Maximum Transient ................................................................................................ 66 5.4 Rapid, Slow and Very Slow Changes in Flow ........................ 66 5.5 Speed of Propagation of Pressure Waves ............................. 67 5.6 Water Filled Pipes....................................................................... 68 5.7 Pipes............................................................................................. 69
5.7.1 5.7.2 Rigid Pipe Model .................................................................................. 70 Elastic Pipe Model................................................................................ 70

Chapter 6: Chapter 7:
7.1 7.2 7.3 7.4
7.1.1

Exercise 6 ........................................................................................ 71 5.8 Valves .......................................................................................... 73 5.9 Pumps .......................................................................................... 74 5.10 Controllers ................................................................................ 75

Transient Simulation Examples........................77 Catalogue Customisation The Basics .........95

Materials ...................................................................................... 95

Create a New Material Based on a Template................................ 95

7.3.1

Sub-systems and Sub-circuits ................................................... 96 Symbols and Symbol Sets ......................................................... 98

Component Symbol ............................................................................ 99

Custom Organisation of Catalogues ................................... 101

Table of Contents 7.4.1 Shortcuts.................................................................................................... 102 7.4.2 Copying Components to Catalogues ................................................. 102

Chapter 8:
8.1 8.2 8.3 8.4
8.1.1

Additional Features .......................................105

Schematic Configuration and Background........................ 105

Adding a Background Image.......................................................... 106

Chapter 9:
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8

Catalogue Searches ............................................................... 106 Dynamic Colouration.............................................................. 108 Layers......................................................................................... 109 Exercise 7 ...................................................................................... 111 8.5 Pack / Unpack ......................................................................... 113

Advanced GUI Capabilities .........................117

Chapter 10: Services and Support ..................................145 Other Courses.......................................................................147 Appendix - Results................................................................151

Add/Replace Components................................................... 117 Descriptive Sub-Forms ............................................................. 118 Exercise 8 ...................................................................................... 119 Adding Custom Help Descriptions ........................................ 120 Component Templates........................................................... 123 Composite Components........................................................ 130 Exercise 9 ...................................................................................... 131 Audit Trail................................................................................... 137 Variable Parameters ............................................................... 140 Analytical Models An Introduction .................................... 142

Introduction

Chapter 1:

Introduction

Welcome to Flowmaster. This course will take you through the user interface and functionality of V7.

1.1

Who is Flowmaster Group?

Flowmaster Group develop, market, sell and support a market leading fluid flow solution, Flowmaster, giving you tools to perform thermal and fluid simulations on complex systems throughout your development process.

Our aim is to make complex fluid flow simulation accessible throughout your development process, to enhance your design decisions and ensure sustainable return on investment.

The Group employ 95 staff in 6 countries. With 12 authorised Value Added Resellers covering the Far East, Australia, South Africa, the Middle East and Eastern Europe. We have 16 support teams around the world, giving you access to our skilled support services at the right time.

Flowmaster is developed to BS-EN_ISO 9001:2000 & TickIT standards.

Introduction

1.2

Flowmaster V7

Flowmaster V7 is an advanced CAE/CFD Virtual Systems Modelling tool that enables engineers to model the most challenging transient hydraulic problems in complex systems. You can understand the fluid flow effects within a complex system, by calculating the internal flow and thermal effects through the use of empirical and mathematical relationships of pressure, flow rate and temperature.

1.3

Flowmaster V7 Key Strengths

Collaboration
Flowmaster provides you with the tools to ensure that your simulation data and component models can be safely shared across your organisation and supply chain. Organise your simulation data within customised catalogues, ensuring all team members have fast access to data relevant to your application, thereby increasing workflow and productivity.

Integration
Flowmasters architecture allows you to integrate with your existing design and manufacturing systems and share data with other leading CAE/CFD tools.

Data Management
Establish complete traceability and audit trails for simulation models allowing you to find, identify and interrogate past simulations and their associated model parameters.

Scaleable

Introduction
Whether you are using a single license of Flowmaster or running multiple users and projects across numerous offices, Flowmaster offers you the flexibility to configure the software to meet your working procedures or collaboration needs.

Smart Modelling
With in-built system intelligence, Flowmaster ensures you only use compatible components within the appropriate system models, coupled with reducing required user experience and eliminating possible human error.

Continuity
Flowmaster offers a completely upwardly compatible system, minimising the disruption of your simulation projects and enabling you to make full use of your legacy data when upgrading to future versions.

Software Architecture
With a flexible .NET architecture, Flowmaster provides you with tools to customise the software to fit your application and integrate with your existing systems and processes. With a secure Microsoft SQL server underpinning its architecture, Flowmaster can provide access to all designs, libraries and customised components to all project team members across an entire organisation.

Flowmasters GUI

Chapter 2:

Flowmasters GUI

Flowmasters Graphical User Interface (GUI) allows you to design and test your systems quickly and efficiently. Working from left to right in an ordered manner means you dont miss out crucial data you may need for your simulation. All stages are fully customisable by you and you can access Help windows at all stages, as well as add your own project or company notes. This chapter will cover the following topics: o o o o o o Starting Flowmaster Project Views Building a Network Network Views Running Simulations Viewing Results

2.1

Starting Flowmaster

To open Flowmaster double click on the desktop icon. When the License Selection window appears click Select.

You will then be prompted to select the Database you would like to log on to. If working locally you will need to have first attached a database using SQL Server Management Studio Express (see section 2.1.1) or equivalent SQL Server tool, otherwise you simply type in the name of your central SQL Server database.

Flowmasters GUI
The Data Source refers to the computer name where Microsoft SQL Server 2005 Express is running. If the local machine is the data source this will have the form HOSTNAME\SQLEXPRESS.

The Database Name is the name assigned to the database in the SQL Server Management tool (Express version is supplied as standard but individual companies may use larger capability SQL tools), the default name is Flowmaster.

To select a Project to log on to, click on the button to the right of the Project Name. On first installation you will need to select Flowmaster as this is the only Project available.

The only predefined User in a new Flowmaster V7 database is Admin, with a blank password. Additional users can be created in the application and will log then need to log in to their pre-defined project with their own user name and password. We recommend that you give the Admin user a password immediately to ensure the database is secure.

To log on to a database created by another user, please ensure that you have a user account then enter the relevant Data Source and Database name in the Logon window.

2.1.1

Database Management Overview

The Flowmaster SQL database comprises of two files Flowmaster_Data.MDF and Flowmaster_log.LDF.

Flowmaster_Data.MDF This file contains all the Flowmaster supplied database data and the user defined data (including network configurations etc). This file should be carefully backed-up periodically. In the SQL Express version supplied with Flowmaster this database is limited to 5 concurrent users and has a size limit of 4GB. Higher spec versions allowing more concurrent users and indefinite size limits are available to purchase from Microsoft.

Flowmaster_log.LDF This file contains a log of all the database transactions (a transaction is any event that will changes the database eg entering a new curve/network/unit set) which occurred in the database since it was last backed up. This file does not affect the size limit of the database. The idea of this file is to allow a database to be rebuilt form a previously backed up .MDF file to the last known status by simply using the .LDF file to re-run all the transactions. The LDF file does not have to be stored in the same location as the .MDF file. In fact if working on a central database it is a good idea to store the two files on different servers for extra redundancy should anything happen to one of the servers.

Flowmasters GUI
Use of SQL Express When you first Launch SQL Server Management Studio Express you will be greeted with a log-in screen as follows:

The Server name will have the format HOSTNAME\SQLEXPRESS When logging in using Windows Authentication (strongly recommended) the user name will have automatically been set using the windows log-in of the user.

Once the server name is entered the connect button should be selected to start the server.

Flowmasters GUI

Once SQL has connected the above screen will be visible. To attach a new (or previously used database) simply follow these steps.

Attaching a Database in SQL 1. Right click on databases folder (top left corner) to reveal context menu. 2. Select attach option to open database attach window (as seen below). 3. click on the add button and browse to the required .mdf file. 4. Click on the .mdf file to attach and add them to the database attach window. 5. If required (as all database attached must have distinct names) you can rename the database by typing in a new name in the attach as section. 6. Click on the OK button (bottom right) to complete attaching of database.

Flowmasters GUI

Once database is attached it should appear on the list of attached databases as in the screenshot below (Database name Flowmaster). Flowmaster V7 is now ready to be launched with the attached database.

Flowmasters GUI

Note:

Databases can be renamed after they are attached by right click on the database folder and selecting the rename option from the context menu.

Important:

Existing system database should not be deleted or modified in any way as these are used solely by SQL to manage the databases and are not directly Flowmaster related.

2.2

Project Views

The Project Views work pane is your starting point. Here you can create new projects and networks within your project as well as access your Catalogues.

2.2.1

Networks

Creating a New Project

You create a New Project from the Networks pane. To activate the New Project Networks tab and then click the top level administration folder. icon, click on the

Alternatively, right click on the top level folder and choose New Project.

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Flowmasters GUI
A new folder will appear in the tree structure, you can rename it if you wish. To display or modify its properties, click on your Project name and the relevant properties will appear in the lower part of the Project View pane.

You can toggle this view using the Show/ Hide Properties pane.

icon at the top of the Project View

You can add a description and select unit and symbol sets by doing the following: To add a Description Click on the adjacent cell and then click the button to open the Description dialogue. Click OK. To select a Unit Set Click the adjacent cell, then click the button to open the Select Unit Set window, choose the required unit set and click OK. To select a Symbol Set Click the adjacent cell, then click on the button to open the drop down menu and select the required set.

Creating a New Network

To create a new Network you can either:

Activate the New Network chosen project.

icon, click on the Networks tab in the Networks pane and click on your

Or alternatively, right click on your chosen project and select New Network.

When you click on New Network, the network is added to the project and highlighted as New Network Name. You can now enter a name for your network.

11

Flowmasters GUI
Creating a network will also open the networks properties window in the lower pane and open the Network window.

You have now created a new network. As with Projects, you can see and modify a Networks properties in the lower pane:

To give a Description to the network, click on the adjacent cell to display a button and then click on the button to open the Description window. Once you have entered a Description, click OK.

To set a Simulation Type Filter, click on the adjacent cell to open the drop down menu and select the required filter.

Moving a Network
Networks can be easily dragged between projects, you will find this useful when you are unpacking networks (see Pack/ Unpack section).

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Flowmasters GUI 2.2.2 Catalogues

Flowmaster files all database elements in Catalogues, from components to curves and surfaces.

The following Catalogues are provided with Flowmaster: Analytical Models - Mathematical representations of all the Flowmaster components are stored here. You can add sub-catalogues to this main catalogue to hold the models that you create. Components - This catalogue holds a list of all Flowmaster supplied components. You can add sub-catalogues, each of which can contain components relating to specific applications. Materials - Holds all Flowmaster supplied fluids, liquids and solids. Also supplied is a range of templates that you can use to create new fluids, liquids or solids. Performance Data - Holds all Flowmaster supplied equations, curves, surfaces, etc. As above, you can create a sub-catalogue that holds performance data used by specific applications. Scripts - Holds all Flowmaster supplied scripts (Flowmaster Supplied Generic catalogue). You can save your own scripts in the User-defined catalogue. Sub-systems - This catalogue is used to store sub-circuits. Symbols - Holds symbols of all Flowmaster supplied components. Again, you can add subcatalogues, each of which can hold symbols for components for specific applications as described above.

2.2.3

Users

A user account holds details of a users individual privileges. The account details what a user can and cannot do in Flowmaster. For example, one user could be granted permission to create projects, whereas another user may only have permissions to create and configure networks. The Users pane is used to manage user accounts and is primarily used by the following personnel: 1. Administrators - have complete control over all the operations that can be performed from the Users pane. Also, as an administrator responsible for setting up user accounts, it is up to you to decide what aspects of Flowmaster, your users can access. 2. Project Owners - as a Project Owner, you can: allow a new user access to projects that you control amend their access rights, or delete a user providing you have administrator status.

3. Individual Users - as an individual user, you can only change your password.

13

Flowmasters GUI
To access the Users pane click on the Users tab.

In the example shown above, the top pane shows that two users have been set up for the top-level Flowmaster entry while a single more restricted user has been configured for each of the defined projects. The lower pane shows the user privileges assigned to User 1 of Project A. The window to the right shows the selection of catalogues that the administrator has assigned to that user. These work on a traffic light system as follows: Red catalogue will not be visible to user Amber certain sub-catalogues or items are selected to be available to user Green Catalogue/sub-catalogue or item is available to user. To see the details for other users, select each one to display their details.

14

Flowmasters GUI 2.2.4 Share

The Sharing function allows you to 'share-out' selected projects to other projects. When you do this, the exported projects networks are also exported. Click on the Share tab to display the Share pane. Next, right click on the project you want to export and select the Share option. The Select Project to Export To window will appear, giving a list of projects. Select the project that you want to export to. To enter a description, click the Description button and the Description window will appear. Enter the description and then click OK to close the window and then click OK. The list expands to show the exported project has been added to the 'owning' project. Also the properties for the exported project are displayed in the lower left pane.

The above example shows that project A has been shared out to the users of Project B with permission to only view the network and the set network data. However the users of project B can run project A analyses and view the results.

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Flowmasters GUI

2.3

Building a Network

The Schematic View work pane enables you to create a visual view of your network by dragging and dropping components from Catalogues into the work pane. This pane is part of the Network window which will automatically open each time you create a new network. If you want to open an existing network, you can either double click on the network in the Networks pane, or right click on it and choose Open.

2.3.1

Click, Drag and Drop

From the Catalogues pane, you can click, drag and drop components from the Components catalogue directly onto the Schematic View pane to quickly build your network. The components are classified in sub-catalogues, e.g. Bends, Sources, Pipes.

When hovering over a specific component, its graphical representation in the Schematic View will appear next to the cursor (exemplified with a pressure source seen here on the right):

If you want to add several components of the same type, you can use the components already placed on the schematic. To do so, right click on the component in the schematic and select Copy (or choose the Copy function from the toolbar). You can then drop the components multiple times by left clicking on the schematic (or right click and select Paste).

2.3.2

Connections

You can connect components, by hovering over the connection points on the component, then holding the left mouse button down, point to a connection point on another component. Flowmaster will tell you if you are unable to connect two components, e.g. they cannot be connected as one is a mechanical component and the other a fluids component.

When you make your first connection in each network, the Circuit Type Precedence window will open. Select your circuit type and click OK.

16

Flowmasters GUI
You can also choose what type of connection you want, i.e. straight or orthogonal. To change the connection type, right click on a node and select the desired connection type:

2.3.3

Toolbar Functionality

In the Schematic Toolbar at the top of your Flowmaster window you will find tools to: show or hide the grid in the background of the Schematic View pane snap the position of components and nodes to the grid after moving mirror X-axis mirror Y-axis rotate clockwise align horizontally align vertically insert comment move text display or suppress component name display or suppress component ID display or suppress node name display or suppress node ID

In the Schematic Zoom & View Toolbar you will find tools to: percentage zoom zoom out zoom in zoom to fit normal network overview pan

17

Flowmasters GUI
For more details on any of the above-mentioned tools, please refer to the Toolbars section in the Flowmaster/Reference Help (which can be found in the Help menu, see also chapter 8).

2.3.4

Filter

When creating a network, the components are selected in the Components catalogue and then dragged and dropped into the Schematic View pane of the Network window.

Clicking the Filter icon will hide all catalogues not containing drag-able components, providing you with an intuitive and clear work area.

2.3.5

Palette

The Palette appears as a tab on the left hand side of the main work pane when you open a network and automatically expands when you click on it. When you click on a Catalogue, for instance Bends, all the available Bends will be displayed in the Palette window and when you click on the tab, its name will change accordingly, as seen on right. The Palette is particularly useful when you have a catalogue containing all the components that you use in a network (the next section describes how such a catalogue can be created and populated). You can easily select each component in turn without having to open each catalogue to select the required components. Furthermore, when picking a component from the palette, it stays pinned to the cursor, allowing multiple copies to be placed.

18

Flowmasters GUI

Exercise 1
This exercise will enable you to familiarise yourself with the GUI.

