Case story
Water Hammer Calculations on a Three-Way Valve in a Waste-to-Heat Plant
The project was part of the establishment of a modern waste-to-energy plant, also known as a waste-to-heat facility, where energy from waste is converted into heat. The client acted as the EPC contractor and was responsible for delivering a solution that was both efficient and reliable.
A key challenge was ensuring that the design of the OCR unit and heat exchangers was not compromised or exposed to risk when using a three-way valve. If the valve switched too quickly, it could cause water hammer and cavitation damage—serious issues in a system operating with steam and heat under high pressure and temperature.
Process
To solve the task, we worked closely with the client from start to finish. We received the necessary technical data, including P&ID and 3D models, and built a digital simulation model of the system. We then ran a series of scenarios to test how the system would react at different switching times—how fast the valve changes from one flow direction to another. This speed is critical because a rapid switch can create pressure surges (water hammer) that stress pipes and components. The goal was to identify the threshold where operational safety remained intact and the risk of water hammer was minimal. The results provided the client with a clear decision basis: at switching times of 1 second, the system was stable, while faster switching could lead to severe pressure surges and cavitation issues.
This process not only ensured technical documentation but also peace of mind for the project team, as they could proceed with the design without risking damage to critical components.
The project was carried out by two of our engineers from our Dutch office in ’s-Hertogenbosch.
Fact Box: What is Water Hammer?
Water hammer occurs when a liquid flow is suddenly stopped or redirected, creating pressure waves in the piping system. This can cause severe damage to components and pipes, especially at high temperatures and pressures.
Fact Box: What is an OCR Unit?
An OCR unit (Organic Rankine Cycle unit) is a technology that utilizes thermal energy to generate electricity. It works by converting heat from industrial processes or waste heat into mechanical energy, which drives a generator. Instead of water, the OCR process typically uses an organic working fluid with a low boiling point, enabling heat recovery at lower temperatures than traditional steam turbines.
Benefits:
- Efficient utilization of waste heat
- Reduced CO₂ emissions
- Can be integrated into waste-to-heat and other energy systems
Service and scope of the project
- Detailed report with simulations and recommendations
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