how cae can provide roi in oil and gas - subsea uk · 2015-10-07 · how cae can provide roi in oil...
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Key partner inDesignProcess Innovation
Holistic Services and Knowledge Transfer
CONSULTANCY More than 3000 complex engineering
consultancy services performed by
over 120 highly specialized engineers
SOFTWARE More than 1500 CAE associated
software licenses sold in Europe
TRAINING Provided both as a high level
engineering consortium and a portal
for on-line learning
RESEARCH PROJECTS Historical and current base of
research projects with public co-
funding
SERVICES & PRODUCTS
2
Key partner inDesignProcess Innovation
Technology Experience
Mechanical
Structural Dynamic Linear & Non Linear
Thermal Structural
Thermo Electric
EMAG
Acoustic
Impact/Crash
Explosion
Biomechanics
Coupled-physics
Computational Fluid Dynamics
Turbomachinery
Combustion
Multiphase Flow
Fluid Structure Interaction
Heat Transfer
1-D System-Level
Aeroacustic
Design Shape Optimization and Mesh Morphing
Manufacturing
Materials
Casting
Forging
Stamping
Injection
Heat treatments
Design Chain methodology: proc residual stress
mechanical response
Multidisciplinary and Optimization
Statistics and Design of Experiments
Multiobjective Optimization
Metamodels and Calibration
Process Integration
Uncertainty Quantification
Business Analytics
TECHNOLOGIES & COMPETENCES
3
Key partner inDesignProcess Innovation
5
BENEFITS
REDUCE TIME
LOWER COSTS
INCREASE QUALITY
ACCELERATE PRODUCT
PERFORMANCE
INCREASE RELIABILITY
Benefits in using virtualization process
Key partner inDesignProcess Innovation
CFD Analysis
Foundry Process Optimization
CASE STUDIES
6
Radiator
Ferroli aluminium radiator:
CFD analysis (geometry optimization)
Casting simulation (process optimization)
Key partner inDesignProcess Innovation
Fixed cost items Without Optimization With Optimization
Fixed cost design -5.000 € -20.000 €
Fixed cost tools -70.000 € -70.000 €
Cost review + mold tooling (-9.600x3) - 28800 € 0 €
Samples cost (-2000x3 ) - 6000 € 0 € (no sample)
Downtime cost (Scraps excees, samples problems, ecc.) (-1000x3 ) - 3000 € 0 €
Total fixed cost - 112.800 € - 90.000 €
Fixed cost difference The design using virtual Optimization determines a costs
reduction amounting to € 22,800 compared to a classical design
Annual request 160.000 pz Without Optimization With Optimization
Scraps 160.000 pz (50 %) 1000 pz (0,5 %)
Annual production 320.000 pz 161.000 pz
Single cast cost (row cast + quality control) 3 € 3 €
Total cost scraps/year -450.000 € -3.000 €
Recovery scraps value +245.000 € +1.543 €
Total production losses (scraps and mold revisions -205.000 € -1.457 €
Annual economic benefit (production about 5 year)
The design using virtual Optimization determines a annual
production losses reduction amounting to € 203,500 compared
to a classical design
Note: alluminum alloy price= 1.464 €/Kg, particular weight= 1.054 Kg
CASE STUDIES
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Key partner inDesignProcess Innovation
8 07/10/2015
BMW - Overview Aim
The aim of this activity is to optimise conflicting objectives in diesel engine
development
Objectives
CFD Optimisation
Parameter Optimisation
Robust Design Optimisation
Results
20% decrease in fuel consumption in the 118d MT model
16% decrease in fuel consumption in the 320d MT model
14% decrease in fuel consumption in the 520d MT model
Key partner inDesignProcess Innovation
9 07/10/2015
Ferrari - Overview Aim
The aim of this activity is to optimise conflicting objectives in the design of
exhaust pipes
Objectives
A design with a combination of:
a good uniformity of the flow inside the catalytic converter
a low radial pressure gradient
a low total pressure drop
Results
A brand new methodology for the optimisation of the exhaust flow
was implemented and validated by using a test case
A best real design was pointed out validating virtual best designs
Key partner inDesignProcess Innovation
10 07/10/2015
JLR - Overview Aim
The aim of this activity is to optimise a number of constraints for a vehicle set up