Build the network represented below:

To get started, you need to create a Project and a Network, for help look back through this chapter.

1. Create a project named Proj_1 and a network named Net_1. 2. Select the Company unit set for your project. 3. Once you have created your project and network, move on to the Catalogues pane by clicking on the Catalogues tab. 4. In the Catalogues pane, go to the catalogue called Components - dont forget you can use the Show Only Drag-able Items filter icon. 5. Browse the Catalogues and start to build your network by dragging and dropping components onto the Schematic. 6. When you have placed all the components on the schematic, you need to connect them. When connecting the first two components, you will need to specify the connection type. In this example, use Incompressible. 7. You have now completed the network drawing.

Later in this chapter you will enter data, run a simulation and go through the different results options.

19

Flowmasters GUI

2.4

Network Views

The Network Views window can be found in the right hand work pane. This View enables you to set component data, variable parameters, simulation data, run results and create reports. You can also track the different steps of your project with the Audit Trail tool (see Chapter 9).

When you click on one of the tabs in the top pane, its properties are reflected in the lower pane. Selecting individual items from a pane displays its properties. For example, selecting an item from the Data list will display the input data sheet for that particular component or node.

2.4.1

Data Collection

The Data pane is used to collect components and nodes. When you select a component or a node, its properties are displayed in the lower pane. The lower pane is used to set the data for selected components and nodes.

When a component is placed onto the schematic or a node is created, they automatically get listed in the Data pane. They also get numbered in their order of creation (with the distinction C for components and N for nodes in front of the number).

When opening a network you can collect components and nodes in several ways: o o by right clicking on a component or node and selecting Collect by using the Add drop down menu and selecting all or specific components and nodes o o by double clicking on a component or node by rubber banding a selection of components and/ or nodes and then right clicking and selecting Collect

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Flowmasters GUI
In the toolbar on the top left side of the pane you will find the following tools: Go to the selected component in the schematic (the component is highlighted)

Open the component search and selection dialogue (see below) Remove the selected component from the schematic

Clear the current selection Replace the selected component type Show the current components description

Show the description of the analytical model for the selected component Open the reference help for the selected component

The component search and collection dialogue is a powerful tool that gives you a wide range of criteria to define your search and component selection:

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Flowmasters GUI
The Replace the Selected Component Type feature enables you to easily change specific or groups of components in your network with a simple step-by-step methodology. . This functionality is discussed in more detail in Chapter 9 (Advanced GUI Capabilities).

2.4.2

Data Input

When selecting a component from the list, the lower pane will display the input data sheet for that component. To enter a value for a variable, just click on the cell next to it. A drop down menu will automatically appear 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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Flowmasters GUI

Using the Toggle icon you can directly enter data for one specific variable, e.g. diameter, into multiple components across component types. Consider, for example, that you want to enter the diameter data into all the components in the collection (only components in the collection will be considered when using this function) that have a diameter entry. To do so, you have to select one of the components in the collection that have a diameter field. You must then go to the lower pane and tick the grey box next to the variable of your choice, in this case Diameter:

Once youve done this, select the Toggle icon to go to Multiple Component Edit view. This will list the Diameter entry field for all the components in the collection that have such a field:

As you can see, the chosen variable is displayed in the Feature text field and all the components in the collection containing a diameter entry are listed by component number. To get back to Single Component Edit view, just click the Toggle icon again.

2.4.3

Copying Data

To copy a value from one component to another/ others, the first step is to tick the box next to the desired value in the Copy column and then select the Copy pane. This will open the Copy Features window where you can specify the copy function of your choice: icon in the top right of the lower

23

Flowmasters GUI

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 swing-check valve, you can choose the Relaxed matching (only matches data field name i.e. Diameter).

2.4.4

Selecting a Unit Set

To access the unit set window, go to Tools in the menu and select Units:

To create a new unit set, you must first create a copy of one of the six unit sets provided by Flowmaster. To do so, select the unit set you want to copy, click Copy Unit Set and choose a name for your new unit set.

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Flowmasters GUI
In your new unit set, you can now add new units and change the default units. You can see the default quantity for any given parameter in the Unit Quantity Defaults pane. If you click in the unit cell, two buttons will appear, D and S:

If you click on D, details about that unit will be displayed:

If you click on S, a selection window where you can choose the default unit, will open:

In the bottom of the right hand pane, you have the possibility to add new units to a parameter. For instance, if you want to add m3/h to the Volumetric Flow Rate parameter, click on Add New. A new line will appear where you can enter a symbol, a factor and an offset for your new unit:

25

Flowmasters GUI 2.4.5 Curve Data

Once you have created a new catalogue, right click on it and select New and then, for example, curve:

The Curve window will now appear. Select the Factor Data button in the lower left pane of the Curve window, it will open the Table Value Scaling Function window, which allows you to factor the x and y data:

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Flowmasters GUI
To add a curve to a component, select the component you want to add the curve to and click on the cell next to the appropriate entry in the input data sheet. Two new cells will appear:

The D stands for Display Item and if selected will open a window showing any curve that has already been set for this variable.

The S stands for Select Item and is the one you must select to add a curve. This will open the Selection From Catalogue window where you can then browse for the curve of your choice. These steps are the same whether you want to include a curve, surface, pump curve or an equation.

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Flowmasters GUI

Exercise 2
To practice, you can now create the following curve and place it in the My_Data folder: Performance Data: X (m3/s) 0 0.1 0.2 0.4 0.7 1 Y (Bar) 0 0.1 0.22 0.55 1.2 2.3

Curve title: Forward Pressure Difference vs Flow Rate X Axis Title: Volumetric Flow Rate X Axis Unit: Volumetric Flow Rate (m3/s) X Axis Scale: Linear Y Axis Title: Forward Pressure Loss Y Axis Unit: Pressure (Bar) Y Axis Scale: Linear Degree Fit: Automatic

To create a surface, proceed as for a curve, but choose Surface instead of Curve after selecting New.

However, there is a distinction between curves and pump curves (see Exercise 3).

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Flowmasters GUI

Exercise 3
Create the pump curve below. Remember that before entering the data points for a pump curve, it is important to (in this order):

1. Choose your Pump Characteristics, Head or Torque (in this example, Head).

2. Enter a Reference Flow Rate and a Reference Head or Torque (in this example, X=0.85 m3/s and Y=50m). 3. Select Actual Values. 4. Enter your pump curve data. 5. Select Automatic from the Degree Fit drop down menu (just above the Pump Characteristic). 6. Click OK in the bottom right corner. Your curve is now created and saved.

Reference point: X=0.85m3/s Y=50m X (m3/s) 0 0.07 0.25 0.5 0.67 0.85 1 1.1 1.15 Y (m) 69 68.9 68 65 59 50 39 23 12 Rotation (Default) + + + + + + + + +

2.4.6

Surface Data

Surface plots are 3-D curves which are used to define component/fluid properties based on three values. These can be entered in Flowmaster as either x, y and z data or as a 3-D equation over a particular range of values. (Example 4 shows a surface created from an equation.)

With all surfaces, Flowmaster reads in the X and the Y value and outputs the Z axis value.

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Flowmasters GUI 2.4.7 Equation Editor

Flowmaster has a flexible tool to enable you to create equations. You can choose between creating a 2D or 3D equation. Depending on your choice, a 2D Equation or 3D Equation window will open. The Properties pane is used to enter the properties data, such as the Equation Title, X and Y Titles, Units and Scale Factors. The pane shown on the right is used to enter the equation data. At the top of this pane are a row of buttons which enable you to perform a range of editing functions.

You can see what the buttons do by passing the mouse over a button to display a tooltip. The lower pane shows compilation information, such as whether it was successful or not. The pane to the right displays the completed equation. The equations are entered in CSharp (C#).

Exercise 4
To practice, you can now create the following equation:

Z = Math.Pow(x,4)-Math.Pow(y,4)
The axis properties can be taken as normalized values for the purposes of this example. In the example screenshot below the X and Y axis range was taken to be from 0 to 5.

30

Flowmasters GUI

Tip: If you type math. in the equation editor you get a list of options for things like pi, sin, cos, abs, etc

31

Flowmasters GUI 2.4.8 Simulation Type Filter

You can use the Simulation Data Filter to keep processing time to a minimum. You can select the filter of your choice from the drop down menu in the bottom of the lower pane of the Network Views window:

2.5
2.5.1

Running Simulations
Simulation Types and Options

The upper pane lets you choose the simulation type, ambient conditions, etc:

The information in this pane adapts to the type of simulation you are running. For example, if you choose to run a transient simulation, fields for time step, simulation start and end time will appear. To run a simulation, click Run.

32

Flowmasters GUI
While the simulation is running, you have the possibility to Abort, Pause and Disable Feedback. Once the simulation is done, you will get a message in the bottom right hand pane informing you about the simulations success or failure:

If you now click the Result Sets/Audit tab, you will see a list of all simulations that have been run for this network:

Directly under the simulations list, you will find a set of icons (seen below) enabling you to delete a simulation, view the error report, view the warnings report, create a custom result report or view the ph diagram (only for AC networks):

To view the data for a specific result set, double click on it (or single click, go to the Data tab and select the Results instead of Data radio button):

33

Flowmasters GUI

Exercise 5
In this exercise you can now practice what weve just learnt by inputting data into the example we created in Exercise 1.

Upstream Pressure Source Total Pressure: 2 bar Pipes: Cylindrical Elastic Length: 20m Absolute Roughness (Friction Data sub-form): 0.025mm Diameter: 0.1m Wave Speed: 1000m/s Pump Radial Flow Rated Flow: 0.85m3/s Rated Head: 50m Rated Speed: 1000 r.p.m. Rated Power: 200kW Pump Inertia: 0.5kg m2 Motor Inertia: 5kg m2 Speed Ratio: 1 Friction Torque: 200N m Initial Speed: 1000 rpm Initial Logic State: Running at Constant Speed Suter Head Curve: Use curve created in exercise 3. For now, use the provided Suter Head Parameter Radial curve. Valve: Swing-Check Diameter: 0.1m Characteristic Operation Time: 0.1s Minimum Velocity: 1m/s Downstream Pressure Source Total Pressure: 1.5 bar Run a Steady State simulation.

34

Flowmasters GUI 2.5.2 Errors and Warnings

Errors will stop your simulation running, for example missing data.

Warnings provide important information but wont stop your simulation running, however they may affect your simulation results.

2.6

Viewing Results

You can view results directly from Network Views. When you run a simulation the Results Set are loaded into the Results Set/Audit form. You can see these Results Sets by clicking on the tab. The sets are arranged in the order that the simulations were run.

If you have already run a simulation, click the Results Sets/Audit tab to see all the results sets and select the required set.

Click on the Data tab to see all the components in the list and select the Results radio button.

2.6.1

Viewing Component and Node Results

Flowmaster offers you a wide range of interface facilities for looking at the results of an analysis run. You should always ensure that the results for any network are realistic and, as far as possible, as expected. Otherwise, you should use a combination of the results and either the Errors or Warnings reports to point you towards the problem in either the data or the model. The Network Views dialog shows details about all the analyses that you have run. If you click the 'Results/Audit' tab, you can see in the top pane, the analyses in the order that they were run. It is divided into three columns and shows the following information: Analysis number Analysis type (e.g. Incompressible Steady State) Description

When you select an analysis, its properties are shown in the lower pane. These include: 1. Analysis Type - shows details of the analysis type 2. Description - shows a brief description of the analysis 3. Owner - shows the name of the person 'owning' the analysis 4. Data and Time - shows the data and time that the analysis was run 5. OK? - shows the status of the analysis which can be: a. Yes b. No c. Crash

35

Flowmasters GUI
6. Observations - allows you to enter details about the analysis. To do this, click in the adjacent cell to display a button. Click the button to display the Result Observation window. Enter the details and select OK. There are circumstances where the analysis will fail to achieve a converged solution and will successfully store the unconverged results. The status will be reported as 'NO'. When this occurs, you should examine the network to ensure that the data is set correctly and examine the log file as stated above. You can also use the appropriate Reports form to print out warnings and error messages.

2.6.2

Drawing Results

Select the components that you want to interrogate (Hold CTRL down to multi-select)

Draw

Select the type of result and click on draw.

Diagram shows the flow rates through each component, Arm 1 flow rates in the case of Pressure Sources and Arm 2 for all others.

36

Flowmasters GUI

It is possible to draw multiple results onto the schematic. Select the type of result and click on Draw, tick the append box and this will keep the previous drawn results.

37

Flowmasters GUI 2.6.3 Plotting Results

When looking at transient results, the data is presented in the following way:

To view the result for a specific property, click in the relevant Inspect area, three icons will appear (see above) enabling you to do the following: Plot the selected feature in a plot window List the selected feature in a list view window Set the feature as X-axis for plotting.

2.6.4

Report Generation

Reporting buttons can be found in the Result Sets/Audit Tab

38

Flowmasters GUI
Reports include: Error Report o o o Written to if analysis fails Error messages point to problem Empty if run is successful

Warning Report o o o Contains assumptions made Non convergence warnings Parameter out of range and curve extrapolation warnings

Customized Result Report o o o Can select types of results to be reported Can select which components and nodes to output results for Personalize Report format, including company logo header.

Input Data Audit Report o Report on the difference between two result sets

39

40

Steady State

Chapter 3:

Steady State

Steady State capabilities are: Single pipelines systems Multiple branching systems Looped and branching systems.

Flowmaster Incompressible and Compressible modules provide the capability to model a real flow situation with the use of many types of system components. These include: Air conditioning Airside systems Pipes and passages Bends Valves Transitions Pumps Controllers COM controllers Electro-mechanical sources Discrete losses Heat exchangers Lubrication systems Junctions Orifices Reservoirs Accumulators Diaphragms Weirs Miscellaneous Super components Solids

The number of components you may use in any network is restricted by your license agreement. The complexity of the system is not restricted. As in any model development, simplifications should be made where possible. Simplifications can avoid unnecessarily long computer run times and will lead to a more manageable model without compromising the validity of the simulation.

Simplifications that should be considered include: Not including fittings in networks where the loss due to the component is negligible (i.e. where pipe friction losses dominate) Combining the loss coefficients of fittings and using the discrete loss component Representing parts of the system with a discrete loss component with an associated pressure loss versus flow rate performance curve Representing several pumps with a combined characteristic pump curve.

41

Steady State

3.1
3.1.1

Details of Each Component Family

Pipes

There are six pipe types: o o o o o o Cylindrical Rectangular Hexagonal Prismatic Rotating hose Internal duct

There are also four friction options: Colebrook White Hazen Williams Fixed Friction

Friction Model
The Flowmaster pipe implementation allows the user to specify the friction factor model from correlations or use a fixed value.

Option

Laminar flow Re 2000

Transition zone 2000 < Re 4000

Turbulent flow Re > 4000

Colebrook-White

f = fl =

64 Re

f = xft + (1 x )fl

f = ft =

0.25 k 5.74 log 3.7 D + Re 0.9

2

Hazen-Williams

f = fl =
f

64 Re

f = xft + (1 x )fl
f

f = ft =
f

1014. 2Re 0.148 . CHW 1852D 0.0184

Fixed
where x =

Re 2000 . Note: Hydrodynamically developed flow is assumed for the entire pipe length. 2000

Option 1: Colebrook-White

Requires specification of pipe internal wall roughness. Useful data tables are available in Flowmasters Reference help.

Option 2: Hazen-Williams

Common equation sometimes used in the water supply and distribution industry.

42

Steady State
Option 3: Fixed Friction

Generally f becomes constant above Re = 106, so the option can be used to reduce computation in networks with many pipes. Use to calibrate model against a known pressure gradient. Can lead to simulations failing to converge (see below). BEWARE - If proceeding to a Transient simulation this model can lead to surge pressure

prediction errors.

Solution Stability
There are limits to the stability of the numerical solution to the pipe model. The criterion is:
2 2d 5 < 10 7 kg s / m 2 & 8 fL m

From this equation it can be seen that if

& m 0 then f needs to for stable solutions. This

characteristic is met by Options 1 and 2, but not Option 3.

