The high quality standards of our products demand a software environment that effectively supports our product design. Our trained users develop optimal solutions to meet the technical
requirements using a combination of commercial and in-house developed programs for process systems and mechanical engineering.
Our in-house software DimBo® has been used successfully over many years for the thermodynamic simulation of steam generators and has been continuously developed to keep pace with the progress of our products and fields of activity. The modular software architecture enables the processing of a wide variety of tasks for all common steam generator designs, including the associated processes in a closed system solution. Originally developed for conventional fossil fuel fired power plant steam generators, the area of application has now been expanded to accommodate our entire product range:
- All types of direct fired steam generators including grate and fluidized bed boilers
- Waste heat boilers for industrial plants
- Heat recovery steam generators behind gas turbines
- Heat exchanger systems for chemical production plants
- Coal gasification
- Solar power plants with molten salts as heat carriers
Meanwhile, DimBo® has been expanded to perform simulations of transient processes which enables us to study the influence of time-dependent processes on the steam generator.
Using a common basis of calculation with DimBo® a wide variety of programs were developed for the detailed design of components for firing systems, steam generators and gas treatment including:
- Fuel drying unit and burner design, burn calculations and emission estimates, combustion chamber dimensioning
- Heat transfer for special applications and pressure loss calculations for water and steam systems
- All standard treatments for reduction of NOx, particulates and SO2 in flue gases
The in-house developed programming is supplemented with commercial software.
- The process engineering software ANSYS Fluent is used for single and multiphase media for three-dimensional flow simulations, including heat transfer and chemical reactions. A high-performance computer cluster with 224 processor cores performs combustion chamber calculations with more than 10 million volume elements so quickly that a gradual optimization of the combustion chamber geometry and the allocation of fuel and air supply are possible during the order processing stage.
- Beyond the steam generator itself, if the entire water-steam circuit of a power generation process is being studied, the appropriate tool for the planning, design and optimization of the plant is EBSILON Professional of STEAG.
The mechanical design includes both static and strength calculations.
- The software Probad by IBM is used for pressure part calculations according to standard regulations (e.g. EN 12952, ASME I, ASME VIII/1 or AD2000). The FEM software ANSYS is used for verifications not covered by these regulations and for the optimization of components.
- We also use the Rohr 2 software from SIGMA for static calculations and for elasticity analysis of piping systems (e.g. according to EN 13480 or ASME B31). In addition to the primary weight load from stationary internal pressure, secondary loads from thermal expansion as well as occasional loads, e.g. wind, earthquake and other external forces are considered.
- Steel structures and their required static verification are managed using the RSTAB (framework calculation) and RFEM (finite element) software from Dlubal.
All of the commercial tools mentioned above are integrated into our company IT.
Licenses are available for all software and our users are trained to use the software.
Their knowledge remains current through continuous use and targeted training programs.
The entire range of suitable CAD products from AUTODESK are used by our design department.
- AutoCAD Mechanical is used for the traditional draft production. The design drawings serve as the product documentation and are passed on to the production plant as the basis for the manufacturing of the products.
- Using Inventor we develop complex geometries presented in a 3-D model before the production drawings are derived.
- Piping and instrumentation diagrams are not only drawn but, using the database-aided planning tool AutoCAD P&ID, such systems and the installed control devices and measuring instruments are configured in a way that allows lists of components and the associated technical data consistent with the drawings to be generated.
- Finally, AutoCAD Plant 3D is used for the installation and piping planning. On this basis entire systems with multiple components and the connecting piping are planned such that collisions are avoided and accessibility is guaranteed at all times.
AutoCAD Plant 3D is used to export data, for example, to the Rohr 2 program to perform the related static calculations for the pipe isometrics and to RStab for the static calculations for the supporting framework structure (see statics and strength). If required we are flexible to work with alternative CAD models.
Product specific software and the high training level of employees responsible for the tasks result in a highly efficient design process, which is closely integrated with the related engineering tasks.
In this way, the efficient design and development of products is assured from the initial design concept to the finished product, through integrated software and a continuous flow of data and information.
CFD (Computational Fluid Dynamics) and HPC (High Performance Computing) are closely related at Steinmüller Engineering. Over recent years the hardware development and the advanced development of CFD software make it possible to perform complex calculations in parallel, on multiple processor cores. As a result, calculations can now be handled that were once reserved for the computer centers of universities or large companies. Today it is possible for us to perform such simulations with our own in-house hardware and professional software.
By applying CFD in all product areas we ensure the continuous use of the installed hardware and software, in addition to the continuous training of the employees assigned to these specialized tasks.
- ANSYS Fluent, Version 16.0
- 4 x Fluent Solver
- HPC Workgroup 256
- Job scheduler for the assignment of processor cores to the pending simulations
- HPC Cluster of the company Dell with 4 x 24 and 4 x 32 processor cores, in total: 224 processor cores
- Several high-performance PCs for model development as well as pre and post-processing
Up to 4 simulations can be carried out simultaneously with each simulation being assigned an individual number of processor cores.
The hardware configuration was defined in cooperation with the Computer Science Department of TH Cologne at the Gummersbach campus and the Dell Research Center in Cambridge, UK. The provision of Fluent trial licenses by ANSYS for these trials enabled testing of different configurations until an optimum constellation of hardware components was found for Steinmüller Engineering.
The graphics show the impressive range of possible applications and give an impression of the optimization potential we can provide on our products in the interest of our customers.