Follow this 1 Simple Trick to set your CFD Projects on a Path to SUCCESS

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Computational Fluid Dynamics (CFD) has now become a critical part of fired heater evaluation, particularly for revamps. However, even though the use of CFD is now common, there is no industry standard procurement process or scope definition methodology. The result is that the very tool being used to reduce technical risk for your project now introduces schedule and scope risk. In industry, a decent percentage of CFD projects infamously drag on well past the anticipated completion dates with no end in sight. For example, in one of the past projects I was involved in, the contract negotiations lasted 13 months and the project moved forward without the CFD simulation, finally suffering in getting approval from the end user. Ensuring better upfront communication and supplying the few key pieces of information outlined below, you can start your CFD project off in the right way, resulting in receiving higher quality bids, knowing your deliverables, and reducing project schedule risk.
Typically, a project manager solicits bids for CFD simulation pricing using a brief description in an email. The CFD simulation vendor then requests some additional preliminary information such as general arrangement drawings, heater data sheets, operating conditions and the objective of the study. The project manager then collects this information over a span of a week or two and sends it to the CFD vendor. A proposal is put together by the vendor with estimates of cost and schedule. This process, while it works, is inefficient.
 
It would be more efficient if the project manager compiled a packet of information described below prior to submitting the Request for Proposal (RFP):
  1. A one-page summary document describing the equipment, and the problem to be studied. It should have a simple title and a project number that can be referenced. It should also include the geometric scope of CFD modeling including any simplifications to be incorporated. If certain specific models need to be included in the study, they should be described as well. These could include simplifying a tube bundle by treating it as a porous resistance, the need for multi-phase modeling in oil fired burners, the need to include certain species in the combustion model, etc. If the project manager is not certain about it, then a request for this information from the CFD vendor must be included.
  2. A list of key dates
    1. Required proposal date
    2. Expected start date
    3. Required completion date
    4. Meeting requirements
  3. General arrangement drawings
  4. Detailed drawings that include details and dimensions of the equipment in the scope such as burners, convection section, air ducts, air preheater, etc
  5. Operating conditions to be modeled if they differ from the datasheets. Special attention should be paid to units and physical properties to be used.
  6. The expected report format and the information to be included. This will encompass model description, inputs to the model, sectional views of velocity, temperature, pressure, species, isocontours to visualize flame shape and length, etc. Any specific data that needs to be validated by field measurements. Expectations for summary and recommendations to be detailed must also be included.
  7. Terms and conditions. The project manager should also understand that the terms and conditions for a CFD vendor differ vastly from the equipment providers as CFD vendors are typically service providers. Enough lead time to negotiate contract terms should be included in the project the timeline estimate. Certain terms regarding intellectual property take longer to resolve and must be anticipated by all sides. It is a best practice to ask for CFD vendor’s terms and conditions with the proposal or request details of a master service agreement if one is in place already.
  8. Vendor questionnaire about references, experience in CFD, specific examples of the project type, organization details, contact information, etc.
RFP example form attached here
 
Standardizing this part of the solicitation will improve the quality of bids received, increase the probability of meeting the project expectations and reduce the lead time in going back and forth over the details. Moreover, the responses received through this standardized process will provide an apples-to-apples comparison of vendors, so you can impartially weigh the bids, reducing any favoritism in hiring a vendor and eliminating guesswork in the product that is delivered.
 
These savings in cost, time, and communication burden will enhance reliability of use of CFD in project cycles and reduce disruption and/or need for warranty work. This will be a win-win for companies that solicit CFD simulation work and for the CFD vendors.
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ERWIN PLATVOET
As CTO of XRG, Erwin is a true innovator, whose career spans more than three decades in heat transfer and combustion industries. Erwin is a graduate of Twente University in the Netherlands with a MS in Chemical Engineering. Erwin has served the industry around the globe in a variety of roles including Research and Development Engineer, Cracking Furnace Specialist, and Director of Engineering, and now CTO. Erwin holds eight patents in fired heat transfer and emissions control technology, has published numerous papers, and co-authored the John Zink Combustion handbook and Industrial Combustion Testing book. Erwin has been an active member of the API 560 and API 535 subcommittees and taken an active role in revising these standards.
BAILEY HENDRIX
Bailey graduated from Oklahoma State University with a Bachelor of Science in Mechanical Engineering. Upon graduation, she joined the private sector as an Applications Engineer in Tulsa, OK at a local combustion company where she managed the sales activities for the process burner refining market. She quickly accelerated her career, becoming the Refining Account Manager responsible for all business development and sales of process burners in North and South America. Her strong leadership skills and interpersonal qualities led her to a position as the Western Hemisphere Sales Director for the process burner business, leading a group of sales engineers in the areas of new equipment, retrofits and burner management systems. Her financial and commercial acumen drives the success of XRG Technologies’ business development.
ALLEN BURRIS
Allen’s background includes 10 years of experience in designing and selling process burners. Allen is a graduate of Oklahoma State University with a BS in Mechanical Engineering and is a licensed professional mechanical engineer in the State of Oklahoma. His knowledge and superior customer focus led him to a career change to process design, custom-engineered fired heater sales, and associated sub-systems for the petrochemical, refining and NGL industries. With more than two decades of experience in the combustion and fired heater industry, Allen has what it takes to overcome challenges associated with complex projects and possesses.
TIM WEBSTER
With over 25 years of experience in the combustion industry, Tim brings a wealth of industry experience and technical expertise to XRG. Tim graduated with a Bachelor of Science in Mechanical Engineering from San Jose State University and received a Master of Engineering from the University of Wisconsin. Tim began his career engineering custom combustion systems for a wide range of applications including boilers, heaters, furnaces, kilns, and incinerators. Tim is a licensed professional mechanical engineer in the states of California, Texas, Louisiana and Oklahoma, has authored numerous articles and papers, and has co-authored several combustion handbooks.
matt martin
As the Lead Scientist at XRG, Matt has over 30 years of experience in the combustion industry. He specializes in CFD of fired equipment, including UOP platforming heaters, burners in process heaters, thermal oxidizers and flares with over 300 simulations of installed, field-proven equipment. Matt received a Bachelor of Science in Computer Science with a minor in Mathematics from the University of Tulsa. He has written numerous publications, is listed as inventor or co-inventor on 27 patents and was awarded the title of Honeywell Fellow in 2011 for technical excellence and leadership.
gina briggs
Gina is a native Oklahoman and attended the University of Tulsa, graduating with a BSBA in Accounting. She is a Certified Public Accountant and Chartered Global Management Accountant. Gina began her career with the Tulsa office of Deloitte Haskins and Sells, providing audit and tax services. Since leaving Deloitte, she has held CFO positions with privately held companies in the manufacturing, construction and distribution industries. In 2013, she began a consulting practice providing contract CFO services to companies, one of which was XRG and joined XRG as CFO in 2019. Gina has always enjoyed working in the small business arena, helping business owners to profitably grow and manage their businesses.