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Chemical and Process

Our comprehensive simulation capabilities include pressure vessel analysis and fluid flow troubleshooting of process equipment, helping clients determine structural integrity, improve efficiency, increase throughput and reduce downtime. Our  complementary technical safety and reliability services have been engaged throughout the world by chemical, LNG, CHP and other processing plants.

Software and Consulting

The integrity of process equipment can be assessed by our experienced structural mechanics engineers or through the supply of Ansys software and training. Projects have included pressure vessel assessment to PD5500 / ASME VIII Div 2 and thermal & dynamic pipe stressing, with typical deliverables involving stress linearisation, analysis-to-code and fatigue checks. We also have specialised fracture mechanics capabilities.

Steam pipe/branch intersection analysis including weld details
Steam pipe/branch intersection analysis including weld details
Courtesy: Micro Matic Ltd
Structural analysis of tap and valve (Courtesy: Micro Matic Ltd)
FEA of gas holder (Courtesy: Motherwell Bridge Ltd Clayton Walker Gasholders)
FEA of gas holder (Courtesy: Motherwell Bridge Ltd Clayton Walker Gasholders)

Safety assessment, standards compliance, troubleshooting and up-scaling of capacity is also supported by computational fluid dynamics (CFD). We make extensive use of industy-leading Ansys CFX / FLUENT simulation software to help process engineers reduce energy consumption,  increase plant efficiency and understand the implications of changes in scale. In particular, we have expertise in pumps, valve & seal performance  and mixing & reactor design.

Industrial Process Mixing (Courtesy: Fillworth (UK) Ltd)
Mixing simulation (Courtesy: Fillworth (UK) Ltd)
Courtesy: Chembridge Technologies Ltd
Cyclone analysis (Courtesy: Chembridge Technologies Ltd)

Our fluid dynamics team have also undertaken projects to simulate transient thermal-based manufacturing processes.

Modelling the infra-red pre-heating stage of coating curing (Courtesy: Glasscoat International Ltd)
Modelling the infra-red pre-heating stage of coating curing (Courtesy: Glasscoat International Ltd)

In water and waste water applications, we use CFD simulation to match retention, mixing, reaction or settling time requirements to actual residence time distribution, with significant experience in UV disinfection units.

CFD study into plant treatment and sewage
CFD study into plant treatment and sewage
Seawater filtration investigation including vortex-shedding prediction (Courtesy: MAHLE Industrial Filtration UK Ltd)
Seawater filtration investigation including vortex-shedding prediction (Courtesy: MAHLE Industrial Filtration UK Ltd)

Plant-level flow characterisation and equipment selection decisions, including the diagnosis of under-performing units and evaluation of alternative new or retrofits designs, can often be tackled most effectively using 1D flow models. Our Flownex thermo-fluid software is able to account for large fluid ranges including two-phase, slurries, gasses, liquids and gas mixtures, ideal for boiler, pipe/duct network, pump/compressor and even SCADA systems and control design. Integrated with 3D CFD as appropriate, we can provide process and equipment design engineers with both software tools and insight at all levels of operation.

flownex-process-industry

Through an experienced team of safety consultants, we have supported companies with IEC 61511 functional safety standards for more than 20 years. LOPA and SIL assessments, HAZOP chairing and Safety File compilation activities are undertaken while a wide range of training courses in Safety Instrumented Systems (SIS), Alarm Systems Management and specific topics are delivered.

We have considerable expertise and experience in providing safety consulting services at  gas storage sites for over a decade including Avonmouth, Glenmavis, Kirriemuir, Partington and Grain LNG. Our assignments have covered every aspect of process safety including work on construction projects.

Safety File written for 45MW combined heat and power site (Courtesy: SSE)
Safety File for 45MW combined heat and power site (Courtesy: SSE)

RAMS Analysis, including FMECAs, is offered through our reliability services team to identify potential system failures and help optimise production throughput.

Appropriate ReliaSoft Synthesis software tools, used by companies such as Dow, Dupont and Shell Chemicals, can also be installed at a client’s site with dedicated training. This enables process, quality and maintenance engineers to:

  • Effectively capture and organize plant-specific data that reflect the actual equipment failure frequencies and maintenance practices used to quantify the reliability of components and systems.
  • Generate a well-defined maintenance plan rather than an equipment failure-driven breakdown maintenance plan to reduce costs, increase operational availability and improve inventory control.