3.1.2

Bends

Bends are relatively low loss components. They should only be modelled if they contribute significantly to the overall loss. In long pipelines they should certainly be excluded. The Steady State
V a lv e s
4 m a in g r o u p s :

pressure/flow equation used is:

V a lv e s C o n t r o l C h e c k V a l v e s S i n g le

r

P h a s e

F lu id

P o w

e r

V a l v e s C o n t r o l V a lv e s

D ir e c t io n a l R e lie f

V a l v e s C h e c k V a lv e

P o p p e t

U T

6 .3

S l i d e

o f

9 6

where

kb

bend loss coefficient ('Internal Flow Systems', D.S.

Miller, 1st Edition) CRe = correction for laminar flow ('Internal Flow Systems',

D.S. Miller, 1st Edition) Cf = roughness correction factor.

The bend loss accounts for the length of the flow path and adjacent pipe lengths should be taken up to the start of curvature. The inclusion of bends in networks significantly increases the computation required for Transient simulations. Fluid inertia is modelled in all but mitre bends and increased accuracy in pressure surge calculations will only be achieved by their inclusion if fluid inertia in the component is significant in the system.

The Transient simulation assumes that the bend is held rigidly and no reflection of pressure waves occurs. Usually the movement of the pipe work (a phenomena known as 'Fluid Structure Interaction') will reduce the magnitude of pressure waves.

43

Steady State 3.1.3 Control Valves

The valve position can be specified either in the valve data sheet or by a connected controller. If connected the position specified by the controller will take precedence.

Loss coefficients are provided for various valve types as Loss Coefficient versus Position curves ('Internal Flow Systems', D.S. Miller, 1st Edition). The pressure/flow equation used is

p = kCRe
where k CRe = =

v 2 2

valve loss coefficient correction for laminar flow.

Note:

If loss data for the particular type of valves in the system being modelled are available you should create the curve in the catalogue and reference in the appropriate component.

The variable throttle valve is similar to the 2-port 2-position DCV. The variable throttle (short orifice) should be used where the channel area vs position data is not known.

The pressure reducing valve is directly interchangeable with the 3-port 2-position DCV. The data requirements are the same, and the appropriate component is selected on the basis of a symbol.

The pressure relief valve is using the mathematical model for a short orifice. It is intended for use with valve dynamic controllers to model various types of dynamic control valves. This component represents the flow control element which is opened or closed by the attached controller.

The simple relief valve requires only a curve to be set. This curve defines the pressure vs flow relationship.

3.1.4

Check Valves

There are six check valve models for use in Steady State simulations:

Swing-Check Valve
The swing-check valve component can be used to model any type of one-way valve, such as a check, reflux or non-return valve.

The model simulation check valve behaviour, and is used to assess the type of behaviour that is likely to occur, using a head loss versus velocity through the valve to characterise the specific valve.

44

Steady State
Clapper-Check Valve
This component models the behaviour of a specific type of swing-check valve in which a clapper is hinged at the top and is held open by the fluid flow. The clapper closes under its own weight and closure may be assisted by reverse flow. The required input data demands a detailed knowledge of the valve behaviour including hydrodynamic torque coefficient versus position.

Plug-Check Valve
In this valve, the main body forms a 90 angle through which the flow turns. The closing plug is able to move vertically up and down inside the body. When closed the plug seat is as far down as possible. When the upstream pressure is greater than the downstream pressure, the plug is raised (provided the differential force is sufficiently large to lift the plug) and flow is allowed.

Poppet Check Valve

This component models the behaviour of a general type spring check valve. It can be used to prevent backward flow through a pipeline. Forward flow will only occur when the resultant net force on the valve disc is larger than the spring force.

The component can also model the hysteresis-effect due to the pressure distribution along the valve opening clearance. The hysteresis-effect can become significant when studying the dynamic behaviour of a check valve operating partially opened.

Simple Check Valve and Spring Operated Check Valve

These simple check valve components can be used to prevent backward flow through a pipeline. Furthermore, the forward flow will only occur when the pressure differential across the component exceeds the required crack pressure. You can use these components to model a shuttle valve by simply connecting two simple check valves (without springs) back to back.

When the valves are completely closed there is only slight leakage.

Pilot Check Valve

This pilot check valve is modelled as a two-armed component, which has two flow ports. The pilot pressure port is internally connected to the fluid inlet connection. It operates in the same way as the simple check valve except that the pilot pressure may open the valve for reverse flow.

A typical use for a pilot check valve is to lock a hydraulic cylinder into position. It is important to realise that the pilot pressure node is not necessarily one of the connection nodes to the component itself. A curve defines the pressure drop across the valve as a function of the flow rate through the valve for the free flow direction, and a second curve defines the relationship for the piloted reverse direction.

45

Steady State
3.1.5 Directional Control Valves

Directional control valves are modelled using definitions of Channel Area versus Spool Position and Pressure Drop versus Flow Rate.

The open channel area is determined from the port connectivity, spool position and channel area ratio curve. The pressure drop is read from the pressure drop versus flow rate curve for the specific channel using: Flow rate for required pressure drop = Actual flow rate Channel area ratio

3.1.6

Relief Valves

Poppet Relief Valve

The poppet relief valve simulates the venting of liquid from a system. It can be used in both Steady State and Transient simulations. It can be used to model venting to atmosphere or differential pressure relief (e.g. for a pump). If the pressure across the valve exceeds the trigger pressure the valve accelerates open. Instabilities in the simulation can occur if the time step is insufficiently small compared to the characteristic operating time.

Pressure Relief Valve

This simple relief valve remains closed, with a slight leakage, until positive pressure differential greater than the crack pressure is supplied. The valve then opens and the flow rate is governed by the curve definition, dependent on the upstream and downstream pressures.

3.1.7

Junctions

Flowmaster's junction components include various angle T-junctions (i.e. a junction in which the through pipe is straight) and Y-junctions with different branch area ratios. T 30 T 45 T 60 T 90 Y (A1 + A2 = A3) T (A1 = A2 = A3)

Junctions are low loss components and should only be modelled when the associated losses are expected to have a significant effect on the performance of the network. The inclusion of junctions in networks significantly increases the computation required for Transient simulations. Fluid inertia is not modelled in junctions and increased accuracy in pressure surge calculations will only be achieved if their losses are significant in the system. The length of connecting pipe is not accounted for in the junction loss.

46

Steady State
The range of T-junction loss data in DS Millers Internal Flow Systems does not extend below branch flows of about 10% of the combined flow or to side branch areas of less than about 20% of the through branch size. Flowmaster uses a 'smoothing' function in evaluating loss coefficients outside this range. Unfortunately there may be cases where networks fail to achieve steady state solutions because of small branch flows. In such cases the loss in the T-junctions will be negligibly small and junctions with small branch flows should be removed from the network. The loss coefficient of a T-junction with zero branch flow is zero, so any errors will be negligible.

The extreme edges of Y-junction loss data are similarly poorly defined and to avoid spurious results numerical limits on the values of loss coefficients are imposed.

3.1.8

Transitions

Flowmaster provides two transition components: Abrupt Transition Gradual Transition

These components can be used to model the pressure losses associated with changes in pipe diameter. In long pipelines where their loss is insignificant to system performance they should be omitted and different diameter pipes connected via a single node.

In a Transient simulation fluid inertia is modelled for the gradual transition, but no fluid inertia is associated with an abrupt transition. Pressure waves will be reflected from points of section change; however this will be modelled by simply connecting pipes of a different section via a node. No increase in accuracy for pressure surge calculations is achieved by including inertia effects unless the fluid inertia is significant in the system.

Care should be taken to understand that the losses associated with a gradual area enlargements (diffusers) are influenced by the inlet and outlet conditions and the flow Reynolds number.

Flowmaster provides surfaces of loss coefficients for several arrangements and you are advised to consider which is appropriate.

3.1.9

Orifices

Flowmaster provides a range of orifices described by geometry:

Sharp-Edged (Conical) Long Radius Square Sharp-Edged (Standard orifice plate)

47

Steady State
The flow equation used is

v 2 p = CReCo k o 2
where CRe Co ko = = = correction for Reynolds number correction factor dependent on orifice type loss coefficient dependent on orifice type

3.1.10 Pumps
There are three general pumps available: Radial Mixed Axial

Mathematically these pumps are broadly classified by specific speed (Ns),

NQ 1/ 2 N s = 3/ 4 H
where N Q H = = = speed (rpm) volumetric flow rate at BEP (Best Efficiency Point) (m3/s) head at BEP (m).

Flowmaster provides data from test results for the following classes of pump: o Radial Ns = 25 o Mixed Ns = 147 o Axial Ns = 261

Flowmaster requires a pump characteristic to be entered. The data entered can be in a normalised form or can be the actual values for flow vs head.

Flowmaster is capable of modelling pumps in series and parallel. This is important for modelling a Transient event which affects individual pumps. However, if the event does not affect individual pumps consideration should be given to using a combined characteristic and a single pump component.

There are three displacement pumps available for use in hydraulic power applications: o Vane o Piston o Gear

48

Steady State
The gear pump can only model a fixed displacement, whereas the vane and piston pumps can model either fixed or variable displacement pumps.

3.1.11

Motors

The generic motors model can be used to simulate fixed or variable, uni- or bi-directional motors with fixed or variable loads. In a motor, fluid energy is converted into shaft energy, therefore the function of a motor can be considered as the inverse to that of a pump. The actual construction of a motor is often similar to a pump, and in some cases, a motor can perform the function of both a motor and a pump. For these reasons the performance equations for pumps and motors are closely related.

3.1.12 Reservoir
Flowmasters Incompressible module provides eight reservoir models:

General Reservoir Constant Head Reservoir Variable Head Reservoir Finite Area Reservoir Storage Vessel 2-Armed Tank 3-Armed Tank Thermal Expansion Reservoir

The general, constant head and variable head reservoirs are used to set a pressure boundary for the network, given by:

PT = Ps + g (L + Z ) k

v 2 2

The general reservoir also allows the inflow and outflow losses of the reservoir to be taken into account. Several curves are supplied to model common configurations.

Care must be taken as the data sheet entry 'Intake radius' refers to a different dimension depending on the entry configuration being modelled (see the Single Phase Steady State Reference Help).

The variable head reservoir allows the height of liquid in the reservoir to be a function of time for a Transient simulation.

The finite area reservoir on the other hand models the flow into and out of a vessel. If the liquid level is NOTSET the simulation assumes zero flow between the component and node and the vessels equilibrium liquid level is calculated. If liquid level is set the component specifies pressure at the connecting node. This component should be used to model a surge shaft.

49

Steady State
The storage vessel is used primarily for modelling an underground storage vessel. Oil extraction and storage are modelled. Extraction is achieved by pumping brine into one side, this in turn forces the oil out of the other side.

The 2-armed tank can be used to model any reservoir which has 2 connections. The level of the connections can be different.

The 3-armed tank component is based on the 2-armed tank component. The three-armed reservoir has three decoupled branches with user-defined characteristics. It employs similar pressure flow equations at each of these decoupled branches as in the two-armed reservoir.

The key difference is the flow behaviour when a branch is uncovered (liquid level < branch level) and the internal pressure is greater than the external node pressure. Under these conditions the component provides zero flow to the branch (the two armed reservoir employs the use of retracted volumes under these conditions).

Thermal Expansion Tank component is also based on the 2-armed tank component. It models a closed vessel which can be pressurised, with two branches and a variable liquid level. Heat transfer between the tank and its surroundings is also modelled.

3.1.13 Accumulators
Flowmaster provides three types of accumulator models:

Air Vessel Bladder Accumulator Vented Air Vessel

The air vessel models an enclosed vessel containing a fixed mass of gas trapped by the liquid in the system. The bladder accumulator is similar except that gas is enclosed in a bladder. In the vented air vessel the liquid level determines when gas is admitted or released from the vessel.

Accumulators (air vessels and bladder accumulators) need to be designed to maintain system pressures between the minimum and maximum pressure limits. This is achieved by expelling sufficient volume of liquid during the down surge and allowing gas compression during the upsurge. The volume of liquid and mass of gas in the vessel needs to be optimised for minimum vessel size. Further design refinement and optimisation can be achieved by throttling the flow in and out of the vessel.

50

Steady State
The Hydraulic Power module provides one accumulator model. The data set will determine how the component operates. Flow rate, actual pressure or actual volume may be set. If only the flow rate is set then the component acts as a flow source and the pressure and volume are calculated between the accumulator and the rest of the system. If pressure or volume is set, the flow rate is calculated between the accumulator and the system.

Note:

If the pressure is set then the volume will be calculated from the total volume and the precharge pressure and vice versa. This can be used for modelling a pressurised tank which has a pressurisation system that is unable to compensate instantly for changes in liquid volume. The accumulator then acts as a pressure specifier.

If the flow, pressure and volume are not set, then the accumulator is assumed to be in equilibrium with the system and the pressure and volume are calculated for the total nodal pressure with zero flow between the accumulator and the system.

3.1.14 Sources
Flowmaster provides four source components for incompressible: o o o o Flow Source (controllable) Blank End Pressure Source (controllable) Pressure versus Flow Source

These components are used to model the network boundary conditions. Typical uses include:

1.

Fixing the pressure boundaries to find the flow rate versus pressure drop system characteristics.

2.

Fixing pressure boundaries and flow boundaries to solve for the required driving pressure to meet the flow demand.

3.

Quick pump modelling.

For the Flow Source component a positive volumetric flow rate indicates flow from the component to the system and a negative volumetric flow rate indicates flow to the component from the system.

The pressure and flow sources can also receive input signals from external controllers. The pressure source can receive three separate signal input types. These are: Pressure Temperature Absolute Humidity

51

Steady State
The flow source can have four inputs. These are: Volumetric Flow Mass Flow Temperature Absolute Humidity

These inputs can be used when you require the boundary source to change depending either on a preset input or based on feedback from another area of your network.

Note:

Care must be taken when using the copy ALL function for flow sources because in terms of simulation a Blank End is a Flow Source with a predefined zero volumetric flow rate. The copy ALL function will overwrite this zero value.

3.1.15 Controllers
A controller imposes a signal upon a component. This signal can be: i) Read directly from user input data (e.g. data from a tabular controller) or ii) Derived from other data available in the network (e.g. nodal pressure, etc.) or iii) User supplied script or equation.

The Controllers are a range of controllers, gauges and miscellaneous components that can be connected to existing Flowmaster components such as pumps, valves, etc. A number of the components have built in algorithms that enable them to function in the desired way.

As well as performing automation functions, the controller and gauge templates can also fire events to which other applications or components respond to. The miscellaneous components, such as the clock can be used to provide a control signal to a component, while the signal generator can be used as a signal source. You can use the signal splitter to send an identical signal to two components. The recorder can be used via the gauge component to record Opvars, node or component variables.

3.1.16 Cylinders
There are three cylinders available for use in a Hydraulic Power simulation. These are: o o o 1 rod 2 acting 2 rod 2 acting 1 rod 1 acting

These components can be used to model all types of hydraulic cylinders and rams, as well as hydraulic plungers, latches and diaphragm actuators. They can also be used to model free floating piston devices such as intensifiers and bootstrap reservoirs.

52

Steady State
It is possible to specify a load on the rod, rod displacement and rod velocity. For simplicity, cylinders have an inbuilt facility to impose a fixed load on the rod. This is usually adequate for Steady State. If displacement or velocity control is required then an external controller component must be connected.

The steady flow equations that are used in the simulation are:

dx & Cl 0 ( P P2 ) m1 = A1 1 dt dx & + Cl 0 ( P P2 ) m2 = A2 1 dt
Where:

& m1
& m2
A1 A2

= mass flow rate to node 1 = mass flow rate to node 2 = fluid cross-sectional area at end 1 = fluid cross-sectional area at end 2

dx dt
Cl

= velocity of the cylinder = leakage coefficient = standard viscosity = actual viscosity = pressure at node 1 = pressure at node 2 = fluid density

P1 P2

3.1.17 Loads
These components are similar to the curve input and tabular data controllers described earlier. For a given time or operational variable, the load applied to a cylinder or a motor is manipulated according to a defined curve or data set.

