Simcenter Flomaster

Industry Applications


FloMASTER, formerly known as Flowmaster, is the leading general purpose 1D computational fluid dynamics (CFD) solution for the modeling and analysis of fluid mechanics in complex piping systems of any scale.

Companies can maximize their return on investment by integrating FloMASTER at every stage of the development process, taking advantage of the data management and collaborative capabilities of this analytical tool. It is used by companies across a wide range of industries to reduce the development time and costs of their thermo-fluid systems. It helps systems engineers to:

  • Simulate pressure surge, temperature and fluid flow rates system-wide
  • Understand how design alterations, component size, selection and operating conditions will affect the overall fluid system performance accurately and quickly.

FloMASTER is a powerful 1D CFD solution for solving thermo-fluid design challenges across a wide range of industries.

Aerospace & Defense

FloMASTER can be used to address questions about the following systems: 

  • Environmental Climate Control
  • Fuel Systems
  • Hydraulic Systems
  • Lubrication Systems
  • Ancillary Fluid Systems

Environmental Control System (ECS) Modeling & Simulation

The successful development of an Environmental Control System (ECS) is dependent on maintaining a comfortable environment for passengers and tolerable working conditions for safety and electrical equipment while also ensuring the system is optimized to minimize material wastage and weight. FloMASTER can be used at the concept stage to model and simulate all the sub-systems of an aircraft’s entire environmental control system from simple ducting systems to complex cabin design. You can carry out detailed simulations on individual sub-systems and / or simulate them together in a single model to review their interaction as a whole.

Fuel & Propulsion System Modeling & Simulation

Aircraft fuel systems are complex, involving interaction between the fluid, mechanical and electrical systems on-board an aircraft. It is vital these systems perform as intended and within regulations and without adversely impacting other areas of an aircraft’s system performance. FloMASTER can also be used for a variety of rocket propulsion systems. You can use it to evaluate designs for mitigating surge pressures while minimizing propellant tank-to-thruster inlet pressure drop.

Hydraulic System Modeling & Simulation

Hydraulic systems are becoming ever more sophisticated with complex assemblies of electronic, hydraulic and mechanical components. It is vital that these systems are cost efficient but remain within tight performance and safety regulations. Systems must work correctly first time, requiring engineers to have at hand detailed and accurate information about system performance. FloMASTER enables you to analyze system level models of aircraft hydraulic systems at the concept stage of the design process. The performance of these models can aid in focusing and more tightly defining physical tests.


FloMASTER can be used to address questions about the following automotive related systems: 

  • VTMS (Vehicle Thermal Management Systems)
  • Fuel Systems
  • Exhaust System
  • Waste Heat Recovery (ORC) 

HVAC System Modeling & Simulation

Proper system integration of air conditioning systems by suppliers and OEM’s is vital in maintaining acceptable performance characteristics as cost and packaging constraints are imposed. Physical testing of design changes is expensive and time consuming. FloMASTER allows you to design and optimize your system during the early stages of design to optimize component selection and overall system design.

VTM - Airside & Cooling System Modeling & Simulation

Thermal management is a significant challenge in the design of modern vehicles and a well-designed cooling system is vital in overcoming this challenge. Designing and optimizing for packaging space restrictions, powertrain architecture variations and thermal loads is essential.  With FloMASTER you can model your cooling system and optimize its design before building the real thing, whether you vary the design parameters of the thermostat to ensure a constant temperature in the cooling system or resize key components to packaging constrains.  You can even investigate the interactions of close-coupled heat exchangers using automatic air flow path segmentation.

Lubrication & Fuel Modeling & Simulation

With energy prices rising and both markets and legislation demanding more efficient engines, optimizing the lubrication systems of your powertrain systems is essential to ensuring as efficient and economical vehicle operation as possible. FloMASTER enables you to understand the complex dynamics of an entire lubrication system allowing for quick and easy evaluation of your lubrication design. While for fuel systems, a range of simulation modes enables you to model the complex system in order to predict fuel system behavior for critical design cases to ensure adequate fuel flow and pressure, accurate fuel metering, avoidance of interaction effects and control pressure transients.

Exhaust Modeling & Simulation

The modern automotive exhaust system is critical in enabling powertrain systems to meet their performance, efficiency, weight and packaging targets. However, during the vehicle development process, it is the exhaust system that is often left until the very end to design. Using FloMASTER, you can model entire systems from the engine to the rear silencer/muffler and subsequently run simulations under real operating conditions to accurately predict pressures, losses, flow rates and other performance parameters for a given design.

Electric Vehicle Thermal Modeling & Simulation

As vehicles continue to progress toward additional electrification and potentially autonomy, there is additional requirement for thermal management of these new systems.  The ability to maintain appropriate temperatures for critical components either through active or passively cooled systems is an essential part of any electric vehicle design.  With FloMASTER you can model the system to ensure these temperatures but also to understand how these thermal management requirements may impact the overall performance of the vehicle from a cabin comfort as well as drive range perspective.

Plant & Process

Systems engineers working on plant and process problems can use FloMASTER to understand behavior in a wide range of systems: 

  • Cooling
  • Compressor stations
  • Data center infrastructure
  • Lubrication
  • Safety and fire
  • Subsea
  • Surge analysis
  • Transportation

Cooling Water System Modeling & Simulation

The laws of thermodynamics make it clear that where we use heat to generate power, there will always be a proportion rejected to a cold sink. Cooling networks can be extremely complex, vary widely in scale and design but they are always critical to the safe and continued use of the installation they support. The design of such networks is thus fundamental to the safe operation of systems. FloMASTER was designed from the outset to aid the design of cooling water networks. The accuracy of the empirical data that underpins the solver ensures that designers can be sure they’re sizing their system based on the best information available. The transient solver enables designers to understand the response of their system to changing loads and demands and identify where water hammer is a real risk.

