Bougebrayel Technology Summit-TYB-j

Swagelok Technology Summit
CFD Prediction of Liquid Flow through a 12-Position

Modular Sampling System
Tony Bougebrayel, PE, PhD
Engineering Analyst
Swagelok Co.
Swagelok Company, 2005
AGENDA
How is the driving pressure consumed?

Why do liquids require more driving pressure?
Predicting driving pressure for a conventional system
What is CFD?
CFD application to a 12-position modular system
Results: CFD vs. Actual
Conclusion
How is the driving pressure consumed?
Momentum Loss:
Pipe size reduction
Control Components (valves, filters, check
valves, meters, gages)
Entry and exit effects (velocity profile)
Contraction/Expansion
Directional Changes (elbows, Ts..)
Potential Energy: Height
Viscous Losses: Boundary Layer formation
Turbulent Energy
Modular systems experience Momentum,

Viscous, and Turbulent losses
Driving Liquids
Flow in a straight pipe

Darcys equation: P = .000216 x f x x L x Q2 / d5
f Re,(Re = U d/)
Re f P
Re f P
10x increase in yields 71%

increase in P
10x increase in yields in
580% increase in P
Density is dominant
in straight pipes
f values taken for smooth pipes flowing at 10 4 and 105 Re
Driving Liquids
For Non-Uniform Geometry
Navier-Stokes Equations (Incompressible, Laminar, in 3D Cartesian Coordinates)
2u 2 u 2u
u
u
u
u
p
u v w 2 2 2
t
x
y
z
x
y
z
x
Local
acceleration
Momentum
terms
Piezometric pressure gradient
Both Density and Viscosity

affect 2nd order terms
Viscous terms
Conventional System: Predicting Driving Pressure

Bernoullis Equation (mechanical energy along a streamline)
z1 + 144 p1/1 + v12/2g = z2 + 144 p2/2 + v22/2g + hL

Potential
Energy
Pressure
Energy
Kinetic
Energy
Total
Head Loss
Where, hL = K v2 / 2g
Ki = f L / D (Ki: Flow Resistance)
Ktotal = Ki
Fitting
L/D
Globe Valve
340
non-pipes i.e. valves, fittings
Lift Check Valve
600
Ball Valve
Flow resistance approach in

systems design
Tee- Branch flow
60
Elbow- 90
60
Bend r/D = 20
50
L / D: Equivalent pipe length for
Conventional System: Predicting Driving Pressure

Q, ml/min
300
Pipe friction, f 0.0308
OD
Wall
Thickness
1/4"
0.065
Non-Pipe friction, f_T 0.0379

Component
Quantity
Ki
f*Ki
90-Elbow
20
60
2.27
45.4
Check Valves
600
22.71
22.7
Globe Valves
500
18.93
151.4
90-Bends, r/d=8
20
24
.91
18.2
Flow-thru-branch
60
2.27
13.6
Pipe, inch
120
K values are empirical

30.8
K_total
282.1
h, in
265.8
P, psi
9.6
Courtesy of Exxon Mobil
Pressure Required for a MPC
Empirical Approach (Cv or K):
Cv = 29.9 d2 / k1/2
(1/Cv-total)2 = (1/Cv-i)2
Testing
CFD
Cv-5
Cv-4
Cv-3
Cv-2
Cv-total < Cv-i
Cv-1
Flow
Flow
What is CFD?
A numerical approach to solving the Governing flow equations
over any Geometry and Flow conditions
CFD is used to solve the general

form of the flow equations
CFD The Governing Equations

F= d(MU)/dt = u(u/x)dxdy +
v(u/y)dxdy
(u/y)dx|y+dy
Differential Control Volume
pdy
[p+(p/x)dx]dy
C.V.
dy
y
x
External Forces
(u/y)dx|y
dx
[u+(u/y)dy][v+(v/y)dy]dx
u2dy
The flow equations are based

on the conservation laws
Change in
Momentum
C.V.
uvdx
[u+ (u/x)dx]2dy
CFD The Governing Equations

Navier-Stokes Equations for an Incompressible, Laminar flow
2u 2u 2u
u
u
u
u
p
u v w 2 2 2
t
x
y
z
x
y
z
x
2v 2v 2v
v
v
v
v
p
u v w 2 2 2
t
x
y
z
y
y
z
x
2w 2w 2w
w
w
w
w
p
u
v
w
2 2 2
t
x
y
z
z
y
z
x
Local
acceleration
Inertia terms
Piezometric pressure gradient
Viscous terms
u v w
0 Continuity equation
t
x
y
z
The N.S. eqs. are highly elliptical

and impossible to solve manually
CFD How does it

Work?
Solve: y + y = 0 (1st order PDE)

for 0 x 1
y y
y
i 1 i
x i xi 1 xi
From Taylors: y '
yi 1 yi
yi 1 0
xi 1 xi
Plug into (1):
-yi + (1+ x )yi+1 = 0 (3)

