Manifold Analysis Case Study

The key engineering challenge lay in accurately modelling complex multiphase flow behaviour within an ageing heat exchanger system. Capturing the interaction between liquid and vapour phases, along with the dynamic effects of flooding and transient pressure fluctuations, required a robust and carefully validated simulation strategy. Limited design documentation for the legacy equipment also meant that critical assumptions had to be made regarding geometry and operating conditions, demanding meticulous calibration to ensure realistic and meaningful results.

Jesmond Engineering conducted a baseline CFD simulation of the heat exchanger using a multiphase flow model to determine whether the unit was adequately flooded under normal operating conditions. Full-scale simulations were then performed to evaluate the pressure drop across the exchanger and to identify regions prone to maldistribution or flow imbalance. The insights gained from these studies guided an iterative redesign process, allowing multiple configurations to be tested virtually for flow uniformity and performance before implementation.

The simulations demonstrated that inadequate flooding within the heat exchanger was responsible for significant discrepancies in flow rate distribution across the header manifold—directly contributing to the water hammering issue. Through a CFD-driven iterative design process, Jesmond Engineering identified a configuration that delivered balanced flow and eliminated the operational instability, providing a robust and verified solution to the client’s problem.

The simulations demonstrated that inadequate flooding within the heat exchanger was responsible for significant discrepancies in flow rate distribution across the header manifold—directly contributing to the water hammering issue. Through a CFD-driven iterative design process, Jesmond Engineering identified a configuration that delivered balanced flow and eliminated the operational instability, providing a robust and verified solution to the client’s problem.