In this case study, we delve into a significant challenge faced by a North American Refinery – a problem with their Regeneration Blower that persisted for over 40 years. The issue, which caused intense vibrations and sometimes sparking, led to multiple shutdowns and damages, resulting in losses of over $10MM.
However, the advent of Akselos’ digital twin solution provided a revolutionary way of approaching the problem. The system allowed for high-fidelity analysis of the entire system, modelling the blower and the suction and discharge piping together. Using this full system model, engineers discovered under-designed expansion joints exerting 20 times the allowable strain on the blower. This insight led them to simulate and compare eleven different design changes, eventually finding a modification combination that substantially reduced the pipe strain and allowed the blower to expand thermally in an acceptable manner.
With the successful implementation of these changes, the refinery anticipates savings of more than $10MM over several years, underlining the power of Akselos’ solution in enabling accurate structural intelligence and well-informed, real-time decisions.