Transient - Chapter 4 - Cooling Water System Part 1

PIPENET VISION
TRAINING MANUAL
TRANSIENT MODULE
CHAPTER 4
A COOLING WATER SYSTEM INCLUDING A

CONTROLLER 1 – VALVE CLOSURE
Revision 2.5, September 2017

PIPENET VISION TRAINING MANUAL TRANSIENT: CHAPTER 4
PAGE 1 OF 31 REVISION 2.5, SEP 2017
1. INTRODUCTION.......................................................................................................... 2
2. THE NETWORK .......................................................................................................... 2
3. DATA FOR THE NETWORK (STAGE 1) .................................................................... 3
3.1 UNITS ..................................................................................................................................................... 3
3.2 TRANSIENT OPTIONS ............................................................................................................................... 4
4. LIBRARY DATA .......................................................................................................... 5
4.1 CREATING A PIPE SCHEDULE ................................................................................................................... 5
4.2 SELECTING A PIPE SCHEDULE .................................................................................................................. 7
4.3 HEAT EXCHANGER DATA ......................................................................................................................... 7
4.4 PUMP CURVE .......................................................................................................................................... 9
5. DATA FOR THE NETWORK (STAGE 2) .................................................................. 10
5.1 ENTERING THE NETWORK ...................................................................................................................... 10
5.2 PIPING DATA ......................................................................................................................................... 11
5.3 DATA FOR THE HEAT EXCHANGERS ........................................................................................................ 12
5.4 PUMPS.................................................................................................................................................. 13
5.5 FLUID DATA........................................................................................................................................... 13
5.6 VALVES................................................................................................................................................. 14
5.7 SPECIFICATIONS .................................................................................................................................... 14
6. THE SCENARIOS...................................................................................................... 15
6.1 SCENARIO 1 .......................................................................................................................................... 15
6.2 SCENARIO 2 .......................................................................................................................................... 20
6.3 SCENARIO 3 .......................................................................................................................................... 22
6.4 SCENARIO 4 .......................................................................................................................................... 27
6.5 SCENARIO 5 .......................................................................................................................................... 28
6.6 SCENARIO 6 .......................................................................................................................................... 30
1. Introduction
The modelling of cooling-water systems is a major application of the PIPENET VISION

Transient Module. In this chapter, we consider an example of such an application.
2. The Network
The following network is used in this example. Note that, for illustration purposes, some
entities are coloured green, to indicate that results have been selected.
3. Data For the Network (Stage 1)
3.1 Units
The units that are used in the model are tabulated below.
Variable Unit
Length metres
Diameter mm
Velocity m/sec
Temperature Celsius
Density kg/m3
Viscosity Pa s
Time seconds
Mass kg
Mass rate kg/s
Torque Nm
Inertia kg m2
Force N
Volume m3
Surface Tension N/m
Thermal Conductivity W/(m K)
Heat Capacity J/kg K
Young’s Modulus G Pa
Pressure Bar Gauge
Flow type Volumetric
Flow rate m3/hr
Input these units into the Transient Module (using Option | Units, if the Windows menu
style is used; or Init | Units, if the PIPENET menu style is used; for the remainder of
this document, it is assumed that the former style is used). Note that, to make the flow-
rate units visible, double-click on “Flow type”.
3.2 Transient Options
Set the following module options (using Options | Module options).

4. Library Data
4.1 Creating a Pipe Schedule
In Libraries | Schedules, create a new pipe schedule (called “New Pipe”) by clicking on
the New Button and entering the following data.
Pipe roughness = 0.007 mm

Poisson’s ratio = 0.25
Young’s modulus of elasticity = 26 GPa
Nominal Bore (mm) Internal Bore (mm) External Diameter (mm)

100 100 109
150 150 159
200 200 210
250 250 261
300 300 312
350 350 363
450 450 464
500 500 516
600 600 618
700 700 720
750 750 771
800 800 822
900 900 924.6
1000 1000 1027.6
1100 1100 1130.0
1200 1200 1232.8
1400 1400 1438.2
1500 1500 1540.8
2000 2000 2051.0
The dialog box is as follows.