X1
(Eq. 2): Discretized, Algebraic Equation
Discrete
Domain
XN
For a structured grid: x = Xi+1 - Xi
Apply equation (3) to the 1-D grid at nodes 1,2,3:
y1
y2
y
j
0
i
y3
-y1 + (1+ x )y2 = 0 (i=1)
(4)
-y2 + (1+ x )y3 = 0 (i=2)
(5)
-y3 + (1+ x )y4 = 0 (i=3)
(6)
y4
Convert the PDE into

an Algebraic equation
Equations 4, 5, & 6 are 3 equations with 4 unknowns

The B.C. y1=1 completes the system of equations
What is CFD?
Next, we write the system of equations in a matrix form: [A]{y}={0}
1
-1
(1+ x )
-1
(1+ x )
-1
y1 = 0
(BC)
y2 = 0
(4)
0
(1+ x )
To solve, is to find [A]-1

Much CFD work revolves around
optimizing the inversion process
Accuracy is grid
dependent
y3 = 0
(5)
y4 = 0
(6)
CFD Application to Current System

Check
Valve
Pressure
Switching
Valve
Pressure
Toggle
Shut-off
Pneumatic
Switching
Valve
Pneumatic
Shut-off
Manual
Shut-off
Pneumatic
Shut-off
Toggle
Shut-off
Flow
Toggle
Shut-off
Flow

Build the Geometry
Extract the Fluid

volume
Create the
Mesh: 3.2
million cells
Set Boundary Conditions
Solve
Results
Pressure required to drive 300 cc/min through the
12-position system, psi
MPC
Tested
MPC
Conventional
Calculated
CFD Predictions
Water
15.6
16.9
9.6
Diesel
17.9
15.1
10.8
Gasoline
12.5
11.7
7.1
Pressure required to drive liquid samples through

modular systems are in line with available pressure

Results: CFD vs. Actual
CFD predictions are very

accurate when fluid
characteristics are known
Results: Density vs. Viscosity
Water @ 65 F
Diesel Fuel #2
@ 100 F
Unleaded
Gasoline
SG
, cP
.85
1.69
.73
.47
Viscosity effects are more

prominent than density
effects in modular systems
Testing conducted by Colorado Engineering Experiment Station Inc.
Results: Density vs. Viscosity

SG
= /, cSt
Water @ 65 F
Diesel Fuel #2 @ 100 F
.85
Unleaded Gasoline
.73
.64
Pfluid/Pwater ( fluid/ water)0.5
The Kinematic viscosity

compares relatively well
to pressure
Conclusion
Reasonable pressure required to drive typical liquid
samples through NeSSITM systems
CFD can be employed to accurately predict flow under
different conditions
The Kinematic viscosity of the liquid sample is a good
indicator of its pressure requirement
Questions?

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Swagelok Technology Summit

CFD Prediction of Liquid Flow through a 12-Position

Swagelok Company, 2005

Swagelok Technology Summit

How is the driving pressure consumed?

Swagelok Company, 2005

Swagelok Technology Summit

How is the driving pressure consumed?

Potential Energy: Height

Viscous Losses: Boundary Layer formation

Modular systems experience Momentum,

Swagelok Technology Summit

Flow in a straight pipe

10x increase in yields 71%

f values taken for smooth pipes flowing at 10 4 and 105 Re

Swagelok Technology Summit

For Non-Uniform Geometry

Navier-Stokes Equations (Incompressible, Laminar, in 3D Cartesian Coordinates)

Piezometric pressure gradient

Both Density and Viscosity

Swagelok Technology Summit

Conventional System: Predicting Driving Pressure

z1 + 144 p1/1 + v12/2g = z2 + 144 p2/2 + v22/2g + hL

non-pipes i.e. valves, fittings

Lift Check Valve

Flow resistance approach in

Tee- Branch flow

L / D: Equivalent pipe length for

Swagelok Company, 2005

Swagelok Technology Summit

Conventional System: Predicting Driving Pressure

Pipe friction, f 0.0308

Non-Pipe friction, f_T 0.0379

K values are empirical

Courtesy of Exxon Mobil

Swagelok Technology Summit

Pressure Required for a MPC

Empirical Approach (Cv or K):

Cv-total < Cv-i

Swagelok Technology Summit

CFD is used to solve the general

Swagelok Technology Summit

CFD The Governing Equations

Differential Control Volume

The flow equations are based

Swagelok Technology Summit

CFD The Governing Equations

Piezometric pressure gradient

The N.S. eqs. are highly elliptical

Swagelok Technology Summit

CFD How does it

Solve: y + y = 0 (1st order PDE)

From Taylors: y '

Plug into (1):

-yi + (1+ x )yi+1 = 0 (3)

(Eq. 2): Discretized, Algebraic Equation

For a structured grid: x = Xi+1 - Xi

Apply equation (3) to the 1-D grid at nodes 1,2,3:

-y1 + (1+ x )y2 = 0 (i=1)

-y2 + (1+ x )y3 = 0 (i=2)

-y3 + (1+ x )y4 = 0 (i=3)

Convert the PDE into

Equations 4, 5, & 6 are 3 equations with 4 unknowns