What is PNAO?

PNAO is Pipe Network Analysis & Optimization.

Pipe Network Analysis (also called as Hydraulic Analysis) is the analysis of the fluid flow through a pipeline network, containing several interconnected branches. Computer models of pipelines are prepared & flow/pressure data is measured to identify bottlenecks, pressure losses and energy saving opportunities in the systems due to undersized pipes, inefficient pumps or several other reasons that increases the system resistance.

Pipe Network Optimization is identifying best upgrade options using simulation techniques to increase the system overall efficiency.

Application of PNAO to the Hydraulics network offers numerous Advantages. PNAO helps in

  • Understanding existing system
  • Recognizing the blockages in the pipe network,
  • Recognizing core reason for the problems within the pipe network,
  • Providing low cost solution for the problems,
  • Higher output and improved Product quality with efficient system operation.

PNAO must be carried out with

  • Systems Important to plant operations,
  • System with high energy consumption,
  • Old system,
  • Any changes planned,
  • Any flow or pressure issues in the system,
  • Any flow-circulation issues,
  • Utility system changes required as per new product design,
  • New users to be added,
  • New equipment to be installed (pumps, heat exchangers, compressors, nozzles, sparger, etc.)
  • Major Flow or Pressure Issues in the existing network
  • If a major equipment is been added or shutdown or any significant changes have been done in the utility section.
  • PNAO can be done if the client has planned a major expansion project.

HYDRON’s engineering team will attend the client’s facility for collecting data and will perform a walk-down capturing essential facts, figures and drawings. With the help of this data and Piping Drawings a detailed calibrated Computer model of the existing facility network will be developed using an advanced Fluid Flow simulation program. Then by analysis & interactions, HYDRON will provide a solution to the issue identified.

  • Plot Plan or system drawings,
  • Pump curves,
  • Data for equipment (Pump curves, Heat Exchanger, nozzles, etc.)

Several Industries from various sectors have benefitted using the HYDRON’s PNAO service. List can be provided on request.

Clients from any part of the world can send the required data to HYDRON. HYDRON will perform diagnosis of the system and provide solution to the issue.

All is needed is data and interactions. The computer models do a lot of talking. We have engineered this Remote Diagnostic process so as to ensure accurate analysis is done without visiting the clients’ facility.

HYDRON is expert at what it does. The principles of fluid flow are very robust and if used correctly, will provide accurate results.
It is important to consider all elements of the system before concluding on such calculations, and we know exactly what those elements are.

For Existing System

Design Data:

  • Pipelines: Drawings provided should contain pipe length, diameter and fittings are provided correctly (for length +-5% is allowable)
  • For Pump, Heat Exchanger or other equipment the design data provided is correct
  • In some cases, the design data may not be available. In such case, the design data can be calculated from some other inputs.

Field Data:

  • Flow: the flow rate provided at main lines should be accurate (+-5%)
  • Pressure: The pressure at key places should be accurate and preferably a calibrated gauge is recommended.
  • In case flow or pressure measurement is not possible at some places, anyone input can be sufficient, or for some analysis, flow or pressure may not be required.
ENERGY AUDIT PNAO
The analysis of the energy consumption of installed equipment. The scientific fluid-flow analysis of the hydraulics network, containing several interconnected branches.
Overall focus is on HVAC (Heating, Ventilating & Air Conditioning), lighting, and production equipment that use the most energy. Overall Focus is on the Pipes, Pumps, heat exchangers, Compressors, Nozzles, valves, equipment inlet & outlet detail dimensions, process medium.
Excel based models in several cases Complete simulation based model with precise results.
Estimate Energy saving Potentials. Estimate Bottlenecks, root cause issues and Energy saving opportunities.
Identify clients’ concern, needs and Satisfy financial criteria of client and sophisticated investors. Identify clients’ and facility concern, needs and Satisfy financial criteria along with improved product quality, efficient operating system and Intangible benefits.
Try alternative energy efficient measures for energy savings. Identify the Energy saving prospects on the current scenario on a detailed scientific study.
Consider External atmospheric and equipment conditions for cause of energy loss. Consider external, internal process conditions, material properties, thermodynamic factors for the issues occurred.

Pipelines

  • Re-designing existing pipelines
  • Designing pipes for proposed lines.
  • Network analysis of existing Pipelines for systems such as
    • Cooling Water
    • Chilled Water
    • Steam
    • Compressed Air
    • Condensate
    • Natural Gas
    • Nitrogen
    • Hot Water
    • Process fluid
    • Other systems
  • Validation of projects planned by client (related to changes in pipelines)

Pipelines

  • Identify potential of implementing VFD’s to pumps – Can it provide required flow and pressure.
  • Identify increase in flow and pressure by deploying new pumps
  • Selecting correct pump curve (to get desired flow rates and pressure)
  • Benefits of new pumps
    (By calculating improvement in flow, pressure or power consumption)
  • Designing right pump suction piping (as it is important for system efficient performance)
  • Identify performance of pumps

Compressor

  • Selecting correct pipe size for compressed air header to minimize pressure drops
  • Proper pipe designing to ensure required pressure to users

Nozzles, Sprinklers

  • Calculate reason for low flow through existing
    • nozzles,
    • headers
  • Selecting right pump to provide required flow and pressure through existing nozzles
  • Selecting right nozzle to provide desired flow and pressure

Heat Exchangers

  • Selecting right Heat Exchanger for existing systems (right design flow rate and pressure drop to draw required flow from existing system)
  • To calculate flow rate increase by installed new equipment, like Heat Exchanger, coil, etc.

Valves

  • Selecting valve % open to balance flows through existing systems (like typical Cooling or Chilled Water)
  • Selecting right valves for pipe flow rates (to ensure low pressure drop)
  • Selecting right location to place valves

Flow meters

  • Selection of Flowmeters
  • Calculating pressure drops for flow meters (orifice, venturi, turbine, etc.)

Strainer

  • Designing correct strainer
  • Calculation of pressure drop due to strainer

Insulation

  • Calculating heat losses due to un-insulated pipes
  • Determining optimum insulation thickness
  • Identifying ROI for insulation
  • Selecting right type of insulation and its thickness