4.2 Selecting a Pipe Schedule
The pipe schedule (in this case, “New Pipe”) can be selected using Options | Pipe
types, and is illustrated below.
4.3 Heat Exchanger Data
The data for the heat exchangers is tabulated below.
Heat Exchanger Duty Flow Rate Pressure Loss

Reference (m3/hr) (bar)
48/49 30638 1.5
50/51 690 1.5
52/53 3287 1.5
54/55 614 1.5
56/57 62 1.5
58/59 63 1.5
64/65 83 1.5
90/91 1860 1.5
Input the heat exchangers into the user-defined fittings library as device fittings (using
Libraries | Fittings). A sample dialog box is shown below.
User-defined fittings are named according to the type, as follows. The types “90º bend”,
“Device”, “Multiple bend”, “Mitre”, and “Reducer” all begin with a two-letter suffix, which
is “BE”, “DE”, “MB”, “MI”, and “RE” respectively. Note that there is no such suffix for a
fitting of type “K-factor”. After the suffix (if there is one), the user should enter between
one and five characters to complete the name of the fitting. Note that the names of
fittings must be unique.
In our model, a numbering convention has been adopted; namely, Device Fitting DE48
corresponds to Heat Exchanger 48/49. On the schematic, this exchanger is labelled
“48/49”.
4.4 Pump Curve
The pump in the network is modelled using a simple pump in the Transient Module. Its
pump curve is input in the form of data points, which are shown in the following table.
Flow Rate (m3/hr) Head (bar fluid)

0 6.804
10000 5.874
18000 4.895
25000 2.937
This data is entered into the dialog box obtained from Libraries | Pumps – Coeffs.
unknown, with the fitted curve being a quadratic.
Data for the Network (Stage 2)
5.1 Entering the Network
Please input the following network in the same sequence as shown in the schematic
below. In this case, the entity labels will be the same, and so it will be easier to add
attributes later.
5.2 Piping Data
Enter the following pipe data.
Label Input Output Diameter Length Net Height Roughness Additional Section Type
Node Node (mm) (m) Change (m) (mm) K-factor
1 1 2 1500 10 0 0.007 0 Constant Gradient
4 9 11 1500 24 -2.4 0.007 0 Constant Gradient
5 10 11 1500 24 -2.4 0.007 0 Constant Gradient
As an example, the property window for Pipe 1 is shown below.
Note that PIPENET VISION automatically calculates the wave speed.
5.3 Data for the Heat Exchangers
After the pipe data has been entered, the heat-exchanger data should be input
according to the following table. The heat exchangers, which were created as library
fittings earlier, now need to be associated with the appropriate pipes. For this purpose,
click on the Fittings Tab of the Properties Window, and then add an instance of the
required heat exchanger to the pipe (by selecting the fitting from the list of available
fittings, and clicking on the Add Button).
Pipe Heat Exchanger Duty Flow Rate PRESSURE

Label Reference (m3/hr) LOSS
(BAR)
14 48/49 30638 1.5
15 52/53 3287 1.5
16 50/51 690 1.5
17 54/55 614 1.5
18 58/59 63 1.5
19 56/57 62 1.5
20 90/91 1860 1.5
21 64/65 83 1.5
5.4 Pumps
Similarly, we need to associate the pump type (which was created earlier) with each of
the two pumps in the network.
Select the
pump type
5.5 Fluid Data
Input the following data for the fluid (via Options | Fluid).
5.6 Valves
We have not created any library valves. We need only supply the valve coefficient, C v,
for the specific operating valve that we are using. When the valve is fully closed, the
value of the coefficient is zero; when the valve is fully open, the value of the coefficient
is 118258.9502 (m3/hr, bar1/2). The fully open value needs to be entered into the
Properties Window for the valve.
5.7 Specifications
This system contains a cooling tower, for which the pressure specification at the input
and output nodes is a constant of value 0 bar G. If we wanted to take into account the
water depth in the cooling tower basin, we could set the input pressure to an
appropriate value, such as 0.2 bar G (at the input node). However, in this example, it is
set to 0 bar G.
The return lines enter the top of the cooling tower. Here, again, it is sensible to set the
pressure to be 0 bar G (at Nodes 33 and 34).
6. The Scenarios
6.1 Scenario 1
In Scenario 1, it is assumed that the pumps continue to run as the valves close. The
specification at the information node of each pump is a constant value of one (as each
pump is assumed to run at 100% rpm).
In this scenario, the shut-off valve closes in 240 seconds, as displayed below.
We shall now discuss how to select results that are to be output.
Before a calculation has been performed in PIPENET VISION, the user selects the
graphical and tabular results that are to be output. Let us consider why this is
important. Suppose that we have a network that contains 50 pipes, each subdivided
into 5 sections (or grids), and each pipe having 5 items of results for output. If the
number of time steps is 5000, then the total number of results that need to be stored is
5001 x 50 x 6 x 5 = 7,501,500
(if all of the data is stored). Note that 5001 (and not 5000) is used in the calculation, as
the initial set of data is also output. Also, pipe results are given at both ends of the pipe
(so that there are 6 values for the 5 subdivisions).
It is not a good idea to store such large files routinely. Further, the process of searching
and plotting results from such large files is usually relatively slow.
Graphical results can be selected for an entity by right clicking on the entity in the
Schematic Window, choosing “Select Results”, and then selecting the required results
from the available options.
All graphical results can be selected for the operating valve as follows.
Select the
valve, right-
click, and
choose “Select
Results”
The procedure for a pipe is slightly different, and, as an example, all variable-against-
time results for Pipe 19 are selected below.
Select the pipe,

