EFFICIENT ANALYSIS, DESIGN & CONSULTATION IN REAL LIFE PROJECTS USING STAR-CCM+ ERWIN EICHELBERGER & REHAN YOUSAF

Transcription

1 EFFICIENT ANALYSIS, DESIGN & CONSULTATION IN REAL LIFE PROJECTS USING STAR-CCM+ ERWIN EICHELBERGER & REHAN YOUSAF

2 Content Pöyry Overview 3D CFD & Why STAR-CCM+? Successfully Concluded Projects with STAR-CCM+ Designing Ventilation Systems Evaluating Safety in case of Emergency Estimating Detonation Effects Investigating Free Surface Flows Estimating Solar Thermal Effects Optimizing Waste Water Treatment Plants Currently Running Projects with STAR-CCM+ Conclusion 2

3 Pöyry Group Overview Pöyry is a global client- and technology-oriented consulting and engineering company Net sales in 2015: EUR million 10,000+ projects annually About 6,000 experts in various countries worldwide Project experience in more than 100 countries Pöyry Switzerland has about 350 employees 3

4 Pöyry Group Overview Urban planning Real estate development Transport planning Rail infrastructure Road infrastructure Construction management Building design Water supply and sanitation Water resources management Geosciences Environmental services Environmental consulting Pulp and paper Chemicals & Biorefining Mining & Metals Hydropower Renewable energy Thermal power Nuclear energy Transmission & distribution 4

5 3-D CFD & why STAR-CCM+? Mid 1990 s : No 3-D CFD used at Pöyry End 1990 s : 3-D CFD work started at Pöyry (mainly outsourced) : Limited use of Fire Dynamics Simulator (FDS) : Use of ANSYS CFX, OpenFOAM and FDS : Use of STAR-CCM+ Two reasons to shift from ANSYS to CD-adapco (STAR-CCM+) Licensing methodology Technical Equipment Cupboard Supply Duct 1 working day Meshing 30 minutes Exhaust Duct Technical Equipment Cupboard Technical Equipment 5

6 Designing Ventilation Systems Client: AlpTransit Gotthard AG Project: Tunnel ventilation & cooling in Gotthard Base Tunnel Services: Variant and feasibility studies Preliminary & detailed design Construction design Fire & safety concepts and assessments Construction supervision Testing & commissioning Execution period: Estimated Project Costs (Ventilation): 75 Million CHF 6

7 Temperatur [ C] Designing Ventilation Systems Investigation: Air supply duct optimization in a cross connection of the GBT Tunnel Methodology Used: CFD simulations using single phase heat transfer study Comparison with previously conducted empirical and 1-D calculations Outcome: Without adverse effects on ventilation efficiency, air supply duct length can be reduced by 4 m (original length 28 m) Achievement: Savings of 0.5 M CHF for the complete tunnel (167 cross connections) (Duct supplier was very unhappy) Technical Equipment Cupboard Supply Duct Länge Querschlag [m] Basisvariante 4 m Verkürzt 8 m Verkürzt Exhaust Duct Technical Equipment Cupboard Technical Equipment 7

8 Designing Ventilation Systems Client: Swiss Federal Railways Ltd Project: Normal & emergency ventilation of Cross City Link Zurich Services: Variant and feasibility studies Preliminary & detailed design Construction design Construction supervision Testing & commissioning Execution Period: Estimated Project Costs (Ventilation): 5 Million CHF 8

9 Designing Ventilation Systems Investigation: Providing proof of proper functionality of emergency ventilation system in the underground station of cross city link of Zurich main station in Switzerland Methodology Used: Hot smoke tests Aerodynamic tests Calibrate the 3-D CFD model without fire load Conduct 1-D transient network simulations Use information from different tests and simulations as boundary conditions for the calibrated 3-D model with design fire load Outcome: CFD results accepted by the Authorities Having Jurisdiction (AHJs) Achievement: Building Award 2015 in Luzern (Switzerland) 9

10 Evaluating Safety in Case of Emergency Client: First Railway Survey & Design Institute of China Project: Ventilation and safety design review for 170 km high speed rail track with 17 tunnel Services: Design Review Execution period: Estimated Costs (Ventilation & Safety) 18 M CHF (estimated 10

11 00:00 00:30 01:00 01:30 02:00 02:30 03:00 03:30 04:00 04:30 05:00 Number of persons [-] Evaluating Safety in Case of Emergency Investigation: Design review of an emergency station of Chengdu-Lanzhou Railway track in China Methodology: Coupled evacuation and STAR-CCM+ simulations Outcome: Optimized design of escape facilities Worst case analysis Persons in incident tube Persons in cross connections Persons on Train Achievement: Tunnel control system is optimized for an improved safety Ventilation system optimization savings amounts to approx. 1 M CHF Time [mm:ss] 11

12 Estimating Detonation Effects Client: Finnish Building Authorities Project: Safety design of buildings & structures Investigation: Investigate the effect of high pressure wave propagation on the surrounding topography due to ammonium nitrate explosion Methodology: 3D CFD simulation of compressible flow Outcome: Estimation of extent of possible damage Achievement: Provision of detailed information to the Finnish building authorities 12

13 Q Hegi, QHRR [m 3 /s] Investigating Free Surface Flows Client: Construction department of the canton of Zurich, AWEL HRR Q_CFD HRR Q_Exp Hegi Q_CFD Project: Design of a flood retention area in Winterthur Switzerland Investigation: Design of flow separating weir Methodology: Model validation based on scaled experimental data Free surface flow Variation study Outcome: Optimized design Hegi Q_Exp Q zu [m 3 /s] Achievement: Avoid costs due to scaled experimental test (ca. 10 K per test) 13

14 Investigating Free Surface Flows Client: Finnish Municipal Authorities Project: Localize dead water zone in Tesoma supply/storage tank Investigation: Flow and residence time of water Methodology: Free surface flow (air/water) for a full daily cycle Outcome: Information about mixing level in the tank Achievement: Avoiding the need to take constructional measures that easily save approx. 50 K CHF 14

15 Estimating Solar Thermal Effects Client: Metropolitana Milanese SpA, Milan Investigation: Estimating direct and diffuse solar thermal effect for pedestrian bridge used at the Expo Milan in 2015 Methodology: Solar-thermal multi-band modelling for critical sections of bridge with specialized type of cool roof Outcome: Information about local heat fluxes, air velocities and temperature variations used to evaluate thermal comfort conditions Achievement: Avoiding the need to install a ventilation/cooling system costing almost 100 K Euro for the complete bridge system 15

16 Optimizing Waste Water Treatment Plants Client: Finish Municipal Authorities Investigation: Estimating the residence time and short circuiting of flow in waste water basin of a water treatment plant Methodology: Validation/geometrical calibration of mixer Using validated geometry for complete basin Outcome: Verification of preliminary design Achievement: Design team could go forward with their optimized design of basin and with their choice of mixer and won the contract 16

17 Running Projects using STAR-CCM+ Sewage treatment plant using STAR-CCM+ for multi-phase sludge/water/air flow 17

18 Running Projects using STAR-CCM+ Investigating recirculation of hazardous gases at portals of GBT 18

19 Running Projects using STAR-CCM+ Validation of smoke spread and flow velocities in emergency station of GBT 19

20 Running Projects using STAR-CCM+ Optimization of ventilation strategy to avoid fog build-up and dispersal of pollutants in a Bio-waste refinery 20

21 CONCLUSION As long as CFD remains Computational Fluid Dynamics in engineering practice, it saves a lot of money and nerves. BUT As soon as CFD becomes Coded Faked Diagrams in engineering practice, it costs a lot of money and nerves. 21