For time based controllers you can provide the load v time relationship as either: 1. A curve or equation associated with the curve input load controller or 2. Directly as a set of data pairs in a tabular data load controller

The operational variable controller requires a curve or equation describing the operational variable relationship.

53

Steady State
The purpose of these load controller components is to provide variable load values for motors and cylinders. To define other operational variables such as pump speed or motor/pump displacement use the basic controllers described earlier.

54

Steady State Examples

Chapter 4:
already completed.

Steady State Examples

The objective of this section is to provide you with the opportunity to reinforce the interface training

There are four examples given. All the necessary data is given for the models.

For all components requiring curves to be set, use the default curves unless other data is given.

Tip
Apply incompressible steady state data entry filter to eliminate all data entry fields that may not require data set for an incompressible steady state analysis.

Steady State Example 1

UPSTREAM RESERVOIR (Constant Head) Pipe Diameter Liquid Level Above Base Base Level Above Reference Surface Pressure 0.3 m 2m 0m 1 bar

DOWNSTREAM PIPE : CYLINDRICAL RIGID Length Friction Option Absolute Roughness Diameter 200 m 1 0.05 mm 0.3 m

55

Steady State Examples

RADIAL FLOW PUMP Rated Flow Rated Head Rated Speed Rated Power Initial Speed SWING-CHECK VALVE Diameter 0.3 m 0.15 m3/s 25 m 1,495 r.p.m. 45 kW 1,495 r.p.m. NODE DATA Elevations for nodes left to right on schematic: DOWNSTREAM RESERVOIR (Constant Head) Pipe Diameter Liquid Level Above Base Base Level Above Reference Surface Pressure 0.3 m 9m 0m 1 bar

UPSTREAM PIPE : CYLINDRICAL RIGID Length Friction Option Absolute Roughness Diameter 800 m 1 0.05 mm 0.3 m

ID 1 2 3 4 5

Level in m 0 1 2 10 8

SIMULATION DATA Default Materials : Ambient Conditions:: Liquid Type Ambient Temperature Atmospheric Pressure Water 20 C 1.013 bar

56

Steady State Examples

Steady State Example 2

This network is a simple looped system connected to a cross flow heat exchanger. Its aim is to give you practise at building networks using Flowmasters GUI. No thermal effects are modelled in this system; the main areas of interest are flow rate and pressure loss. Build the network shown in the diagram below.

PIPE: CYLINDRICAL ELASTIC (All Pipes) Length Absolute Roughness Diameter 0.75 m 0.01 mm 0.025 m

BENDS: CIRCULAR (All bends) Deflection Angle Radius/Diameter Roughness Diameter 90 deg 2 0.01 mm 0.075 m

PUMP: RADIAL FLOW Rated Head Rated Flow Rated Speed Rated Power Initial Speed 60 m 0.021 m3/s 6000 rpm 14 kW 1500 rpm HEAT EXCHANGER: THERMAL Loss Coefficient 1 Area 1 Loss Coefficient 2 Area 2 10 0.0005 m2 10 0.002 m2

SOURCE: PRESSURE (All Sources) Total Pressure 2 bar

SOURCE FLOW Vol Flow Rate 0.015 m3/s

57

Steady State Examples

Node Data: No node data is required

Simulation Data: Default Materials: Ambient Conditions: Liquid Type Ambient Temperature Ambient Pressure Water 20 C 1.013bar

58

Steady State Examples

Steady State Example 3

59

Steady State Examples

ACCUMULATOR; F.P. Outflow Loss Inflow Loss Valve area Total volume Precharge pressure Actual volume Maximum pressure ratio RESERVOIR: FIN. AREA Outflow Loss Coefficient 1 Inflow Loss Coefficient 1 Pipe Diameter 25 mm Horizontal Cross Sectional Area 1 m2 Height of Top Above Base 1m Base Level Above Reference 0 m Surface Pressure 1 bar Liquid Level 0.5 m

0.1 0.1 490 mm2 100 Litres 100 bar 50 Litres 20

PIPE:CYLINDRICAL (all pipes) Length Friction Option Absolute Roughness Diameter

5m 1 0.025 mm 25 mm

FP DCV 4-PORT 2POSN Spool posn 0 1st Channel 2nd Channel Spool posn 1 1st Channel 2nd Channel Spool position (0 to 1)

0 0 1 6 1

CYLINDER SINGLE ROD DOUBLE ACTNG Cylinder diameter 100 mm Rod diameter 30 mm Max rod travel 0.5 m Standard viscosity 0.05N s/m2 Leakage coefficient 0 L/mn bar Viscous friction coeff 1e-6 Nsm-1 Coulomb friction coeff 0 Stiction force 0N Stiction velocity 0 m/s Mass of piston and rod 2 kg Piston load 35700 N Initial rod position 0.01 m

NODE DATA Node data should be left as the default entries. SIMULATION DATA Default Materials: Liquid type Ambient Conditions: Ambient temperature Atmospheric pressure

Hydrol 46 20 C 1.013 bar

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Steady State Examples

Steady State Example 4 (Air Fuel Tank Exercise)

Create this network to represent the initial development of an aircrafts collector, header and transfer tank interaction. Component 8 (a flow sink) represents the engines fuel demand.

Enter the network data as listed below (selecting SS in the Simulation Data Type Filter under the Setup tab) and run an Incompressible Steady-State simulation. From the results file, draw the Flow Rate and Pressure distributions.

61

Steady State Examples

Simulation Data Default Materials: Liquid Type = Kerosene Ambient Conditions: Ambient temperature = 20 <deg C> Atmospheric pressure = 1.013 <bar> 3-Armed Reservoirs Common data (to be set for reservoirs 1, 2 and 3) Branch 1 Outflow Loss Coeff. = 0.5 <> Branch 1 Inflow Loss Coeff. = 0.5 <> Branch 2 Outflow Loss Coeff. = 0.5 <> Branch 2 Inflow Loss Coeff. = 0.5 <> Branch 3 Outflow Loss Coeff. = 0.5 <> Branch 3 Inflow Loss Coeff. = 0.5 <> Horizontal X-Sectional Area = 7 <m2> Surface Pressure = 1.013 <bar> Reservoir No. 1 Branch 1 Pipe Diameter = 0.026 <m> Branch 1 Height Above Base = 0.46 <m> Branch 2 Pipe Diameter = 0.05 <m> Branch 2 Height Above Base = 0 <m> Branch 3 Pipe Diameter = 0.05 <m> Branch 3 Height Above Base = 0 <m> Height of Top Above Base = 0.46 <m> Base Level Above Reference = 1.22 <m> Initial Liquid Level = 0.15 <m> Maximum Pressure = 5 <bar> Reservoir No. 2 Branch 1 Pipe Diameter = 0.05 <m> Branch 1 Height Above Base = 0.06 <m> Branch 2 Pipe Diameter = 0.026 <m> Branch 2 Height Above Base = 0 <m> Branch 3 Pipe Diameter = 0.05 <m> Branch 3 Height Above Base = 0 <m> Height of Top Above Base = 0.26 <m> Base Level Above Reference = 1.5 <m> Initial Liquid Level = 0.15 <m> Maximum Pressure = 5 <bar> Reservoir No. 3 Branch 1 Pipe Diameter = 0.05 <m> Branch 1 Height Above Base = 1.3 <m> Branch 2 Pipe Diameter = 0.05 <m> Branch 2 Height Above Base = 0.15 <m> Branch 3 Pipe Diameter = 0.04 <m> Branch 3 Height Above Base = 0.15 <m> Height of Top Above Base = 1.5 <m> Base Level Above Reference = 0 <m> Initial Liquid Level = 1.5 <m> Maximum Pressure = 5 <bar>

Flow Source Vol. Liquid Flow Rate = -0.00045 <m3/s>

Radial Pumps Comp 4 Rated Flow = 0.0001 <m3/s> Rated Head = 80 <m> Rated Speed = 1000 <r.p.m.> Rated Power = 0.1 <kW> Friction Torque = 0 <N m> Initial Speed = 700 <r.p.m.> Comp 5 Rated Flow = 0.004 <m3/s> Rated Head = 38 <m> Rated Speed = 1000 <r.p.m.> Rated Power = 0.1 <kW> Friction Torque = 0 <N m> Initial Speed = 1000 <r.p.m.>

Butterfly Valves: Type A Comp 6 Diameter = 0.026 <m> Valve Opening = 0.5 <ratio> Comp 7 Diameter = 0.026 <m> Valve Opening = 1 <ratio> Cylindrical Pipes All Pipes Absolute Roughness = 0.0137 <mm> Comp 9 Length = 4.572 <m> Diameter = 0.026 <m> Comp 10 Length = 12 <m> Diameter = 0.026 <m> Comp 11 Length = 17 <m> Diameter = 0.04 <m> Comp 12 Length = 4 <m> Diameter = 0.05 <m> Comp 13 Length = 6 <m> Diameter = 0.05 <m> Comp 14 Length = 0.1 <m> Diameter = 0.05 <m> Comp 15 Length = 0.9144 <m> Diameter = 0.04 <m>

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Steady State Examples

Node Data
ID Level (m)

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

1.6 1.6 1.6 1.5 1.4 0.15 1.8 0 1.2 0 1.2 1.6 1.5 0.15 0.15

Note: Node ID numbers will vary depending on order of connection when you build the network.

63

64

Transient Simulation

Chapter 5:
o o o o o o

Transient Simulation

Transient capabilities are: Pump start-up and trip Control valve dynamics Check valve dynamics Relief valve dynamics Behaviour of surge protection equipment Influence of control actions on pressure surge

Flowmasters Transient module provides the capability to model time dependent events in a real flow situation. To enable Transient modelling additional data is required for certain components.

When creating the model of a network the following points should be remembered:

Set the objective for the simulation by deciding what scenarios you want to model (e.g. pump trip, valve slams, etc.). Consider the advice given in Chapter 3 about simplifying the model (e.g. Use of bends junctions etc). Consider the implications of pipe lengths and wave speed predictions on the computer run time. It may be possible to combine two or more pipes into one component, ignore short pipes altogether or model certain pipes as rigid.

Where data is deficient or uncertain perform, sensitivity studies.

5.1

Causes of Severe Pressure Surge

Pressure surges or fluid transients are pressure changes propagated through a contained liquid when the flow is varied. Any system containing a liquid in motion (or liquid which can be set in motion) through pipes or tunnels will experience pressure surges. Other commonly used terms for pressure surge include hydraulic transients and water hammer.

These pressure changes arise from the interchange of kinetic energy of the fluid with strain energy of the fluid and pipe wall. A flow disturbance causes a change in pressure of the fluid at the location of the disturbance, which then propagates through the fluid as a pressure wave.

5.2

Suppression of Fluid Transients

Pipeline failures are principally caused by exposure of the piping system to unacceptably large pressure fluctuations. Fluctuations may be a result of equipment failure or even a result of normal operation.

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Transient Simulation

5.3

Wave Propagation and Estimation of the Maximum Transient

Pressure Change
Consider a valve closing and the resulting pressure wave that propagates up and down the pipe. The maximum pressure change occurs at the location of the disturbance and is given by the Joukowsky equation:

p = av
where p a v magnitude of pressure change liquid density wave speed change in flow velocity N/m2 kg/m3 m/s m/s

In terms of liquid head the Joukowsky equation is:

H =
where H g magnitude of head rise acceleration due to gravity

a v g
m liquid 9.81 m/s2

This simple theory is useful, but in real systems fluid Transient simulation must also account for:

wave reflection pipe friction losses cavitation (if it occurs)

5.4

Rapid, Slow and Very Slow Changes in Flow

Pressure changes due to disturbances are classified as three distinct types dependent upon the relationship between: o the time taken for the change in flow velocity to be complete, t, (e.g. time for a valve to close) and o the pipeline period, 2L/a, (i.e. the time for a pressure wave to propagate to a point of reflection and return).

Rapid Event
A Rapid event is one in which the change in the flow occurs in less than 1 pipeline period. The magnitude of the resulting maximum pressure change is given by the Joukowsky equation. The pipeline MUST be modelled with the elastic pipe model.

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Transient Simulation
Slow Event
A Slow event is one in which the change in flow occurs between 1 and 500 pipeline periods. For Slow events the maximum pressure change is a proportion of the full pressure change predicted for a rapid event. In the case of flow changes which occur in 2-3 pipeline periods the pressure reduction is negligible. For events of greater than 10 x (2L/a) it may be appropriate to assume rigid column behaviour and use the rigid pipe model.

Very Slow Event

A Very Slow event is one in which the change in flow occurs in a time greater than 500 pipeline periods. For these events the magnitude of the maximum pressure change is proportional to the rate of change of flow velocity and independent of wave speed. Consideration should be given to using the rigid pipe model.

5.5

Speed of Propagation of Pressure Waves

This section provides data which may be useful in estimating the speed of propagation of pressure waves, or wave speed, in a homogenous liquid contained in a pipe or tunnel, following a disturbance to the flow.

A good estimate of the wave speed is required for fluid Transient design calculations because:

a) the magnitude of the pressure change in a system is proportional to wave speed,

p a
b) the timing of wave reflections and combinations can be important in system transient behaviour.

There are two ways given for estimating the wave speed, the first uses an equation which applies to any pipe material filled with any liquid and the second presents a graph which is only applicable for water filled pipes.

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Transient Simulation
Equation for Estimating Wave Speed
The wave speed is calculated from:

a=

+
where a k d t E wave speed liquid density bulk modulus of liquid pipe internal diameter pipe thickness

1 k

d tE
m/s kg/m3 N/m2 m m N/m2

Young's Modulus of pipe material pipe restraint factor

The numerical value of may be taken as unity without significant error in many cases and this value has been used in generating the wave speed graph.

5.6

Water Filled Pipes

The graph below shows wave speed in water filled pipes made from various materials. The ordinate is a ratio of pipe internal diameter, d, to wall thickness, t.

The abscissa is the Young's Modulus of the pipe material, the right hand axis gives an indication of the range of values of Young's Modulus for each material.

68

Transient Simulation

1300 m/s 1200 m/s 1011 1100 m/s 1000 m/s Youngs modulus 400 m/s 800 m/s

steel cast iron

concrete asbestos Cement gfp

1010

200 m/s

grp t

perspex pvc

109 0.001 0.01 t/D 0.1

5.7

Pipes
Rigid Compliant Elastic Variable wave speed

Flowmaster provides the following four pipe models for simulating pipes in a Transient simulation:

Only the rigid and elastic pipe models are studied on this course.

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Transient Simulation
5.7.1 Rigid Pipe Model

This models incompressible flow through a pipe where fluid and pipe elasticity are ignored. The model allows you to account for frictional and fluid inertia effects in pipes where elastic effects are negligible. As mentioned earlier you should consider the use of rigid pipes for certain Transient events as they considerably reduce computational time. Situations where the model is appropriate include:

Mass oscillation behaviour Short lengths of pipe in long systems Slow events

5.7.2

Elastic Pipe Model

This models the full elastic behaviour of a pipe containing a liquid in motion (or which can be set in motion). The Method of Characteristics is used and this requires you to define a distance time grid for all elastic pipes in the network.

In order to specify this grid correctly you should draw up a schedule of all elastic pipes in the network. The quantity

S=

L at

should be calculated for each pipe in the schedule, where: S L a Number of internal reach lengths Pipe length Wave speed (m) (m/s)

Note:

To model pipes as elastic, S MUST BE within 0.2 of an integer greater than 3.

It is unlikely that the S criteria will be satisfied exactly for all pipes and the analyst must adjust the values of L, a and t to meet this requirement. This can be achieved by:

Setting an appropriate time step Small adjustments to pipe lengths Modelling the end section of a pipe as RIGID so that the main section satisfies the above criterion for S Adjustments to the wave speed. In general wave speeds can only be estimated to an accuracy of 10% so small adjustments do not affect overall accuracy.

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Transient Simulation

Exercise 6
A 1.675 km water main has a change of section after 1 km. The wave speeds have been determined as approximately 1000m/s and 1250m/s respectively. It is required to analyse a 'rapid' event which does not cause cavitation and conditions in the pipeline during the proceeding 60s.

