Process and Energy

We provide design and analysis services for the process and energy sectors.

Structural analysis

We have many years of experience in structural analyzes of pressure equipment in accordance with the PED 2014/68 / EU directive, PN-EN 13445, AD-2000 and ASME VIII. We use Visual Vessel Design and PV Elite software for the DBF (Design by Formulas) calculations to check compliance with the relevant standards. For cases where the DBF method is not applicable, e.g. not typical solutions or load combinations we use the DBA (Design by Analysis) method with the finite element method (FEM).

Static Analysis (FEM)

FEM simulations provide in-depth understanding of the complex relationships between individual design parameters, improving the efficiency and durability of equipment, reducing costs and reducing design time. We perform FEM static analyzes of non-pressure tanks such as silos, storage tanks, etc., using appropriate procedures and guidelines according to Eurocode 1, 3, 8 for weight, wind, snow and seismic loads.

Fatigue Analysis

Fatigue calculations are required when variable cyclic loads occur. In case of pressure equipment, where the operating pressure and temperature may vary in time we check the fatigue strength primarily for critical welded joints based on the guidelines of EN 13445-3 or ASME VIII standards. For the remaining devices the fatigue strength is determined e.g. using the Wöhler and Goodman charts.

Fatigue analysis


In welded structures the initiation of fatigue crack usually occurs at the weld edges of the elements due to stress concentration. We perform crack propagation calculations on the basis of Paris's law and the integral J.

Dynamics (FEM)

In the process sector dynamic calculations may be necessary to determine the impact of sudden increase in pressure inside a tank or a sudden sealing breakup. The simulation results may support the safety analysis of the pressure equipment. The figure below shows results of the pressure test pool dynamic calculations in the event of pressure device breakup.

Thermal Simulations

The process equipment usually operates under thermal stresses. Thermal loads may have major influence on their performance. Correct estimation of the temperature during steady and unsteady operational conditions is necessary to properly carry out structural analyzes. The termal simulations may include heat exchange resulting from the flow of fluids in contact with the analyzed structure (coupled model).

CFD Flow Simulations

Flow simulations are used to predict the fluid movement (gases or liquids that meet the condition of a continuous medium) and estimate the pressure and velocity. Additional functions give opportunity to calculate concentration of species carried by fluid and to find e.g. mixing efficiency.

It is also possible to take into account the multi-phase flow (e.g. simultaneous presence of steam and water) and phase transitions.

CFD flow simulations

CFD mixer simulation

Chemical Reactions

The flow simulation may also include chemical reactions (e.g. combustion) that can affect the density of the fluid, take or produce the energy. Using such functions of the CFD software, it is possible to simulate very complex processes occurring in process devices and find the appropriate design solution.

Multiphase Flows

Multiphase simulations allow to model different states of matter, e.g., liquid-gas (e.g. water-air) or liquid-solid (e.g. water-ice). The simulations may also take into account phase transitions and related thermal effects (e.g. simulation of ice formation on a heat exchanger).

Supersonic Flow

Supersonic flows occur in process devices such as a jet pumps. The suction of the working medium in the jet pumps takes place due to the creation of negative pressure during the expansion of the driving medium flowing from the nozzle which is usually supplied with high pressure steam. The flow velocities inside the ejector pump may reach up to Mach 4.5.

CFD ejector jetpump simulation

Phase-Change Simulations

Many space devices operate in phase change conditions. CFD simulations may cover phase change and take into account the latent heat.

Phase change simulation

System Modeling

We carry out system modeling of energy systems, in particular equipped with renewable energy sources and seasonal energy storage. We carry out simulations using Matlab Simulink, Modelica and TRNSYS environments. The developed models are used for the synthesis of control systems.



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