Header design requires detailed information about process conditions:
- Location/process unit where the header will be used
- Description of how the header will be used
- Code requirements
- Testing and quality control requirements
The importance of the header in the overall process will guide the tools we use during the design phase. In many cases, our proprietary DescaleWare PRO+ software along with the required impact parameters helps determine the appropriate nozzle size and type, spray overlap, impact distribution, and ultimately the header design itself.
Computational Fluid Dynamics (CFD) modeling delivers exceptional insight into complex processes such as descaling. Inside the header, CFD enables precise evaluation of flow distribution across nozzles, pressure losses, and turbulence — key factors for optimizing system performance.
No one comes close to our steel production experience
It takes more than the right nozzle to produce quality steel – even nozzles as good as ours. Using spray modeling and analysis, we simulate harsh steel plant conditions and factor in all possible variables. Then, Computational Fluid Dynamics (CFD) analysis determines spray performance before fabrication. And, finally, our precision fabrication ensures optimal placement, coverage, and overlap.
We are a world leader in spray technology
If you think there’s not much difference between a pipe with holes and a spray header with a nozzle, think again. Similarly, if you are using a local fabricator or making your own header, or other fluid delivery devices, process performance may be compromised, and you may not realize it.
The importance of the descale header is not widely understood because it’s impossible to see what is going on inside of the header.
Given all the unknowns, doesn’t it make sense to work with an expert in spray equipment? We have that expertise, and here’s how you can take advantage of it.
DescaleWare PRO+ Software
Our proprietary DescaleWare PRO+ software ensures the best possible performance in your operating environment. Using impact and coverage data from our spray laboratories, DescaleWare PRO+ determines the nozzle type and nozzle layout that will deliver the required results for your specific operation. The software graphically displays key layout details — including nozzle type, spacing, coverage, spray height, lead angle, spray overlap, impact distribution and impact values — and is suitable for all steel shapes.
Computational Fluid Dynamics (CFD) for Descale Headers
CFD is a powerful tool for analyzing fluid flow and thermal behavior within Descale Headers. It predicts pressure drops and flow while providing critical insight into turbulence patterns that influence performance and reliability. These simulations help identify design improvements and optimize header geometry for better efficiency.
Key Modeling Considerations:
- Assess flow distribution across channels to detect maldistribution
- Predict pressure drop and its impact on system efficiency
- Model turbulence characteristics to understand mixing and flow stability
- Use CFD results to guide design improvements such as geometry adjustments or flow control features
FIGURE A: This figure compares four Descale/Hescale Header configurations (from top to bottom): (1) Original Header, (2) Increased-Diameter Header, (3) Original Header at Reduced Flow, and (4) Central-Feed Header.For each configuration, the internal flow field is visualized using turbulent kinetic energy (TKE) contours along with velocity-colored streamlines indicating flow paths through the header.
Finite Element Analysis (FEA) for Descale Headers
FEA provides a robust framework to evaluate Descale Headers under conditions beyond their validated operating domain. By simulating pressure and thermal loads, it helps predict stress distribution and potential failure points, ensuring safer design decisions and operational flexibility. Key Modeling Considerations::
- Simulate pressure load distribution to identify localized stress concentrations
- Analyze thermal stresses caused by temperature gradients during transient or high-temperature operation
- Incorporate temperature-dependent material properties for accurate predictions
Fluid-Structure Interaction (FSI) for Descale Headers
FSI combines CFD and FEA to capture the coupled behavior of fluid flow and structural response. The CFD component computes accurate pressure and thermal loads, which serve as refined boundary conditions for the FEA model. This approach delivers more precise and realistic stress predictions compared to standalone FEA, especially under complex operating scenarios. A few key points:
- Uses CFD-derived loads (pressure, temperature) for structural analysis.
- Improves boundary condition accuracy, reducing assumptions in FEA.
- Captures interaction effects between fluid dynamics and structural deformation.
- Provides higher fidelity results for design validation and optimization.
We have decades of experience manufacturing headers
Our staff includes engineering specialists and certified welders.
Other credentials include:
- Manufacturing code compliance: ASME B31.1; ASME B31.3 and ASME BPVC Section IX
- Testing/validation: Hydrostatic testing (LT), material traceability (MTR), liquid penetrant examination (PT), radiographic examination (RT), visual testing (VT), weld maps and ferrite weld testing and ultrasonic examination (UT)
- Certifications: ISO 9001-2015 and ISO 14001-2015; ASME BPVC Section VIII; Canadian Registration Number (CRN) and Pressure Equipment Directive (PED)
All headers are built-to-order and can be designed and fabricated according to ASME B31.3, European Pressure Equipment Directive, and other customer-specified codes.
ASME® B31.1 and B31.3 Testing (Upon Request)
|
|
If you know exactly what your application requires, we will fabricate descale headers based on your specifications. If your application is new or you’re interested in improving or validating performance, we recommend involving us in the design/specification process.
Our local spray experts will help you balance impact, cooling, and efficiency, reducing water and energy consumption, and lowering CO2 emissions without sacrificing performance or quality. Their office is on your plant floor, and each is backed by a deep bench at our regional offices and labs.
Using a single supplier for headers and nozzles eliminates integration and coordination problems, ensuring optimal performance across your spray operations. Depend on our experts to help configure the best solution for you.