What are the appropriate time steps and adjusted values of pipe length and wave speed?

Upstream Pressure source Total Pressure Upstream Pipe Elastic Length Friction Option Roughness Diameter Wave Speed Abrupt Transition Major Diameter Minor Diameter Downstream Pipe Elastic Length Friction Option Roughness Diameter Wave Speed

11 bar

Ball Valve Diameter Valve Opening

0.15m 0.5

1000m 1 0.0025mm 0.2m 1000m/s

Valve Tabular Controller 1st Time Position 2nd Time Position 3rd Time Position 4th Time Position Downstream Pressure Source Total Pressure

0s 1 1s 1 2s 0 100s 0

0.2m 0.15m

675m 1 0.025mm 0.15m 1250m/s

10 bar

71

Transient Simulation
Setting an appropriate time-step

Schedule of Pipes
Pipe 1 Pipe 2 L (m) 1000 675 a (m/s) 1000 1250 L/a (s) 1 0.54

t1 = 0.1s
S1 10 5.4

t2 = 0.02s
S2 50 27

t = 0.02 s satisfies the criterion for S. This solution gives a large number of internal reach lengths and combined with 3000 time-steps requires the largest computational effort.
Length adjustment Pipe 2 is split into a 650 m elastic pipe and a 25 m rigid pipe.

Schedule of Pipes
Pipe 1 Pipe 2a Pipe 2b L (m) 1000 650 25 a (m/s) 1000 1250 RIGID L/a (s) 1 0.52

t1 = 0.1s
S1 10 5.2

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.

Wave speed adjustment The wave speed in pipe 2 is increased to 1300 mIs.

Schedule of Pipes
Pipe 1 Pipe 2 L (m) 1000 675 a (m/s) 1000 1300 L/a (s) 1 0.519

t1 = 0.1s
S1 10 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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Transient Simulation

5.8

Valves

The opening of the control valves for a Transient simulation can be entered into the valve data form or it can be controlled by an external controller.

Using a check valve in a Transient simulation requires additional data to be set. For example the characteristic operation time.

The gas admission and release valve (air valve) models gas flow between an external reservoir and a cavity within the system. It can also be used to model vapour cavity formation and collapse at a node by setting trigger pressure equal to vapour pressure and closing pressure greater than the maximum pressure to be experienced at the connecting node. A simpler way to model cavity formation is to set the auto vapourisation toggle at the relevant node.

In order to model existing gas admission/release valves, a knowledge of the installed device is required to establish the required input data. The overall inlet and outlet orifice sizes can be derived from manufacturer's charts of pipeline pressure versus volumetric discharge and the equations referenced in the help section for the gas admission/release valve.

For sonic flow through orifice

& m = APa

2 RT + 1

+1 1

and for subsonic flow through orifice

& m = APa

RT 1 Pa

Pb

2 /

Pb 1 Pa

( 1) /

where

& m
A

= =

gas mass flowrate overall orifice area external gas reservoir pressure, pipeline pressure ratio of specific heats, characteristic gas constant, temperature

Pa, Pb = , R, T =

The bleed orifice can be disabled by setting the transition volume equal to the initial cavity volume.

These valves must be correctly designed to prevent low pipeline pressures by admitting sufficient gas into the system and to prevent high upsurge pressures by venting gas from the system in a controlled manner.

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Transient Simulation

5.9

Pumps

In a Transient simulation, the mode of operation of the pump can be controlled using logic states. The logic states are: logic state -1 logic state 0 logic state 1 : pump running at constant speed : motor off (pump trip) : controlled torque or speed.

It is possible to switch between the logic states by specifying a switch time.

If the pump is in logic state 1, an external torque or speed controller is needed. The pump will operate as defined only if the value of initial speed is correctly set.

If controlling speed, the initial speed should not be set.

If controlling torque, the initial speed should be set.

Additional data that is required for a Transient simulation is the motor and pump inertias and the friction torque. If exact data is not known, then the values for the inertias can be estimated from the following graph.

74

Transient Simulation

The friction torque can be calculated from where

f = 01( ) .

= friction torque (Nm) and = duty torque (Nm).

5.10

Controllers
Curve Input Controllers Tabular Data Controllers PID Controllers

Flowmaster provides a range of controllers. There are three main groups:

along with two other specialised controller components:

Motor Torque Controller Pressure Unloader Controller

This course will use the simplest controller component, the tabular valve controller. For more complex position versus time relationships, curve valve controllers should be used. These allow a curve or equation to describe the position versus time relationship. These controller components can be used in a Steady State simulation and the position at the 'first time' will be used in preference to the position set on the valve data sheet.

Pump controllers include tabular and curve speed controllers, tabular and curve torque controllers and the motor torque controller. Pump controllers are only available in a Transient simulation. This is because for a Steady State simulation the pump logic state is assumed to be 1 (running at constant speed).

The operational variable curve reader is available for use in both Steady State and Transient simulations. Care needs to be exercised as its operation is governed by the operational variable supplied by the connected component and in some cases by the units used to enter the controller curve.

The set of PID controllers provide a method of simulating the fluid dynamic aspects of more complex control systems. The input data can be complex and requires that the control philosophy be understood and shown to result in stable control. Flowmaster should not be used to design control systems. Unconverged results may be due to the control system rather than the breakdown of the Flowmaster simulation.

75

76

Transient Simulation Examples

Chapter 6:

Transient Simulation Examples

This chapter is presented as a series of worked examples. The objective of this section is to provide you with the opportunity to reinforce the interface training already completed.

All the necessary data is given for the basic models and in some cases suggestions for advanced work is also given.

For all components requiring curves to be set, use the default curves unless other data is given.

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Transient Simulation Examples

Transient Example 1
Figure 0-1 Both Reservoirs : CONSTANT HEAD RESERVOIR Pipe Diameter Liquid Level Above Base Base Level Above Reference Surface Pressure 0.762 m 0m 0m 1 bar

For the Suter Head Curve use the data on the next page.

BALL VALVE Diameter 0.762 m

TABULAR DATA CONTROL VALVE CONTROL 1st time Valve position at 1st time 0s 0 ratio 20 s 1 ratio

RADIAL FLOW PUMP Rated Flow Rated Head Rated Speed Rated Power Pump Inertia Motor Inertia Speed Ratio Friction Torque Initial Speed Initial Logic State 1.917 m3/s 13.3 m 485 r.p.m. 250 kW 18 kg m2 60 kg m2 1 500 N m 485 r.p.m. -1

2nd time Valve position at 2nd time

NODE DATA No node data needs to be set.

SIMULATION DATA Time step Simulation start time Simulation end time Liquid type Ambient temperature Atmospheric pressure 0.4 s 0s 20 s Water 20 C 1.013 bar

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Transient Simulation Examples

Tabular data for pump (actual and normalised given):

Data Format: Flowrate units 1 2 3 4 5 6 7 8 (BEP) 9 10 11 (m3/sec) 0 0.28 0.56 0.83 1.11 1.39 1.67 1.917 1.94 2.22 2.50

Actual Values Head (m) 21.3 20.7 19.8 18.8 17.8 16.5 14.8 13.3 13.2 10.2 7.5 + + + + + + + + + + + Ref. Head/Flow Rotation

Steps to creating a new pump curve for this example:

1. Select 2. Set 3. Set 4. Select

Head from pump characteristic option Ref. Head Ref. Flow Actual Values

5. Enter curve data (see Table above) 6. Select Fit: 7. Enter 8. Save To Automatic Curve Title pumps (family 7)

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Transient Simulation Examples

Transient Example 2 (Pressure Surge and Alleviation)

It is required to investigate the pressure surges due to valve closure in the simple pipeline shown above. The following examples then look at how surge suppression techniques can be simulated.

The first event to be modelled is the 'rapid' closure of the valve in 2s. To effect the valve closure a tabular valve controller is needed. The data required for the network is:

UPSTREAM CONSTANT HEAD RESERVOIR Pipe diameter Liquid level Base level above reference 0.2 m 100 m 0m

PIPE: CYLINDRICAL ELASTIC Length Friction option Absolute roughness Diameter Wave Speed BALL VALVE Diameter Valve opening 0.2 m 0.5 ratio 1000 m 1 0.25 mm 0.2 m 1000 m/s

DOWNSTREAM CONSTANT HEAD RESERVOIR Pipe diameter Liquid level above base Base level above reference 0.2 m 95 m 0m

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Transient Simulation Examples

TABULAR VALVE CONTROLLER Output quantity 1st time Valve position 2nd time Valve position 3rd time Valve position 17 0s 0.8 2s 0 20s 0

Calculate t based on the S criteria with an simulation end time of 20 seconds.

The 'rapid' flow velocity changes due to a 2 s valve closure generate unacceptable pressures in the pipeline. This second simulation investigates the reduction in pressure surge of employing a two stage closure.

You will need to break the connection between the valve and first controller and add a new controller component to the network. In doing so you will need to decide whether you wish to continue in the network you are in and delete the results and the audit history or treat it as a network design variation and create a child network. This is all part of the audit trail function which will be discussed in more detail in Chapter 9. The new slow closure valve controller will be created with the following data:

TABULAR VALVE CONTROLLER

Output quantity 1st time Valve position 2nd time Valve position 3rd time Valve position 4th time Valve position

17 0s 0.8 2s 0.1 8s 0 20s 0

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Transient Simulation Examples

This third part investigates the reduction in pressure surge achieved by adding a suitably sized accumulator upstream of the rapidly closing valve. The data required for the accumulator is:

ACCUMULATOR: AIR VESSEL

Outflow loss Inflow loss Diameter of inlet Horizontal X-Sectional Area Accumulator height Base level above ref. Polytropic index Liquid level Gas pressure

1 1 0.04m 1m2 1m 0m 1.4 0.2m Not Set

Note:

The accumulator alters the nature of the transient event, changing a Rapid event to a Slow event. It is a useful exercise to repeat the simulation with the pipe modelled as RIGID and to overlay the results.

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Transient Simulation Examples

Transient Example 3 (Rising Main)

Two pumps draw fluid from a common feed reservoir. A non-return valve is located on the output of each pump. Both pumps feed a common rising delivery pipe which then branches to feed two discharge reservoirs. The feed reservoir, pumps and non-return valves are all at datum level. The higher of the two discharge reservoirs is 50m above datum, while the lower is at 40m above the datum. The flow to the lower discharge reservoir is controlled by a valve. The effect of a pipe fitting is modelled at the discharge to the higher reservoir.

The network is analysed over a 10 second period. Initially both pumps are running and the control valve is fully open. The valve is then progressively closed over the first two seconds. After a further two seconds, one of the pumps trips out.

It is suspected that cavitation will occur downstream of the control valve - therefore a vapour cavity is built into the network at this point using Auto-vapourisation. The effects of the cavity collapse are quite serious and a number of techniques can be used to overcome the problem: o o o slower valve operation adding an Air Admission Valve downstream of the control valve adding a Surge Tank or Air Vessel downstream of the control valve

It is suggested that the following data is used for the basic model before any of the suggestions are tried.

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Transient Simulation Examples

Component Number: 1 CONSTANT HEAD RESERVOIR Pipe Diameter 0.3 m Liquid Level Above Base Base Level Above Reference Surface Pressure 1 bar 0m 0m

Component Number: 9 RESERVOIR: INFINITE AREA Outflow Loss Coefficient Inflow Loss Coefficient Pipe Diameter Liquid Level Above Base Base Level Above Reference 3 3 0.15 m 50 m 0m 1 bar

Component Numbers: 2 and 3 (common data)

Surface Pressure

PUMP:RADIAL FLOW Rated Flow Rated Head Rated Speed Rated Power Pump Inertia Motor Inertia Speed Ratio 0.1 m3/s 50 m 954 r.p.m. 65.4 kW 4 kg m2 2 kg m2 1

Component Number: 10 BUTTERFLY VALVE TYPE A Diameter Valve Opening 0.2 m 1 ratio

Component Number: 11 TABULAR DATA CONTROL VALVE CONTROL 1st time 0 s Valve position at 1st time 2nd time 0.5 s 0.5 ratio 1 ratio

Friction Torque 0 N m Initial Speed 954 r.p.m. -1

Initial Logic State

Valve position at 2nd time Additional data for component 3: Switch time Logic state 4s 0 3rd time 1s

Valve position at 3rd time 4th time 2 s Valve position at 4th time

0.22 ratio

0 ratio

Component Numbers: 4 and 5 SWING-CHECK VALVE Diameter 0.3 m 1s

5th time 11 s Valve position at 5th time 0 ratio

Characteristic operating time Minimum velocity 1 m/s

Component Number: 12 PIPE: CYLINDRICAL ELASTIC Length 100 m 1 0.025 mm 0.2 m 1000 m/s

Component Numbers: 6, 7 and 8 PIPE: CYLINDRICAL ELASTIC Length 100 m Friction Option 1 Absolute Roughness Diameter Wave Speed 0.3 m 1000 m/s 0.025 mm

Friction Option Absolute Roughness Diameter Wave Speed

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Transient Simulation Examples

Component Number: 13 RESERVOIR: CONSTANT HEAD Pipe Diameter 0.2 m 40 m 0m 1 bar 1 SIMULATION DATA Fluid type Ambient temperature Atmospheric pressure Time step Simulation start time Simulation end time Water 20 deg C 1.013 bar 0.01 s 0s 10 s 2 3 4 5 6 7 9 8 0.000000 0.000000 0.000000 0.000000 20.000000 45.000000 50.000000 20.000000 40.000000 No No No No No No No Yes No Node Number Elevation Auto Vap (m) NODE DATA

Liquid Level Above Base Base Level Above Reference Surface Pressure

This is the end of the data for the simple network with no surge suppression devices included.

Build this network and check the results before attempting to suppress the water hammer effects.

There are three methods you can try in this example to suppress the pressure waves: 1. involves adding an air valve 2. involves adding an accumulator 3. adds a swing check valve and a finite area reservoir.

Example data is given below for each case, however, you may wish to use your own methods for determining the best solution.

85

Transient Simulation Examples

Method 1
Component Number : 1 GAS ADMIS/REL VALVE Main Inflow Diameter Main Outflow Diameter Bleed Outflow Diameter Transition Gas Volume Temperature Char. Gas Constant Polytropic Index Ratio of Specific Heats Opening Trigger Pressure Closing Trigger Pressure Vapour Pressure Characteristic Operating Time Initial Gas Volume External Gas Pressure 0.02 m 0.01 m 0.002 m 0.01 m3 19.85deg C 287 J/kg/K 1 1.4 0.9 bar 100 bar 0.02062 bar 0s 0.01 m3 1 bar

Base Level Above Reference Polytropic Index Vapour Pressure

20 m 1.4 0.02062 bar

Liquid Level

0.5 m

NODE DATA Changes to node data: turn auto vapourisation off at node 9

Method 3
Component Number: 16 RESERVOIR: FINITE AREA Outflow Loss Coefficient Inflow Loss Coefficient Pipe Diameter Horizontal X-sectional area Height of Top Above Base 1 1 0.1 m 1 m2 10 m 20 m 1 bar 5m

NODE DATA Changes to node data: turn auto vapourisation off at node 9

Base Level Above Reference Surface Pressure Liquid Level

Method 2
Component Number : 15 AIR VESSEL ACCUMULATOR Outflow Loss Inflow Loss Diameter of Inlet Horizontal X-sectional area Accumulator Height 1 1 0.1 m 1m2 1m

Component Number : 17 SWING-CHECK VALVE Diameter Characteristic operating time Minimum velocity 0.1 m 0.3 s 2m/s

NODE DATA Node 10 Elevation 20m

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Transient Simulation Examples

Transient Example 4 (PID Control)

Build this network to see how the flow-controlling PID controller can be used to maintain a constant flow rate through the lower pipe (by adjusting the position of the controlled valve) in response to a time-varying torque driving the pump.

Compare how the flow rate through the two valves varies.

