Challenge Overview
Chicago Bridge and Iron's (CB&I) Process Engineering Division was tasked with designing a gasification system for an LNG off-loading terminal in Illinois. The design was required to integrate a new interconnecting circuit with an existing power plant cooling system flowing in excess of 108,000 gallons per minute, without compromising the mechanical integrity or operation of the plant.
A previous analysis produced a design that included check valves, flow control valves, booster pump bypass valves, and full-voltage booster pumps. However, when the system was modeled in Datacor Impulse, the analysis revealed that vacuum conditions would occur in the piping under multiple operational scenarios, including pump trip. Because information on the vacuum capabilities of the existing piping was not available, the design had to be revised.
What You Will Learn
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How Datacor Impulse was used to model both the existing 6-cell cooling tower system and the new LNG interconnecting circuit in a single integrated model exceeding 108,000 gpm
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How steady-state model calibration in Impulse separated actual condenser losses from theoretical values, accounting for plugged tubes and fouling in the existing system
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How transient analysis revealed vacuum conditions and reverse flow risk under pump trip scenarios that were not identified in the original design review
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How a revised design eliminated all check valves, bypass valves, and flow control valves by using variable speed drives instead, reducing component count and simplifying control
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How Impulse-derived recommendations improved system restartability after upsets and enabled rapid recovery with minimal operational concerns
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Why this project was recognized with a Platinum Pipe Award for software features and model creativity
Key Results
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Vacuum conditions were fully eliminated from the revised system design
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Check valves, flow control valves, and bypass valves were removed from the system, reducing mechanical complexity
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Variable speed drives replaced full-voltage booster pumps, simplifying system control
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The system restart procedure was developed and validated in simulation before implementation
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The project received the Platinum Pipe Award for software features and model creativity
Case Study Snapshot
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Product: Datacor Impulse
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Industry: Liquefied Natural Gas
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Region: Illinois, USA
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Application: Surge analysis, transient modeling, LNG cooling system design, pump trip analysis
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Award: Platinum Pipe Award: Software Features and Model Creativity
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System Scale: 108,000+ gpm, 6-cell cooling tower, booster pumps, plate-frame heat exchangers