Precise Flow and Pipe Network Analyses Through Simulations

With 1D and 3D simulations, costs can be reduced and efficiency increased. Through precise calculations, weak points can be identified at an early stage.

Safety glasses are on a map

Siemens Flomaster
Hydraulic Pipe Network Analyses in 1D

With the help of 1D simulation in Siemens Flomaster, complex pipe networks can be modelled and various operating scenarios can be investigated. The flow is simulated along the pipe axis (current thread theory), while pressure losses and energy distribution are calculated using empirical formulas.

Possible Analyses

Stationary (Time-Independent) Simulations

  • How does the pipe network behave when leveled?
  • How are volume flows distributed with different hydraulic resistances?
  • Which consumer receives which flow rate?
  • A lot of information about the equipment, such as manufacturers' pump characteristics or Kv values for control valves, can be stored

Transient (Time-Dependent) Simulations

  • What happens if pump X fails and valves A, B and C close at the same time?
  • What are the consequences of such a sudden load change in the pipe network?
  • Can pressure surges or shock waves occur that endanger valves and equipment?
  • Where are critical areas and what measures can be taken?

Multi-Dimensional Simulations
Combination of 1D and 3D Simulations (CFD)

The 1D simulation provides quick results for large pipe networks, but cannot depict local flow effects such as turbulence, turbulence or multiphase flows in detail. This is where 3D CFD simulation comes in.

When Is a 1D Simulation Useful?

A 1D simulation (e.g. with Flomaster) is particularly suitable for:

  • Quick calculations of large networks — Results are available in seconds to minutes
  • Pressure loss calculations — using empirical formulas.
  • Analysis of flow distribution in complex networks — efficiently and with manageable computing costs.
  • Pressure surge calculations — simplified but reliable for many applications.

However, a 1D simulation is not suitable for detailed local flow effects, the presentation of turbulences or the optimization of geometries.

When Does a 3D CFD Simulation Make Sense?

A 3D CFD simulation is ideal for:

  • Detailed analysis of local flow effects — particularly for critical points in the system.
  • Presentation of turbulences — to make complex flow patterns visible.
  • Investigation of multiphase flows (e.g. gas/liquid) — with high precision.
  • Exact pressure surge analysis — for more precise findings compared to 1D simulation.
  • Geometry optimization — through detailed flow simulations.

However, 3D simulation is more complex and requires more computing time (hours to days). It is therefore particularly suitable for targeted analyses of specific problem areas.

The combination of both methods enables efficient and precise analysis. For example, critical points identified in a 1D simulation can be examined in more detail with a 3D simulation in order to optimize the geometry.

Engineer tests a 3D CFD simulation.

Recognize Loads
Strength Analyses of Pipe Networks

On the basis of isometrics, drawings and apparatus data, strength analyses can be carried out using the finite element method (FEM).

Aims of the Strength Analyses

  • Determination of loads and tensions in the system under various load cases (e.g. dead weight, thermal expansion, bearings).
  • Hydraulic forces from 1D pipe network simulation can be integrated into the strength analysis.

Results

  • Forces, moments and tensions in pipe components and connections
  • Mechanical strength testing in accordance with applicable standards

An Excerpt of Relevant Standards

  • Pipe components: EN 13480-3
  • Internal pressure certificates: DIN EN 13480
  • FE certificates for equipment sockets: EN 13445-3 Annex C

Optimize Stability, Save Material
Fem Calculations for Steel Constructions, Pressure Vessels and Special Constructions

In addition to pipeline systems, FEM simulation can also be used to calculate and optimize steel structures, pressure vessels and special structures.

Fem Simulation Use Cases

Stress and Stability Analyses of Steel Structures

  • Calculation of structures, racks, platforms and machine foundations
  • Investigation of vibration behavior under dynamic loads
  • Evidence of load capacity and deformations

Strength Analysis of Pressure Vessels

  • Internal pressure load test in accordance with DIN EN 13445
  • Consideration of temperature and pressure changes
  • Lifetime analyses for fatigue assessment

Optimization of Special Designs

  • Structure-mechanical evaluation of equipment, heat exchangers and tanks
  • Inspection of welds and fasteners
  • Simulation of installation conditions and assembly states

Relevant Standards for Fem Calculations

  • Pressure vessel: EN 13445
  • Steel construction: Eurocode 3 (EN 1993)
  • Weld seam calculation: EN ISO 9606/EN ISO 5817

With FEM calculation, material savings can be achieved, weak points identified at an early stage and designs can be optimized in a targeted manner.