right-click, and
choose the
required results
The output time step for graphical results can be specified using Calculation |
Options… | Output. In this case, a value of 0.5 seconds is chosen.
The following graph illustrates how the inlet and outlet pressures of the valve change
with time.
This figure shows the pressure at 0 and 20 metres along Pipe 19 (which is of length
20 metres).
6.2 Scenario 2
In this scenario, the valve closure time is changed to 25 seconds.
The variation with time of the inlet and outlet pressures of the valve is shown in the
following figure.
This figure illustrates the variation of the pressure at 0 and 20 metres along Pipe 19.
6.3 Scenario 3
In this scenario, we consider the modelling of control systems. Please note that in this
and the following scenarios the shut-off valve closes in 240 seconds, as in Scenario 1.
For the following reasons, some experience is needed for modelling control systems:
 The initial starting point is sometimes difficult to determine. Therefore, it may be

necessary to experiment with the different tools that are available in PIPENET
VISION to find the initial steady state.
 Controller parameters are difficult to determine.
We shall now add the first of the two sensor (or controller) circuits that are present in the
illustration below. Note that the sensors that are used are both pressure sensors.
In the first circuit, the properties of the pressure sensor are as follows.
The transfer function that is connected to the pressure sensor has the following
properties.
The properties of the PID controller are as follows.

There is a second transfer function in the circuit, and it has the following properties.
Now repeat the above sequence to create the second sensor (or controller) circuit.
Note that the properties of the components in this circuit are the same as those of the
first circuit.
The presence of the two control circuits means that it is no longer necessary to set
specifications on the information nodes (6 and 8) of the pump. Therefore, these
specifications should be disabled.
We now introduce the concept of calculating the initial steady state. As pointed out
earlier, it is often difficult to determine the initial state when control systems are present
in the network.
The following principle is used: If a simulation is performed under fixed boundary

conditions, the system will ultimately reach a steady state, irrespective of the initial state
of the system.
This is the idea behind the use of the term “run-in” in the PIPENET VISION Transient
Module. Naturally, we cannot perform a simulation for an infinite length of time.
Therefore, it is necessary to input a finite run-in time.
We modify the initial-state calculation as follows (via Calculation | Options… | Initial
state).
The simulation time should also be changed to 800 seconds in both Options | Module
Options… and Calculation | Options…| Output.
The variation with time of the setting of Pump 2 and the pressure at the outlet of Valve 1
are shown below.
The pressure at the inlet and outlet of Pump 1 is shown in the following figure.
6.4 Scenario 4
In this scenario, we change the gain parameter for the two PID controllers (from –0.1
bar-1 to –0.2 bar-1), as illustrated in the following figure.
The gain is changed
The graphs that correspond to those for Scenario 3 are as follows.

6.5 Scenario 5
Here, the input set point of the two PID controllers is reduced from 3.9 bar G to 3.2 bar
G.
The initial set

point is changed
The following graphs are obtained.
6.6 Scenario 6
Again, the input set point in the two PID controllers is changed.
The graphical output is as follows.


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PIPENET VISION

A COOLING WATER SYSTEM INCLUDING A

Revision 2.5, September 2017

The modelling of cooling-water systems is a major application of the PIPENET VISION

3. Data For the Network (Stage 1)

3.2 Transient Options

Set the following module options (using Options | Module options).

4.1 Creating a Pipe Schedule

Pipe roughness = 0.007 mm

Nominal Bore (mm) Internal Bore (mm) External Diameter (mm)

The dialog box is as follows.

4.2 Selecting a Pipe Schedule

4.3 Heat Exchanger Data

The data for the heat exchangers is tabulated below.

Heat Exchanger Duty Flow Rate Pressure Loss

4.4 Pump Curve

Flow Rate (m3/hr) Head (bar fluid)

Data for the Network (Stage 2)

5.1 Entering the Network

5.2 Piping Data

Enter the following pipe data.

Note that PIPENET VISION automatically calculates the wave speed.

5.3 Data for the Heat Exchangers

Pipe Heat Exchanger Duty Flow Rate PRESSURE

5.5 Fluid Data

We shall now discuss how to select results that are to be output.

Select the pipe,

In this scenario, the valve closure time is changed to 25 seconds.

 The initial starting point is sometimes difficult to determine. Therefore, it may be

The properties of the PID controller are as follows.

The following principle is used: If a simulation is performed under fixed boundary

The gain is changed

The graphs that correspond to those for Scenario 3 are as follows.

The initial set

The graphical output is as follows.

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