87

Transient Simulation Examples

SIMULATION DATA Time step Simulation start time Simulation end time 0.01 <s> 0 <s> 60 <s>

PID
Measured Signal Input Quantity 1 Set Point Data Input Quantity 2 Output Quantity Minimum Measured Signal Input Maximum Measured Signal Input Proportional Constant Integral Constant Derivative Constant 19 19 17 0.01 <m3/s> 0.02 <m3/s> 5 <> 0.5 <s-1> 0 <s> 0 1 0 0 0 <> 1 <> 0.1 <>

Convergence & Tolerance Criteria: % Pressure Tolerance % Flow Tolerance 0.001 <> 0.001 <>

PRESSURE SOURCES Total Pressure 1 <bar>

Derivative on Signal Negate PID Evaluation Clamp Option

PIPE: CYLINDRICAL ELASTIC Length Friction Option Absolute Roughness Diameter Wave Speed 20 <m> 1 0.02 <mm> 0.1 <m> 1000 <m/s>

Latch Option Minimum PID Output Maximum PID Output Maximum Rate of Change per Sec

Curve / Surface : Manipulated Value v PID Signal = Equation of Y=X, from x=0 to X=1 (both axes dimensionless)

EXCEPTIONS Pipe 5 Length Pipe 7 Length Pipe 15 Length Pipe 16 Length 80 <m> 100 <m> 40 <m> 200 <m>

SIGNAL GENERATOR Signal Source Output Quantity 1st Time Signal at 1st Time 2nd Time Flow Rate 19 0 <s> 0.01774 <m3/s> 1000 <s> 0.01774 <m3/s>

BALL VALVES Diameter Valve Opening 0.1 <m> 0.2 <ratio>

Signal at 2nd Time

RADIAL PUMP Rated Flow 0.0357 <m3/s> 83.5 <m> 1000 <r.p.m.> 200 <kW> 150 <kg m2> 100 <kg m2> 10 <N m> 1000 <r.p.m.> 1

GAUGE Algorithm Type Output Quantity Output Initial Value Output Clipping - min value Output Clipping - max value 1 19 0 <m3/s> -100<m3/s> 100 <m3/s>

Rated Head Rated Speed Rated Power Pump Inertia Motor Inertia Friction Torque Initial Speed Initial Logic State

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Transient Simulation Examples

PUMP-TORQUE CONTROLLER Output quantity 1st time Pump torque at 1st time 2nd time Pump torque at 2nd time 3rd time Pump torque at 3rd time 4th time 26 (torque) 0 <s> 1868.96 <N m> 4 <s> 1868.96 <N m> 5 <s> 1600 <N m> 24 <s>

Pump torque at 4th time 1600 <N m> 5th time 25 <s>

Pump torque at 5th time 2400 <N m> 6th time 60 <s>

Pump torque at 6th time 2400 <N m>

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Transient Example 5 (Hydraulic Power)

PRESSURE SOURCE Curve Description: Curve Title: Pressure v Time FPTR1SOURCE

CYLINDER LOAD FEEDBACK CONTROLLER Input Signal (on Connection) Output Quantity Curve Description: Rod Disp 24. Force Output v Input Op.

PIPE: CYLINDRICAL ELASTIC Length Friction Option Absolute Roughness Diameter Wave Speed 6m 1 0.025 mm 15 mm 300 m/s

Variable Curve Title: FPRT1LOAD

FINITE AREA RESERVOIR Outflow Loss Coefficient Inflow Loss Coefficient Pipe Diameter 1 1 30 mm 1 m2 1m 0m 1 bar 0.5 m

CYLINDER 1 ROD 2 ACTNG Cylinder diameter Rod diameter Max rod travel Standard viscosity Leakage coefficient Viscous friction coeff Coulomb friction coeff Stiction force Stiction velocity Mass of piston and rod Piston load Initial rod position 25 mm 6 mm 0.2 m 0.05 N s/m2 0 L/mn bar 1e-6 Nsm-1 0 0N 0 m/s 2 kg 0N 0.1 m

Horizontal X-Sectional Area Height of Top Above Base Base Level Above Reference Surface Pressure Liquid Level NODE DATA

Node data should be let at the default values.

SIMULATION DATA Liquid type Ambient temperature Atmospheric pressure Time step Simulation start time Simulation end time Hydrol 46 20 C 1.013 bar 0.001 s 0s 0.5 s

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The pressure source should be set up as an equation of f ( x ) = the load should be defined as a curve with the following data:

( 100 + 10 sin 50x ) *100000 , and

Distance (m) 0 0.1 0.2

Load (N) 0 5000 10000

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Transient Example 6 (Hydraulic Power)

FINITE AREA RESERVOIR Outflow Loss Coefficient Inflow Loss Coefficient Pipe Diameter Horizontal X-Sectional Area Height of Top Above Base Base Level Above Reference Surface Pressure Liquid Level 1 1 25 mm 1 m2 1m 0m 1 bar 0.5 m

Spool posn 1 1st Channel 2nd Channel Spool position (-1 to 1)

1 6 1

PIPES: CYLINDRICAL RIGID (All 4) Length Friction Option Absolute Roughness Diameter 10 m 1 0.025 mm 25 mm

VANE PUMP Rotational velocity Volumetric displacement Leakage coefficient Coulomb friction coef. Viscous friction coef. 1500 r.p.m. 0.1 L rev-1 1e-08 ratio 0 1e-6

CYLINDER 1 ROD 2 ACTNG Cylinder diameter Rod diameter Max rod travel Standard viscosity Leakage coefficient Viscous friction coeff 100 mm 30 mm 1m 0.05 N s/m2 0 L/mn bar 1e-6 Nsm-1 0 0N 0 m/s 2 kg 0.5 m

DCV 4 PORT 3 POSN Spool posn-1 1st Channel 2nd Channel Spool posn 0 1st Channel 2nd Channel 2 5 0 0

Coulomb friction coeff Stiction force Stiction velocity Mass of piston and rod Initial rod position

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SIGNAL GENERATOR (TABULAR) Output Quantity 1st time Valve position at 1st time 2nd time Valve position at 2nd time 3rd time Valve position at 3rd time 4th time Valve position at 4th time 17. Valve Opening 0s 1 ratio 3s 1 ratio 3.5 s -1 ratio 11 s -1 ratio

NODE DATA Node data should remain as default

SIMULATION DATA Fluid type Ambient temperature Atmospheric pressure Time step Simulation start time Simulation end time Hydrol46 20 C 1.013 bar 0.01 s 0s 10 s

The load data is: CYLIDER LOAD FEEDBACK CONTROLLER Input Signal (on Connection) Output Quantity LOAD V OP VARIABLE Input op. variable no. Curve Description :Variable Curve Title :FP CHECK VALVE SIMPLE RELIEF VALVE Use the default data. FPTR2LOAD 1 Output v Input Op. Rod Disp. 24. Force Distance (m) 0.0 0.3 1.0 Load (N) 300 300 500

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Chapter 7:
o o o o Materials

Catalogue Customisation The Basics

This chapter will cover the following topics:

Sub-Systems and Sub-Circuits Symbols and Symbol Sets Custom Organisation of Catalogues

7.1

Materials

Flowmaster supplies a comprehensive range of materials, which are grouped into the following categories: o o o o o o Air Conditioning Compressible Humid Air Incompressible Hydraulic Solids

Flowmaster also provides three templates that you can use as a basis for creating your own material: o o o Standard Gas Template Standard Liquid Template Standard Solid Template.

To access materials, click on the Catalogues tab to see all the sub-catalogues. Open the Materials catalogue to see all the entries. Next, open the required catalogue.

7.1.1

Create a New Material Based on a Template

The best procedure to adopt when creating your own materials, is to add a new catalogue to the Materials catalogue, then add your items to this entry. This means all new materials you create are kept separate from those supplied by Flowmaster. To create a new material, open the Materials catalogue to display all the available entries. Right click on the new entry and select the New Material option. The Selection from Catalogue window will appear.

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Now, select Material Templates to display all the available templates. Select your desired template, e.g. Standard Liquid, from the list and then click Select. Depending on the template selected, the new item is added to the catalogue as: New Fluid, Liquid or Solid. Now select the new entry to display its associated Fluid Property Data form. You are now able to enter the required values and performance data for your new material.

7.2

Sub-systems and Sub-circuits

Sub-systems are groups of connected components, sub-circuits, used to build whole networks quickly from tried and tested building blocks. A sub-circuit is a group of components which has one distinct circuit and flow path i.e. the oil path through a cross flow heat exchanger. A sub-circuit cannot have the oil and coolant paths as this would be two distinct circuits. However components can be added to a sub-circuit to create the aforementioned sub-system.

This tool is useful if you have a string of components that you frequently use and know work together or are a standard functionality for your company or project. Instead of re-creating this known group each time, you can save them as a sub-circuit in your Sub-Systems Catalogue and then use it in exactly the same way as you would with other components by dragging and dropping them into the Schematic View to build your network. All components will show in your network.

To create a sub-circuit, you can either use an existing network, or create a new one. If you use an existing network or part of a network, the existing component data is also copied into the sub-circuit. The steps shown below assume you are using an existing network to create a sub-circuit. To do this, continue as follows: 1. Open your chosen network.

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2. Right click on a link between two components and select Calculate New Sub-circuit. The following window will appear: 3. Enter the name of the sub-circuit in the Circuit Name field. Note: It is important to note that it is NOT possible to change the circuit type that is displayed. Doing so and clicking Save to Catalogue will result in an error message. 4. Click the Save to Catalogue button. This will open the Select Containing Catalogue window. Select OK.

The sub-circuit is now stored in your Sub-Systems catalogue (the default catalogue into which subcircuits will be stored) and you can click, drag and drop it just as any other component:

Using the above methodology, i.e. right clicking on a link and choosing Calculate New Sub-circuit, will identify the whole network as a sub-circuit. If you wish to just use part of a network as a sub-circuit, you first need to isolate it from the rest of the network. This is done by blocking links around your subcircuit. Consider this network:

If you right click on any of the links in this network and choose Calculate New Sub-circuit, the whole network will be identified as a Sub-circuit. Let us now consider a case in which we just want to use the first pressure source and the two first discrete losses as a sub-circuit. To achieve this, we need to isolate them from the rest of the network, which is done by blocking the link between the second discrete loss and the ball valve. You can do this by right clicking on the link and selecting Block/Unblock Link:

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You can now see that this link has been highlighted in red:

Now, you can right click on any of the links in the part of the network you want to save a sub-circuit and proceed as described earlier. You will then see that only the parts leading up to the blocked link will be selected:

7.3

Symbols and Symbol Sets

The appearance of Flowmasters symbols can be changed according to pre-defined so called Symbol Sets, i.e. Coloured, Greyscale and Outline. Below is an example of a ball valve in the three different views: Coloured Greyscale Outline

When building a network in the Schematic View, you can switch between these different views by going to Tools/Symbol Sets. This will open the Maintain Symbol Sets window from which you can then choose a symbol set and select OK.

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All Flowmaster provided components are linked to a counter part with the same name in the Symbols catalogue. For example, the symbol for the ball valve will always be found in the file with the same name under the Symbols catalogue:

7.3.1

Component Symbol

Any one component can only have one symbol saved per Symbol Set. For instance, in the example above, the ball valve already has one symbol assigned for each one of the Coloured, Greyscale and Outline Symbol Sets. Therefore, if you want to add a new symbol to the ball valve, you have to create a new Symbol Set to which you can add a new symbol.

To create a new Symbol Set, go to the Tools menu, select Symbol Sets and click the Add button:

Now, give a name to the Symbol Set, e.g. User, and click OK. You can now add a symbol to an existing component by right clicking on its counter part symbol and select Edit Image:

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Give a name to the symbol, then choose the newly created User symbol set and browse for your symbol by clicking on Select New Image:

Finish by clicking OK. You have now added an image to your component. In order to make sure that this symbol will be used in the schematic, you need to ensure that your User Symbol Set is selected. To do that, go to the Maintain Symbol Sets window (Tools/Symbol Sets) and check that User is marked.

All other components, for which no new symbol has been added, will default to the Symbol Set that is on top of the list, i.e. Coloured. In order to change this, you can use the Search Order arrows on the right hand side. Below, Greyscale has been moved up a step and is now the Symbol Set that will be used as default for all components not having a symbol added to them in the User symbol set.

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It is also possible to create your own symbol, not associated to any of the pre-defined Flowmaster ones. For this, it is advisable to create a new catalogue under Symbols, e.g. User symbols, in order to separate them from the ones provided. Next, right click on this catalogue and choose New. From here, you can proceed as described previously. This can be useful if you create a composite component (see Chapter 9 Advance GUI Capabilities) and want to add a symbol to it.

You can use your own symbols in place of those supplied by Flowmaster. Symbols can be in one of the following formats: .bmp .ico .gif .jpg

The only restriction is that the symbols should not be greater than 48 x 48 in size. This provides good resolutions at most screen settings.

7.4

Custom Organisation of Catalogues

In addition to the Catalogues provided, you have total freedom to create your own Catalogues and fill them with the items of your choice. The best approach to adopt when adding items, e.g. Analytical Models or Components, to a Catalogue is to create a new Catalogue and then add your items to this entry. This way all the items you create are kept separate from those supplied by Flowmaster. For example, you could create a sub-catalogue

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for components, give it a name such as Custom Components and then add any new components that you create to this catalogue.

The example below shows how to create a new Catalogue, where a catalogue called Favourites is created in the Components catalogue.

Example: With the Catalogues pane selected, right click on the catalogue where you want to create your new catalogue, in this case Components, and select New Catalogue:

A new catalogue with the name New Catalogue Header will be added. You can now rename it to Favourites. You can also choose to change the name at a later stage by either right clicking on the Catalogue and selecting Rename, or by going to the lower pane and clicking on the cell next to Catalogue Header:

Note: You cannot write over the Catalogues supplied with Flowmaster V7.

7.4.1 Shortcuts
You can create and group shortcuts to all the items that you frequently use into one single catalogue. Instead of having to switch from one catalogue to another each time you pick components of different types, you can quickly build up your network using one single catalogue.

In the following exercise you will create a shortcut to a Pressure Source in the Favourites catalogue from the previous example.

7.4.2 Copying Components to Catalogues

Making a copy of an existing component before moving it to your custom catalogue allows you to customise the input data, symbol, data security levels and custom help fields. This differs from the shortcut option which links you to the standard non-customisable Flowmaster component.

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These customised components allow you to pre-configure the standard Flowmaster components to replicate commonly used components with the particular manufacturers performance data. This then reduces the data input time when creating future networks while also making Flowmaster feel more applicable to your application.

This is the first step in creating manufacturer specific component catalogues.

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Chapter 8:
o o o o o

Additional Features

This chapter will cover the following topics: Schematic Configuration and Background Catalogue Search Functions Dynamic Colouration Layers Pack and Unpack

8.1

Schematic Configuration and Background

To configure Schematic View, right click on the background. The Schematic Configuration window will open. Here you can: Change the colour of the background, components and nodes Add a background image Choose text and grid options.

Use Apply and OK to test and save your choices.

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8.1.1 Adding a Background Image

You can add a picture to the background of your schematic. To do so, right click on the background of your Network Drawing window, select Schematic Configuration (second from the bottom) and then go to the Image Import tab:

From here you can now attach an image and use it as a background. This will get added onto the background layer (see section 8.4).

Note: To stop the background image being moved while adding components etc this layer needs to be locked into position from the layers menu.

8.2

Catalogue Searches

You can perform a search for any item contained in one of the catalogues in the Catalogues pane via the Selection from Catalogue window. To open this window, click on the Catalogues tab and right click on the catalogue you want to search. For instance, if you are looking for a component, right click on the Components catalogue and then select Search:

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Clicking on the search option open the following window where you can filter specifically for component/curve/script etc. In the example Screenshot below the component catalogue is being searched.

The browse catalogues allows you to specify a particular area to search. This search can then be made more specific by using the filter options in the lower left pane. Once the item is found on the resulting list in the right hand pane the relevant item is then located automatically for the user in the catalogues pane in Flowmaster.

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8.3

Dynamic Colouration

In this pane you can configure a Dynamic Colouration scheme.

