Haimi Jordaan

Challenge

A brownfields rebuild required a replacement lower-shell cooling system that had to integrate into an existing furnace, meet tight thermal and pressure-loss targets, and be deliverable within a constrained outage window.

Solution

Led project scoping and engineering validation (including pressure-loss calculations). Ran CFD analysis and thermal / structural FEA to confirm performance. Facilitated on-site engineering workshops and HAZOP with the client. Produced 70+ fabrication drawings, led technical bid evaluations, and supported contractual and procurement activities.

Outcome

Project successfully completed: cooling system was fabricated, installed and commissioned within the rebuild outage window.

Challenge

The tank had to separate gas from liquids and solids while withstanding significant pressure fluctuations from a gas well blooie line.

Solution

Conceptual, development, and detailed phases delivered using design by analysis to AS1210, with loadings calculated to AS1170. Additional design by rules calculations covered the supporting components.

Outcome

A code compliant, lifecycle engineered vessel ready for fabrication.

Challenge

The existing tray was over constrained and failing when the mast structure vibrated at its natural frequency.

Solution

FEA assessment of the existing tray identified the failure mode. A simple, practical redesign was modelled in FEA and shown to significantly improve life.

Outcome

Eliminated repeated failures with a low cost, easy to fabricate fix.

Challenge

Recurring erosion in a pump discharge line was reducing piping life and creating downtime risk.

Solution

Built a CFD model that replicated the observed wear pattern, then used it to evaluate mitigation geometries. The model also surfaced material valve design oversights.

Outcome

Wear mitigation pathway identified, plus pre emptive flag of valve issues for rectification before failure.

Challenge

A vessel was experiencing premature failure with FIV from approximately 60 m/s gas flow over a baffle suspected as the root cause.

Solution

Transient CFD evaluated the vortex shedding frequency and compared it to the structural natural frequency. The analysis ruled out FIV; the failure was later traced to compressor pulsation.

Outcome

Correctly diagnosed the failure mechanism, redirected mitigation effort, and produced additional vessel performance insight.

Challenge

Plate replacement required safe lifting of plus 1 ton sections without standard rigging available.

Solution

Designed custom lifting hooks tailored to the plating geometry and the lift load case.

Outcome

Enabled safe replacement of stack plating during shutdown.

Challenge

Cooler design needed to maintain integrity under extreme thermal and metallurgical loading.

Solution

Coupled thermal and structural analysis (CFD and FEA) supporting cooler geometry, material, and fabrication decisions.

Outcome

Cooler package validated for the operating duty.

Challenge

The existing exchanger was suffering erosion driven loss of heat transfer area and tube life.

Solution

CFD based erosion modelling identified hotspots; geometry options were tested and ranked.

Outcome

Recommended design changes projected to extend asset life.

Challenge

Baffles redirecting very high volume process air were at risk of fatigue failure from fluid induced vibration.

Solution

Coupled CFD and structural assessment of vortex shedding versus baffle natural frequencies.

Outcome

Risk quantified and mitigation guidance provided ahead of installation.

Challenge

Capture efficiency had to be high while accommodating crane access, charging cycles, and the converter roll out positions.

Solution

CFD driven hood geometry integrated with structural design suited to the operating envelope.

Outcome

Hood design that improved fume capture without disrupting converter operation.

Challenge

Busbars were operating above design temperature, threatening insulation life and reliability.

Solution

Thermal modelling of the tunnel and busbar arrangement isolated the heat balance problem; design changes were proposed to bring temperatures back into range.

Outcome

Temperature reduction pathway delivered with a clear mitigation roadmap.