Clients

We have supplied software, training and consulting services to over 120 operators & product development companies, including:

ABB | Alstom | AMEC | Centrica | Dragon LNG | Dow Chemicals | Edincare Pumped Drainage Systems | EDF Energy | Evoqua

Fillworth (UK) | Givaudan UK | Glasscoat International | Health & Safety Executive (HSE) | Hydro Polymers | ITM Power

Johnson Matthey | K Home International | Micromatic | N G Bailey | National Power | Northern Gas Networks Ltd | Northvale Korting

PowerGen | Roche Chemicals | Scottish & Southern Energy (SSE) | Siemens Industrial Turbomachinery | United Utilities Water | Worley Parsons

The advice you gave me on extracting radial stresses using paths was precisely the information I needed and the fact you provided screen dumps of the actions needed, so I knew exactly where to look, was excellent.

Torquemeters Limited

We have worked closely with the very professional and knowledgeable team at Wilde for many years now. They have recently provided detailed analysis and technical support in connection with our latest high pressure wave ring sealing project. This has enabled our client to make modifications that will reduce VOC emissions and improve safety in certain operating scenarios, ensuring that our client was extremely pleased with the service we provided.

Simon Carves Engineering Ltd

Wilde was very good in assisting us with the transfer of the knowledge required. It was a good partnership in respect to the work undertaken: Wilde not only helped us to gain knowledge but also an understanding of the reasons why, which we were very happy with.

Motherwell Bridge Ltd

Although this was the first time that we have used a consultancy for Moldflow analysis, the expertise supplied was exceptional and gave us a high level of confidence in the results. From the analysis we had a head start in the design process before manufacture, saving money and time. We were kept well informed throughout by very approachable engineers: the results were presented simply without complication, providing us with a greater understanding.

ITM Power Plc

Wilde gave us exactly what we were looking for. Their consultancy service confirmed some of the assumptions we were making and added value to the report to our client. It also increased our level of confidence in the recommendations we made to our client.

WSP CEL

Fantastic support - I have contacted a few times and have always had the problem solved. Professional, friendly and reliable service! The engineer I dealt with has been of great help!

Monition Ltd

MAHLE Industrial Filtration UK Ltd have worked with Wilde on a number of previous occasions where independent specialist knowledge, supported by the use of up-to-date computational techniques, were sought to support designs using conventional design processes.

MAHLE Industrial Filtration UK

The [ReliaSoft] Weibull++ software is a powerful, practical and easy to use package for life data analysis. Its graphical user interface enables new users to master this tool in a relatively short period of time. I recommend this tool in my organisation.

Chevron Texaco

Good course for introductory appreciation of Root Cause Analysis (RCA) and associated tools/methods.

DSM Nutritional Products

…provides a good theoretical basis for reliability engineers who are developing maintenance strategies in process plants.

Pfizer Ireland

Wilde has always demonstrated a knowledgeable and professional understanding to our needs and have been able to quickly and thoroughly assimilate our requirements, and equally quickly produce the necessary results to support our design process and provide guidance on the solution(s) best suiting our needs commercially and technically.

MAHLE Industrial Filtration UK

We are very happy with the service that Wilde provided. Their consultancy work for us offered us peace of mind that investment on our part in tooling is worthwhile and meets the functional brief.

Edincare Pumped Drainage Systems

... without the training & modelling techniques developed by Wilde, it would have been extremely difficult to predict the behaviour of the IR pre-heat oven. ... professional and exceeded the requirements set in the original brief, with extensive communication via meetings, e-mails and telephone conversations.

Glasscoat International

Thank you for the very speedy delivery on our project. In general I find Wilde very responsive to our needs and this is very much appreciated!

Evoqua (atg UV Technology)

[Wilde engineer] attended site to get an appreciation of SSE’s business at Smurfit...... was professional in getting the information at the site and has spent time on the computer system to follow up on this. [He] is giving me peace of mind in the fact that if anything goes wrong we will have the information to hand to back up all our safety systems in one location – the safety file.

SSE

Wilde was instrumental in the modifying of our existing design to ensure that performance met the specific & stringent customer requirements on this particular project. Without the modelling capabilities & advice/service provided by Wilde we would not have been able to identify the limitations in our current design in house, nor have been able to implement the required design changes that the CFD process identified as being required.

Northvale Korting

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How Can We Help?

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From an initial phone call we can often give you an idea of price and time scales.

With subsequent details, we can then send you some solution ideas, scopes of work and a formal quotation.

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