To do so, click the Configure button. This will open a Select Output Features window:

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Select the feature(s) of your choice and click OK. This will take you to a new window, Colour/ Range Band Selection:

The left pane of the window displays a mirror image of the Networks View, i.e. it shows all the projects and their associated networks, plus any colour schemes that have been set-up. In the example shown above, you can see that three colour ranges have been set up for the selected scheme. Once you have set up your colour scheme, click Save then Continue. This will automatically tick the Enable box next to the Dynamic Colouration Configure button.

Tip: To see dynamic colour propagation in pipes more easily it is useful to use the schematic configuration option to increase the standard displayed width of the pipe components.

8.4

Layers
display layer manager add to layer

In the Layer Toolbar you will find tools to:

Layers are useful for visual separation of items on your network, for example, you could put all pumps on one layer so that you can easily access them by turning selected layers on and off.

Layers are created in the Layer Manager, a tool that allows you to control aspects of Schematic View. For example, if you have a network that comprises of a number of circuits, such as an AC circuit and a Cooling Circuit, you could apply each circuit to a different layer. Then, using the controls in the layer window, you can hide one circuit while you work on the other and vice versa.

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You can also: Apply different colours to each layer. For example, the AC circuit components could be displayed in blue and the Cooling circuit components in red. Apply a level of transparency to each layer Make a level active or inactive - if a level is inactive, then the components on that level cannot be seen. Lock selected layers. icon. Alternatively, you can right click in the Schematic

To access the Layer Manager, click the View and select Open Layer Manager:

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Exercise 7
To add a component or a circuit to a layer, you must first create a layer.

Create a new network and build the schematic below which comprises of three pressure sources, three elastic pipes and one ball valve.

Open the Layer Manager by right clicking on the background and choosing Open Layer Manager:

Now create two layers called Layer 1 and Layer 2 by clicking on the Add Layer button and entering a name. Once you have done this, you will see that these two layers have been added to the list. Click OK.

Draw a box around the bottom section of the network using rubberbanding, right click on the selection and choose View/ Change Layer. Alternatively, click the Add To Layer icon .

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Select Layer 1 in the window that opens and click OK:

Repeat this for the top part of the network and add it to Layer 2.

You can now try out the different options mentioned earlier in this chapter. For example, you can set Layer 2 to 90% transparency (0% equals fully visible) and set the colour to red (black is default and gives the standard appearance). Click Apply, then OK when you are done:

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8.5

Pack / Unpack

You can choose to pack a project, specific networks or user-defined database items. To pack a project and its networks, proceed as follows: Go to the File menu and select the Pack option. The List of Items to Pack window will appear. The left pane is used to compile the projects and networks that you want to pack. The right pane shows the properties for selected projects, networks or selected items.

Click the Networks tab to see all the projects. Select the required project (or network if you just want to pack one or several networks) and drag into the left pane. What you see in the left pane is the project and its associated networks. If you open a network containing user created data, it will appear under the network that contains it.

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If you need to exclude any of the items shown for a particular project, uncheck the top level entry, i.e. the project, and then uncheck the items you want to exclude.

To pack the project, click the Pack to File button and the Write to Pack File window will appear.

Browse to your chosen location. Enter the required name and then click Save. An information window will appear.

Click Yes to save the file.

To unpack a file, proceed as follows: First, click the Networks tab to see all the projects and networks

Next, go to the File menu and select the Unpack option. The Open window will appear.

Navigate to the folder where the pack file is stored and select the required XXXX.FMPck file. The List of Items to Unpack window will appear:

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In the bottom left of the window are a number of options: o Prior versions Use existing: This option allows any previously unpacked network, curve or fluid to be overwritten. This action prevents the target database from becoming too large. You should note, that this action is only allowed within projects. If a curve is unpacked first by one project and then by another, then two copies are made. Effectively, the second project is not allowed to overwrite the first project's data as this contravenes security. Add new: When you unpack a network, curve or fluid and select this option, the unpacked items are added to the existing file structures and all other data is preserved. o Name duplication Auto-rename: This option is used to prevent name duplication when Networks or other items are unpacked. For example, if a network is unpacked for a second time, then it must be renamed. The Auto-Rename option will add a + at the end of the network name. Prompt: When you select this option you will be prompted to enter a new name for the Project, Network or item(s) that are being unpacked. Once you have selected the required option(s), click Unpack. Depending on the options selected, then the Duplicate Item Decision window will appear:

The window shows the name of the item being un-packed. At this point, you can: o o Use the existing name, click Use Existing. Select the Custom Name option, enter a name in the New Name field and then click Add New. o o Select the Auto Rename option and then click Add New. Click OK.

In all cases, a confirmation window will appear.

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Chapter 9:
o o o o o o o o

Advanced GUI Capabilities

This chapter will cover the following topics: Find and Replace Components Descriptive Sub-forms Adding Custom Help Descriptions Component Templates Composite Components Audit Trail Variable Parameters Analytical Models An Introduction

9.1

Add/Replace Components
icon and the

The Replace the Selected Component Type feature enables you to easily change specific or groups of components in your network with a simple step-by-step methodology. Click the Component Replacement window will open.

By following the steps in the window, changing entire groups of components is just a few clicks away. If the components were connected before the change, these connections will be kept. If component data can be easily transferred to a match data entry field then this too will be done i.e replacing rigid pipes with elastic pipes will copy the pipe diameter, length and roughness to the new elastic pipes.

Note: The functionality in Step 3 (seen above) will be discussed in the Section 9.6 (Audit Trails).

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9.2

Descriptive Sub-Forms

Descriptive sub-forms allow you to enter descriptive data, which although not used by the simulation, can be of use to you as the user. For example, if you use a particular kind of compressor in an automotive air conditioning system, you could use this option to create a sub-form that allows you to enter data such as: Physical data of the component (e.g. height, weight, length) Performance data (e.g. cooling capacity, performance coefficient) Manufacturers part number and perhaps the type of vehicle the component would be used on (e.g. Ford, Honda, Toyota).

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Exercise 8
To illustrate how to create a descriptive sub-form, we will create one called Custom DSF that specifies the Cost, Weight and Delivery of a particular radiator.

Tip
Place all copies of components in a separate folder in order to differentiate them from the components provided by Flowmaster.

1. In the Catalogues pane, right click on the Analytical Models folder and create a new descriptive subform 2. The Analytical Model editor SubForm window will open 3. Click in the Name field and enter the name of the sub-form, in this case Custom DSF 4. Click in the Description field to enter a description about the new sub-form 5. To add a feature, click the Add New button to open the Feature Type window 6. Select the Real option and click OK. The Real Feature window will appear 7. Enter the name of the feature (e.g. Cost) in the Name field. If required, enter some help details in the Help box 8. Repeat Steps 5 - 7 until you have added all the features 9. When you have finished, click OK.

In this example, we will create a copy of a Heat-Exchanger Thermal and add the sub-form to this copy.

To add a descriptive sub-form to a component, you must first open this components Component Customisation Form by right clicking on it and selecting Edit. Next, right click on Descriptive SubForms in the top pane and choose Add Descriptive Sub-Form

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This will open the Select Descriptive Sub-Form window where you can select the descriptive sub-form of your choice. Once you are done, click OK. You can now see that the sub-form and all its features have been added:

Now, if you go to Network Views and look at the data form for the component to which you have just added the descriptive sub-form, you can see that the sub-form has been added to its data form:

If we then look at the sub-form, we can see that it contains the three features that we added:

9.3

Adding Custom Help Descriptions

You can add your own help text either for a whole component or for specific detail areas. Since Flowmaster provided components cannot be edited, you will first need to make a copy of the component. Once you have done this, you can right click on the component for which you wish to add a description and choose Edit:

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This will open the Component Customisation Form for this component. From here, you can now choose the variable for which you wish to add a help description in the upper part of the window, and then go down to the lower part of the window, click in the cell next to Custom Help and then click the button that appears (in the picture below, we have chosen to add a description for the Characteristic operating time of a swing-check valve):

This opens a new window in which you can enter your description. Once you are done, click OK and then OK again in the Component Customisation Form:

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You have now successfully added a description. Using the Extended Properties icon, you can now access this information when the component is used in a network.

If you select the parameter for which you have added the description (left click in the cell directly to the left of the parameter) and click on this icon, you will open the Extended Properties pane for this parameter at the bottom of the Schematic View:

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9.4

Component Templates

Component Templates are representations of components that can be slotted into specific points in a network. This allows a system to be designed, for instance a cooling system, leaving a slot in the network where a specific component (e.g. radiator) can be slotted-in at a later stage.

When testing the network, you can click on the template to display a drop down list and select the required radiator.

When using component templates, you can define the connections, signal types, assign symbols etc. You can also define what components can be used.

To create a component template, go to the Components catalogue in the Catalogue pane and either create a new or choose an existing folder in which to save it. Right click on the chosen catalogue and select Component Template:

You will now be prompted to choose between basing your Component Template upon an existing Analytical Model or not:

If you base your template on an existing analytical model, there are two additional options to choose from: Allow only components with identical signal ports Specify components that can plug into the template

Both of these are optional. Once you have decided how to define your template, select OK. This will open the Step 1: Selection from Catalogue window, from which you can choose which analytical model(s) you want to be compatible with the template:

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In the example above, the analytical model for a discrete loss has been selected. Once you are done, press the Select button. If you have chosen the Specify components that can plug into the template option, a new window called Step 2: Selection From Catalogue will open and you can now choose which specific component(s) that can be plugged into the template (only components based on the analytical model(s) chosen in Step 1 will be available to choose from):

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Once you have chosen component(s), click on Select and a new window called Step 3: Component Template Editor will open. If you had not chosen the Specify components that can plug into the template option previously, this window would open directly after Step 1 (choice of analytical model) and will consequently be called Step 2: Component Template Editor.

In the lower left hand pane, Allowed Analytical Models, you can see a list of the analytical model(s) that you have chosen in the previous step. If you already have chosen components as well, these will appear in the lower right hand pane, Allowed Components.

Disregarding what you have chosen in previous steps, here you can add or remove both Analytical Models and Components from your Allowed lists.

Next, you need to give your new component template a name by typing it into the Name text field. You can also give the template a description in the Description text field.

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To add an output feature to your component template, select the Add Existing Output Feature button, which will open the Feature Selection:

The window shows a list of features and its associated type, e.g. integer, real, curve, equation or surface. You can search for a feature by entering a search term in the Find field. For example, to search for all features starting with Minor, then enter Mino in the field and then click the Down or Up button to highlight the required feature.

You can also search for features using the Include option. For example, to search on features whose names include the term press, then enter the term and click the Include radio button. Next, click the Down or Up button to highlight the required feature.

To edit the arm connections of your template, click on the Edit Arms button, which will open the Component Connections window. The example shown below is for a two-armed component, in this case a Discrete Loss. The window comprises of three sections. The top pane is used to set a valid arm connection for a particular circuit connection type, e.g. Incompressible or Compressible. The lower left pane is used to define where the arm is placed on the component. The right pane is used to set a fluid interface for specific components, e.g. Blowdown Tank.

The Number of Separate Internal Circuits box at the top of the window shows the number of internal circuits for the component, in this case 1.

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To set the allowable arm connections - Starting from the top pane, for Arm 1, determine what external connection type is required and click the associated check box in the Valid column. In our example, i.e. with a discrete loss, you will notice that the Incompressible and Compressible connection types have been set. As this component has only one internal circuit, the connection types are 'mirrored' for Arm 2. You can see this by un-checking All Arms Have Identical Allowable External Circuits. You can then repeat this step for all remaining arms in case you have a component with more arms. For our example, we will choose Incompressible for both arms. To set the arm placement for each arm - The arms can be placed in one of 59 positions around the component, as shown below:

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It is recommended to place fluid/ force/ solid connections at the centre of a symbol edge since this makes it easier to align the components in a network. To change the placement of the arms, you can either or enter values manually in the Placement column or click on Graphical View and drag and drop the connections:

To add signals to your template, click on the Edit Signals button and the Component Signals Connections window will open. From here, you can add or remove signals from your component model. To add a signal, click on the Add Signal button. By default, the new signal type is added as a normalised value. To set the desired unit quantity, click in the cell to display a pull down menu and select the required quantity. To set the signal type, click on the cell to display a pull down menu and select the required signal:

To choose the placement of your signal(s), click on Graphical View. This will open the Graphical Port Placement window, in which you can drag and drop the signal connection to your preferred position:

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When you are finished, click OK. To add a symbol, simply click the Select Symbol button and find the symbol of your choice through the Selection From Catalogue window. The same procedure applies when it comes to define which analytical models and components that are allowed to be used in the component template.

You have now created your component template. To use the template in a network, just drag and drop it onto the Schematic like you would with any other component. Only components fulfilling the criteria you have defined for your template can now be inserted. If a component does not fit, you will get the following message:

If you want to remove a component that you have plugged into your template, you can right click on it and choose Remove Plugged-In Component:

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9.5

Composite Components

Composite components are a powerful tool to enable you to develop part of a network which contains information from suppliers or other projects. Specific details can be added, such as weight, cost, part numbers or supplier details.

Composite components comprise of a number of individual components, that when connected together, perform a specific function when placed in a network. Any group of components can be made into a composite component.

For example, you could create a composite component that simulated a thermostat in an engine cooling system. This could then be added into the main network. This facility allows you to build a complete range of composite components, each performing a specific function.

Once you have built the component, you can use it like any other component. You place it in a network, set the component data, run the simulation and check the results.

The steps involved in creating a composite component are: 1. We recommend you create a new catalogue, in this case in the Components catalogue, in which new composite components can be stored. This helps you separate your own components from the ones supplied by Flowmaster. 2. Create the component. This stage is the same as building a network, where you drag components into a work pane, similar to the Schematic View pane, and then connect them together. 3. Set the component data. This can be done on a component-by-component basis or you can create an overall data form for the composite. This second step is performed by clicking the Data tab and then defining the data mode. 4. Assign a symbol to the component. 5. Deduce the number of arms and internal circuits needed for the component. 6. Add the required input signals to the model (if necessary). 7. Define the data model.

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Exercise 9
You will now create a composite component. First, right click on the Components folder and create a new Catalogue named Composite Components. Next, right click on your new catalogue and create a new Composite Component:

The Composite Component: Customise window will open, which comprises of a main schematic pane in which you can build your component and a Network Views window containing three forms: Data: This form comprises two panes. The top pane is used to collect components and nodes, and the lower pane shows the properties for selected components and nodes. This is the same form used when creating standard networks. Connections: Used to add a symbol to the component and deduce the number of arms and internal circuits. Data Model: Used to create a data form for the component.

Now, rename your component by typing a name into the Name field in the bottom of the Project Views pane.

Next, create the following component which comprises a cylindrical elastic pipe and a ball valve connected together with an incompressible node.

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Once you have done this, enter the data below for the components in the lower part of the Data form in Network Views: Elastic Cylindrical Pipe Length: 30m Absolute Roughness (Friction Data sub-form): 0.025mm Diameter: 0.1m Wave Speed: 1000m/s Ball Valve Diameter: 0.1m Valve Opening: 1 Now add a symbol to your composite component (here, it is suggested that you create yourself a new catalogue under Symbols in which you then create a new component. Go to the Connections tab (see below) and click on the Symbol button. The Selection from Catalogue window will open where you can select a symbol.

Next, you need to deduce the composite components arms and internal circuits. To do so, click on the Deduce button:

The information above has been Deduced by Flowmaster: Arm: Shows the number of external arms, in this case 2.

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Placement: In general, the placements will need to be set according to the positioning of the inputs and outputs of the composite. In our example, as we have two components adjacent to one another, we have set the placements at 0 and 30. Part No. & Part Arm No.: These show the relationship between the components and the connections of the composite component. If we take a look at the top line, we can deduce that Arm 1 of Part 1(the pipe) is connected to Arm 1 of the composite component. The same goes for the second line which shows that Arm 2 of Part No 2 (the valve) is connected to Arm 2 of the composite component.

The next step in the process is to add the required signals that will map through to the appropriate components in the composite. This step is optional and depends on the type of components used. In our example, we will add two signals for the valve: First, click the Add button. The Signal Mappings window will open in which all components and nodes to/from which signals can be sent are displayed. In this case, we want to be able to: o o o Input a valve opening signal Measure the position of the valve Measure the pressure in the node.

