FEA and CFD Expertise Promotes Efficient Design and Savings

Jōb Industrial provides advanced finite element analysis (FEA) and computational fluid dynamic (CFD) modeling services to our customers. These cutting-edge simulation tools provide significant value to our customers in solving complicated static-structural, thermal, and flow-related problems. FEA and CFD tools are exceedingly useful in the design process when design standards, correlations or applicable codes are not available. Furthermore, FEA and CFD can be applied when codes and standards do exist, but the situations require greater accuracy than can be obtained through the standard code equations. Similarly, FEA and CFD can serve as a third-party evaluation, which can drive project costs down and illuminate potential problems before construction begins. FEA and CFD can play a vital role in all phases of project work from evaluating existing equipment for fitness-for-service and troubleshooting to optimally designing new equipment.


Multiphysics Simulation Experience

Jōb Industrial has experience combining many of these applications into a single study. Many of these applications can be modeled simultaneously or coupled in sequence in multiphysics simulations. Often a multiphysics simulation consists of a CFD flow model to determine flow patterns, heat transfer coefficients, mixing, flow instabilities, hot spots, flame impingement, etc. The flow result can then be appropriately coupled or mapped to the applicable domain of a mechanical FEA thermal or structural model. 


Stress & Fatigue Simulations

Thermal and structural stresses can be simulated, followed by a fatigue simulation. An example of this is a simulation involving flow and temperature induced stress on piping downstream of an injection point or mixing tee. Many of the commercially available FEA software packages today aren’t capable of conducting complicated multiphysics simulations but Jōb uses the industry leading ANSYS software that makes these sorts of studies possible.

FEA Mechanical Applications
  • Structural Stress Analysis
    • Advanced Vessel and Piping Stress Calculations
    • Can be required by ASME Sec. 2
  • Thermal Stress Analysis
    • Insitu Post Weld Heat Treatment
    • Thermal Expansion Compatibility
    • Flow/Temperature Induced Stress from Injection Points, Mixing Tees
    • Heat Transfer Predictions
    • Fatigue Analysis
  • Thermal Cycling
    • Root Cause Failure Analysis
    • Fitness-for-service Evaluation
CFD Applications
  • Process Optimization
    • Predict Flow Rates, Flow Patterns, Flow Distribution
      • Burner Combustion Air Flow Distribution
      • Distributor/Manifold Flow Distribution
    • Reactor Optimization
      • Identifying Flow Biases/Shortcutting
      • Potential Local Hotspot Formation
    • Flow Induced Vibrations
      • Flow Biasing and Flow Instabilities in Piping
    • Pressure Drop Predictions
      • Flow and Pressure Drop Predictions in Ducting, Piping Manifolds, Equipment, Catalyst Beds
      • Mixing and Phase Separation
    • Injection Quill Modeling, Nozzles, Distributors, Ejectors
      • General Combustion
        • Burner Efficiency
        • Flame Impingement
      • Predictive Conjugate Heat Transfer and Heat Transfer Coefficients
        • Conduction
        • Convection
        • Radiation
    • Root Cause Failure Analysis
    • Equipment Design
Here are a Couple of Images From Our Handiwork

CFD predicted thermal profile through a refractory lined tank. CFD was used to help design the refractory system to achieve a more uniform temperature profile through the refractory and on the tank shell.

CFD predicted heat flux results showing heat propagating from the tank floor into the foundation. CFD was used to help design a water-cooled foundation to achieve the necessary level of cooling.

Case Study

Ejector Nozzle Sizing in an Induced Draft Fired Heater Stack

Physics used in this study:

  • Multispecies Transport
  • Compressibility
  • High Mach Number Velocities
  • Significant Wall Boundary Interactions (Mesh Sensitivity Analysis)

Computational fluid dynamics (CFD) can accurately predict flow behaviors in vessels and equipment and is instrumental in optimizing flow patterns, flow rates, pressure drop, mixing, etc. 

In the following example, CFD is used to simulate the amount of air flow rate that a steam driven ejector nozzle can induce in a fired heater stack. The simulation is used to optimize the flow patterns, nozzle size, ejector efficiency, steam flow rate, and induced air purge rate. Critical to the study also, the simulation provides insight regarding the maximum amount of pressure drop the design can overcome.