Industry Gas System Modeling & Simulation

The transportation and handling of gas is an issue present in many industrial processes. These gases may be at elevated temperatures, high flow rates, toxic or any combination of the above. Therefore it is not only essential to understand any proposed network well in order to design the most efficient plant, it is also an absolute requirement for establishing a safe operating environment. FloMASTER enables engineers to build virtual prototypes of their pipelines, enabling components to be sized, different configurations assessed, insulation requirements judged and safety critical scenarios evaluated. Its compressible solver can handle both real and ideal gas models and is complemented by a comprehensive NIST database of fluid properties.

Safety System Modeling & Simulation

Fire mains form the backbone of firefighting strategies for sea going vessels and process plants of any appreciable size. From a hydraulic perspective, they bring together three elements (scale, flow-rate and short response time) that makes them particularly vulnerable to water hammer. FloMASTER enables designers to accurately predict the performance of both open and closed loop systems in steady state and transient. Flow rates to different points of the network can be easily balanced and – if required – surge alleviation measure evaluated and sized.

Marine System Modeling & Simulation

Often containing many miles of pipework transporting high and low pressure liquids and gases, the design of sea going vessels demands that designers understand fluid system performance across a range of operating points and during emergencies. FloMASTER facilitates the rapid design of all types of fluid systems on board marine vessels including engine cooling, fire mains, chilled & potable water, ballast, and fuel systems.


Solve a wide range of power generation and energy related system problems with FloMASTER:

  • Gas turbine
  • Waste Heat Recovery (ORC)
  • Cooling Water
  • Renewable energy
  • Two-phase steam

Gas Turbine System Modeling & Simulation

FloMASTER allows gas turbine designers to get an understanding of secondary air flows, blade cooling, lubrication, and fuel systems accurately early in the process. For secondary air flows it is a powerful tool for engineers to understand the effects of swirl and heat transfer within and throughout the cavity. FloMASTER is able to deliver accurate results for complicated fluid networks under high centripetal forces making it an extremely capable design tool for those involved in the design of lubrication systems or blade cooling within gas turbine engines.

Fossil Fuel System Modeling & Simulation

Fossil fuels remain the most common energy source of power for electricity generation, globally. However, concerns over emissions and operating cost demand that the systems become ever more complex. FloMASTER allows you to understand the interaction of steam and flue gas systems and aids the design of efficient plan operation. FloMASTER’s advanced two-phase solver enables you to model the entire Rankine cycle, with either steam or supercritical carbon dioxide, giving you accurate pressure drop and heat transfer predictions for your systems. It also allows you to explore waste heat recovery options such as the organic rankine cycle to help increase the efficiency of the overall system. 

Renewable Energy System Modeling & Simulation

Renewable energy generation is a rapidly evolving and growing field. FloMASTER has proven itself as a valuable tool for evaluating performance of a number of novel generation and power storage schemes thanks to its accurate solver and open architecture.

Powerful Transient Solver

  • Versatile steady state and transient simulation of incompressible and compressible systems with heat transfer analysis
  • Pressure surge analysis, temperature and fluid flowrate prediction
  • Extensive catalog of customizable component models with built-in empirical data

Open, Extendable Architecture

  • Create bespoke component models
  • Create scripts for controlling components or networks
  • Open API structure allows integration into user product development process including in-house codes, CAE, manufacturing and optimization tools
  • Functional Mock-up Interface (FMI) support for model export and co-simulation allows FloMASTER models to be shared across other CAE tools during the design process through an independent standard for model exchange.
  • Export the hydrodynamic forces generated by a transient event as a time history to leading pipe stress analysis tools such as SST CAEPIPE and Integraph® CAESAR II®.

Secure Traceable Data

  • Secure storage of networks, performance data, components and results in an industry standard relational database
  • Audit trail & tracking of model design history with ‘roll back’ functionality
  • Administration controls for user access permissions to project data
  • Database synchronization to enable engineers to work safely onsite, offline from the server

Design Optimization Capability

The ‘Experiments’ feature in FloMASTER provides users with the ability to conduct superior ‘what-if’ analyses for 1D thermo-fluid analysis.

  • Using a Latin Square algorithm, FloMASTER helps users generate unique combinations of distributed input values between specific bounds. This ability creates an ideal foundation for the creation of meta-models and response surfaces that characterize a FloMASTER system response
  • Monte Carlo simulations can be performed to produce simulation results based on a probability distribution generated from a mean and standard deviation for selected input parameters. This allows the effect of small variations in input values to be examined and enables FloMASTER to be used in risk analysis and quality control environments such as Design for Six Sigma (DFSS)

1D-3D Design and Simulation

  • Using CAD2FM, engineers can automatically generation system level models in FloMASTER from 3D geometry in tools such as NX, Solid Edge, CATIA, Creo, and Solidworks, reducing the network creation time by up to 95%.
  • Simulation Based Characterization (SBC) allows unique or novel component level designs to be characterized thermally or with respect to pressure drop using 3D CFD in FloEFD.  This characterization can then be used inside FloMASTER for more accurate analysis of the overall system behavior.
  • OneSim is a tightly coupled co-simulation workflow that enables a 3D CFD model in FloEFD to be considered as part of a 1D CFD FloMASTER network.  Such a workflow enables the accuracy of a 3D CFD simulation to be applied to parts that would otherwise be overly simplified when represented as system level components.