We therefore choose to tick all the available tick boxes (see picture below). When selecting a Measurement Output (MO) tick box, a Select Measurement Option window will open, letting you choose what parameter you want to measure, in this case the valve position:

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Once you have chosen the signals, the information below is displayed. Notice that we choose to place the signal arms as follows:

The last step is to create the composite components data model. When you do so, you are defining the overall data for it. This is necessary because once you have placed the Composite into a network you cannot access the individual data forms for the components that make up the Composite.

Creating the data model is a three stage process: 1. First you define the data form features for the composite. 2. Next, you need to decide what data items on this form are going to Fall Through, i.e. be passed-down to the corresponding data item(s) for the components in the parts list. For example, the feature Diameter could be set to fall through to the components in the parts list. 3. Lastly, you need to decide what output results (e.g. Pressure Drop) are going to be Passed Up from the components in the parts list, to the corresponding output feature you have defined on the overall data form.

To create the data model in this example: Select the Data Model tab. This will display the Data Model form shown below. The top pane shows the model name that is used to create/ edit the data form and to add a Descriptive Sub-form, if required. The lower pane shows the parts list of all the components comprising the composite. By clicking the required checkbox, you can see the features for that component.

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Next, click on the Create/Edit button. The Analytical Model Editor window will open. Here you can add five existing features: 1. Diameter (input) 2. Length (input) 3. Valve opening (input) 4. Pressure (output) 5. Position (output).

It is important that you notice that some of these features can occur twice in the list. This is due to the fact that one is defined as input and the other as output. Therefore, you need to be careful in your selection and make sure you select the required alternative.

Once you have selected the features in the Analytical Model Editor window, you need to set their Necessity for the different types of simulations (right hand pane of the window). The quickest way to do this is to right click in any of the cells in the Requirement row and select Set all to Mandatory for the three inputs and Set all to Not Needed for the two outputs (if the outputs were set to something else than Not Needed, they would appear in the in-data parameters in the input sheet for the composite component):

If you wish, you can also add a Descriptive Sub-form. When you have done this, click OK. If you now click the + sign next to the model in the upper pane, you will see a list of all the features you just added:

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Now that you have defined the features that will be used in your composite component, you need to set how these will Fall Through and be Passed Up. Let us start by setting the fall through features: o o o o Select Diameter in the upper pane. Check the Check for Fall Thru radio button. If required, a scale factor can be entered for the feature (1 in this example). In the lower pane, click the + sign next to both Ball Valve and Pipe Cylindrical Elastic to see all their features. o o Select the Diameter feature for both of them by clicking the associated check box. Repeat this procedure for Length (pipe) and Valve Opening (valve).

Next, let us set the pass up features: o o o Select Position in the upper pane Check the Check For Pass Up radio button In the lower pane, click the + sign next to either Ball Valve to see all its features o Select the Position feature by clicking the associated check box o Repeat this procedure for Pressure (node)

By entering data for your two components (pipe and valve) earlier, you defined the default values for the different parameters of the components. In case you choose to include all the parameters in the composite components data form, this step is optional and it is up to you to choose whether you want to have default values for the different parameters.

However, if you choose to exclude parameters that are mandatory for specific components, e.g. length or diameter for a pipe, when you define the composite components data form, it is mandatory to enter a value for the parameters you exclude. For instance, in this example, we have chosen not to include the pipes roughness as a parameter in the composite components data form and it was consequently mandatory for us to enter that value.

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9.6

Audit Trail

The audit trail functionality associates results with models and tracks changes as your design progresses. You can also revert back to previous data or rerun simulation on old projects after making changes. Thanks to the audit trail, you will always be able to know what data and which network configuration that produced the specific results you are looking at.

Five stages of Audit trail:

1. Data to Results file save and easy switching

When you enter data for a component, it is stored as usual. However, when a simulation is run, the data will also be linked to all result sets that are created with it. If the data was to be changed at any point, e.g. changing a valve opening from one simulation to another, the previous data is retained and the new data will be associated with all subsequent results.

The above screen shot shows the buttons used to quickly switch between the data used and the corresponding results for a particular component.

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2. View previous simulations It is possible to display how individual variables have been changed from simulation to simulation by right clicking on them and selecting View Data for Prior Simulations:

A Prior Simulation Data window will then open, displaying the values for the specific variable for each simulation that has been run:

Above, we have described how data is associated to each specific simulation, enabling the user to track what data that has been used for what simulation.

3. Load old data and run from this point

If after running numerous analyses you wish to find out the full data set used for a particular result set it is possible to load up the full data set. This is done by selecting the result set number from the pull down list as shown below. (Live refers to the last set of data that was used for an analysis).

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4. Audit comparison report Another option available is to run a report on two result sets to see what parameters changed in the network resulting in the difference in the results. This report is activated by simply selecting the two required result sets by holding the ctrl key while selecting and then clicking on the audit report button.

This results in a report like the following: Network Name : SteadyState1 Network Owner Project: Project A Network Creation Date: 29/11/2006 16:35:50 Input Data Difference Report for Simulation No 2 & 3 --------------------------------------------------------------------------------------------------------------------Network General Data and Simulation Control Simulation Title [Simulation No 2] = 1595 rpm Simulation Title [Simulation No 3] = 1395 rpm ----------------------------------------------------------Component No : 9 Pump: Radial Flow Rated Speed [Simulation No 2] = 1595.0004804(rpm) Rated Speed [Simulation No 3] = 1394.9999412(rpm) -----------------------------------------------------------

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5. New network tree structure

If the network is changed in any way, e.g. by adding a component or changing a connection, this needs to be taken into account this is assumed to be a change in the design direction for that project. This means that either you wish to delete all the work you had previously done or simply make a child (design variation) of the main network.

Therefore, if you make any change to a network for which at least one simulation already has been run, you have to choose between these two options: To keep the results and automatically create a new copy of the network to work on. Automatically delete the results and continue modifying the current network.

If you choose the first option, the new network(s) will become derivative(s) of the original, thereby allowing for design change traceability. Under the Networks tab in Project Views, you will see that a copy network has been created under the original:

9.7

Variable Parameters

The Variable Parameters are way of inputting data in one location, which can then be applied to other components of the same type throughout the network. Entering data in this way can be of great help when performing parametric studies. To create a variable parameter you need to enter a text string in the component data field instead of the numerical value of that data field. This text string must be entered within square brakets e.g. [ ]

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In the example above the pump speed was entered as a text string of [Pump Speed] instead of the numerical value. This will create an entry on the variable parameter tab called [Pump Speed] As shown below.

In the example above there are three such variable parameters set up. The engine speed is set as a single numerical value and gets filtered down to the relevant components. The pump speed and CAM speed are set up as expressions of the engine. To set up an expression you simply select to edit the expression option at the bottom of the variable parameters tab. This opens up the window below in which the expression can be set up. In this example the pump speed is set up to be 0.8 times the engine speed.

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The variable parameters are also included in the audit trail functionality. The values set for previous analysis runs can be accessed by selecting the appropriate analysis run number from the pull down list at the top of the variable parameters tab.

When an alternative simulation number is selected the values for this simulation are shown as the value beside the Parameter name.

9.8

Analytical Models An Introduction

Analytical Models are mathematical representations of Flowmaster components, e.g. pipes or valves. Each model includes all the equations or similar, used by the simulation. All the models are supplied with a basic set of data definitions, e.g. length or diameter and a corresponding symbol. Analytical models cannot be added to a Flowmaster network; to use an analytical model the user must create a component.

A component is based on an analytical model. It can include custom feature names, default data items and different connection points. Multiple components can be based on the same analytical

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model, an example of this is that the ball and globe valves share an analytical model with different default data set at component level.

To access an existing analytical model, go to the Catalogues pane, browse the Analytical Models catalogue for the component of your choice and double click on it. The Analytical Model Editor: Component window will open for this component (below is the window for a Discrete Loss):

The window comprises of two main panes. The Features pane shows all the features (data items) for the selected model, while the right pane shows the Necessity requirements for selected features. As you select a feature, the details in this pane change accordingly. The Help pane at the top is used to display information about the model.

Creating new Analytical Models is outside the scope of this training course. The creation of Analytical Models will be covered in a further training course.

Creating New Components

To create a new Component, the first step is to create a new Catalogue in the Components catalogue. Right click on the Catalogue you have just created, choose New and then Component:

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The Selection from Catalogue window will now open. Select the Analytical Model your component will be based on. Components are based upon Analytical Models.

Once you have done this, the Component Customisation Form window will open:

Here you can now select a symbol for your component from a catalogue, customise the arm placement, customise the component name, add custom help (see section 9.3), add custom names for features (if required) and finally click OK to finish.

Alternatively, you can make a copy of an existing component and modify it to suit your needs.

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Chapter 10:

Services and Support

The Flowmaster website (www.flowmaster.com) offers you many services as a user. a. News & Events: get the latest training courses and dates in your region, sign up to free educational webinars, find out the latest Flowmaster news & events from around the world, subscribe to our free quarterly email newsletter, FlowNews, register for the next User Group Meeting. b. Customer Portal: register for free and gain access to the latest maintenance releases, partner software and downloadable components; the user forum where you can chat and exchange ideas on Flowmaster with other users; check out previous releases of FlowNews; check out whats new at the latest release of Flowmaster; find out what happened and who went to past User Group Meetings; submit your suggestions for enhancements to Flowmaster. c. Case Studies: find how other companies and users have benefited from using Flowmaster.

If you have internet access on your PC you can go straight to the Flowmaster website from the software. Click on the Help menu and select Flowmaster website.

Reference Help is fully integrated into V7. An example of this is the fact you can directly access a components related Reference Help chapter by just clicking on this icon (it is located on the left of the top pane in Network Views).

Alternatively, you can right click on the component of your choice in the Catalogues pane and choose Reference Help:

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Other Courses:
Control and Automation
This course concentrates on the automations functions available within Flowmaster. These features include:Scripts: enabling the user to add control functionality into Flowmaster networks. Examples of usage include pressure\flow rate sensitive valves, and the ability to link to other programs. COM Enabled Components: enabling the user to view and modify analyses while an analysis run is taking place. Linking Flowmaster to other programs: enabling Flowmaster to send data to other programs such as an excel spreadsheet. Linking other programs to Flowmaster: utilising the new COM features to enable databases and spreadsheets to open Flowmaster networks, run analyses and retrieve results. This feature can be used to create a custom interface for Flowmaster. The Flowmaster link for MATLAB: enabling Flowmaster to take advantage of the advanced control capabilities of MATLAB\SIMULINK.

Compressible
This course is aimed at engineers who have some experience in the design of gas systems and have a need to use Flowmaster as an analysis tool to predict system behaviour. The capabilities of the Flowmaster compressible steady state and transient analysis modules are described and time is spent building networks to demonstrate component and system behaviour. This course does NOT cover the theory of compressible flow in theory.

Heat Transfer
Engineers who require a more detailed understanding of the thermal/cooling capabilities of the software should attend this course. The Flowmaster Heat Transfer module provides the user with the appropriate modelling techniques in order to investigate the effects of heat transfer in various application areas. It is a sub-module of both the Single Phase (incompressible) and Fluid Power Steady State and Transient modules and as such can be used to perform a simultaneous analysis of fluid flow and heat flow in time-independent and time-dependent flow conditions.

Automotive Air Conditioning

With Flowmaster V7 you can model automotive thermal management systems. It is possible to simulate vapour compression cycles such as those found in automotive climate control systems, using the Air Conditioning (AC) module.

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Flowmasters AC module allows engineers to gain a deeper understanding of AC system behaviour through parametric studies and what-if simulations, enabling the design of systems with higher efficiencies, lower costs and better performance.

Simulation of the complete thermal management system (coolant, oil, transmission, air conditioning, underhood airflow and cabin air circuits) in Flowmaster is possible. Simulation of the thermal interactions between these circuits gives an insight into overall system performance early in the design cycle. This enables potential problems to be identified and resolved at an early design stage, reducing the need for late and expensive changes, saving time and money.

It simulates the Steady State and Transient operation of AC circuits, predicting pressures, temperature distributions, performance coefficients, qualities and flow rates for changing environmental and engine load conditions. Flowmaster can co-simulate with vehicle performance prediction software (such as Advisor from NREL written in MATLAB/Simulink). This enables you to design your AC system for optimal performance over various drive cycles and environmental conditions.

AC has been developed as a system design tool with the application in mind. It is designed to meet the increasing requirements of users designing vehicle thermal management systems, and in particular the need to account for Transient behaviour of AC systems in their simulations.

System performance can be simulated for variations in charge mass, component sizes and control strategies. All of this is achieved with minimal data input requirements. This means your system can be designed by modification of minimal parameters until the desired performance is obtained, enabling system designers to specify to suppliers the characteristics required for individual components.

Component scripts and controller facilities in Flowmaster enable the imposition of complex control strategies on the AC (and other) circuits. The control system may be modelled directly in Flowmaster or through co-simulation with a package such as MATLAB/ Simulink. Refrigerant fluids are stored in the Materials catalogue as an Air Conditioning category. R134a, R12, R22, R290 & R744 (CO2) are supplied as standard refrigerants. Alternatively, a utility spreadsheet is available for those users who wish to generate refrigerant physical property data and create their own refrigerant fluids.

Flowmaster can model both trans-critical (e.g. CO2) and sub-critical air conditioning systems (e.g. R134a).

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The Three Main AC Systems

Accumulator: FOT System
This system uses an FOT and an accumulator to meter the refrigerant flow and to cycle the compressor clutch to control evaporator temperature.

The accumulator is situated downstream of the evaporator and upstream of the compressor.

Receiver Drier: TXV System

The purpose of the TXV is control the refrigerant flow to the evaporator, based on the amount of refrigerant superheat at the evaporator outlet. Also used is a receiver-drier, which is located upstream of the TXV and downstream of the condenser.

Its function is to ensure that the TXV receives sub-cooled refrigerant.

Accumulator: VOV System

This system uses a VOV in place of the FOT. The system works by changing the diameter of the VOV, depending on the upstream pressure (or temperature). This arrangement allows for greater cooling capacity than the FOT system, at low vehicle speeds and engine idle.

Electro-Mechanical Components
Flowmaster plays a vital role in the design of many hydraulic circuits that interact closely with mechanical components.

The Electro-Mechanical catalogue contains components which enable you to model mechanical lements and electrical inputs (e.g. a servo) using simple, direct models of mass, spring, damper, friction, earth, force and end stops. These interact with the fluid circuit.

The literal one-to-one nature of these models allows the user to improve product quality and lower costs by getting it right first time while reducing the design cycle lead time.

Airside Systems
You can simulate your air systems using the components in Flowmasters Airside catalogue, in the Incompressible catalogue.

Lubrication Systems
The Lubrication catalogue enables you to simulate your lubrication systems, including heat transfer, in automotive systems.

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Appendix - Results

Steady State Example 1

P r e s s u r e

Node Number

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Steady State Example 2

Node Pressures

Pump Component Results

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Steady State Example 3

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Steady State Example 4

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Exercise 6

Plot below shows, Rigid Pipes, Upstream Pipe Elastic Only and Both Pipes Elastic

Timestep Adjustments

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V7 Automatic Wavespeed adjustment Blue line shows Wavespeed is automatically adjusted if the S criterion isnt met. Green line shows a Wavespeed manually adjusted in the downstream pipe to 1300 ms-1, therefore meeting the S criterion. A perfect match, Warnings log show the percentage adjustment made automatically to the Wavespeed.

Blue line shows results due to an adjustment to the length of downstream pipe Green line shows the Wavespeed adjusted results.

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Transient Example 1

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Transient Example 2

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Transient Example 3

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Suppression Methods 1. No Suppression or Autovaporisation (Blue) 2. Gas Admission/Relief Valve (Green) 3. Air Vessel Accumulator (Purple) 4. Finite Area Reservoir and Check Valve (Pink)

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Transient Example 4

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Transient Example 5 Pressure at Node 2

Transient Example 6 Pressure at the 4 outlets of the DCV

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