Case Study: Firewater Performance Testing and Modeling
2017 / CASE STUDY
Hydrus Works Grapples With One of the Largest Industrial Firewater Systems in US
Wealth of Data Used to Target Key Deficiencies
Introduction
A Gulf Coast refinery recently budgeted for an annual investment into their aging, deficient firewater system, seeking to systematically reduce asset risk by addressing weak points and improving overall performance of their firewater system.
As one of the largest refineries in the US, targeting expenditures on a system of this size and scale proved to be a daunting task. That’s when the site decided to leverage Hydrus’ unique expertise.
Like many refineries, the site has undergone multiple major expansions throughout the years, resulting in one of the largest industrial fire protection systems in the US.
The firewater pipe network is exceedingly large and complex, built with multiple materials, spread across numerous expansions, each designed to meet the constantly evolving codes and standards of the time. To add to the complexity, the site has three firewater pump stations each with unique conditions, water supplies, capacities, control schemas, and configurations. Hydrus immediately recognized the need to get arms all the way around the system and deployed a comprehensive analysis strategy based on a rigorous, detailed hydraulic simulation model.
To ensure simulation accuracy for a system this critical, Hydrus canvased the site with high-flow testing to construct a robust dataset to calibrate the model against. This dataset, combined with operational data, online instrumentation, and field observations allowed Hydrus to intelligently calibrate the simulation model within 5% of measured conditions.
275,000 |
PRESSURE DATA POINTS COLLECTED |
7,500 |
FLOW DATA POINTS COLLECTED |
26 |
HIGH FLOW, CROSS-SITE PERFORMANCE TESTS |
5% |
AVERAGE MODEL ACCURACY TO MEASURED DATA POINTS |
HARD DATA, FOCUSED IMPROVEMENTS
With an accurate model in hand, multiple fire cases across the site were simulated, allowing Hydrus to identify the high-risk areas where the firewater system could not adequately meet demands in the case of an event.
For each deficient area, Hydrus evaluated a variety of upgrades ultimately arriving at concise, but focused improvements backed with hard data to prove that the upgrade brought system performance up to par.
Better Tools. Better Decisions.
GRANULAR RESULTS
Normally scattered across drawings, datasheets, online instrumentation, and engineering roles, the tools and data developed by Hydrus offered the site a wealth of data and information about their firewater system in a single, user-friendly package. This enabled the fire team and engineers to have more detail at their fingertips for their system than ever before.
WHEN RULES OF THUMB AREN’T GOOD ENOUGH
Many firms often underestimate the catastrophic risk a deficient firewater system can represent. It’s crucial to stay on top of the critical systems that protect the entire plant. This project demonstrated that Hydrus’ approach is a key element in maintaining the vital infrastructure that defends against the unthinkable.
OPTIMIZATION OPPORTUNITIES
“Hydrus was able to help us pin down our biggest problems”
Hydrus’ data-driven analysis approach revealed multiple points of failure previously unnoticed by the site. While originally engaged to alleviate flow deficiencies, Hydrus was able to offer targeted, multi-pronged improvements that fortified the firewater system with increased redundancy, reduced long-term fouling, and improved operational reliability..
Hydrus identified key upgrades that fixed firewater shortfalls, fortified the system with more redundancy, reduced long-term fouling, and improved operational reliability.
THE HYDRUS APPROACH
MINIMIZE ASSUMPTIONS
Eliminate the guesswork with measured, real-world data to push your project out of the theoretical
DO THE HOMEWORK
Leverage sound, data-driven design analyses and decision making to ensure any project’s success
EXCEED PROJECT GOALS
Uncover opportunities not typically revealed through conventional engineering approaches