Objectives
Optimising
Noise Vibration Harshness
Safety
Functionality
Dynamics
Results
MDO has been successfully applied for Crash, NVH,
Restraints and durability in a very short time to support a
vehicle program
Robust design for frontal crash restraints reduced from
5 months to 2 weeks (EuroNCAP 5 star)
Key partner inDesignProcess Innovation
CHALLENGE WEIGHT REDUCTION
SOLUTION Verification of the structural performance of the
valve (before optimisation) through a FEM model
Implementation of targeted modifications to weight
reduction
Optimisation of the weight of the shutter and
the body of a butterfly valve
BENEFITS A reduction of 10÷20% in weight is achieved
250 STEEL TONS SAVINGS PER YEAR
BUTTERFLY VALVES
Thickness
Radious
Angle
PARAMETERS
Key partner inDesignProcess Innovation
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SCOPE: FEM analyses in order to estimate the fatigue damage for
critical components of the Single Point Mooring system (Hinges,
Triaxial Joints, U-Joint)
U-Joint
Triaxial joint Hinges
Vega Single Point Mooring (SPM) - non-linear Fatigue Analysis
Key partner inDesignProcess Innovation
VEGA Platform
•12 miles south of the southern coast of
Sicily
•Biggest fixed offshore platform in Italy
•Designed to work in extreme environment
condition
• Winds up to 180 km/h
• Sea waves up to 18 meters
• Earthquake up to 9° Mercalli’s scale
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Vega Single Point Mooring (SPM) - non-linear Fatigue Analysis
Key partner inDesignProcess Innovation
Single Point Mooring joints
U-Joint (122 meters water depth)
Triaxial Joint (joint between joke and column)
Hinges (joint between FSO and joke)
U-Joint
Triaxial joint
Hinges
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Vega Single Point Mooring (SPM) - non-linear Fatigue Analysis
Key partner inDesignProcess Innovation
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SCOPE: FEM analyses in order to estimate the fatigue damage for critical
components of the Single Point Mooring system (Hinges, Triaxial Joints, U-Joint)
U-Joint Triaxial joint Hinges
Vega Field Single Point Mooring Requalification
Needs to replace the old single-hull Vega Oil FSO with the
new Aframax tipe double-hull Leonis FSO
Damage below
the limit
OVERVIEW
Key partner inDesignProcess Innovation
16 07/10/2015
Economic impact
Hand calculations would mean:
End of life for the SPM
With FEM analysis:
Requalification of the structure for another 20 years
Targeted inpection (every 4 or 8 years, cost 150k €/day)
Costs FEM analysis activities: about 50k €
Benefits Value of a significant portion of the entire SPM structure, in the
order of some milion €!
Reduction of the inspection costs: about 100k € immediatly plus
other 100k € during the entire life
Courtesy of EDISON
Vega Single Point Mooring (SPM) - non-linear Fatigue Analysis
Key partner inDesignProcess Innovation
Application description
OBJECTIVE: building an oil pipeline from sea to land
CONSTRAINTS: shallow water / the pipelay barge can not approach the
coast
SOLUTION: assemble the pipeline 4.5 km offshore (5 m depth) and tow it
to the coast
BENEFIT: (1) Checked that the largest available winch can complete the
task (2) Verified a new technology to tow pipelines with less force (based
on active floaters) .
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beach
4.5 km pipeline
cable
4.5 km
winch
Shallow water field pipelay barge
Key partner inDesignProcess Innovation
Key Issues
how many floaters ?
which size?
which spanning?
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need of reducing the pipeline residual wet weight to perform the towing
use air-filled floaters to apply local buoyancies
limited available winch force
apparently, simple questions…
Key partner inDesignProcess Innovation
Key Issues
Floaters have to win the pipe wet residual weight
Pipe wet residual weight is practically undeterminable
irregular coating thickness
variable coating density
unpredictable coating soaking
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insufficient
buoyancy
excessive
buoyancy
high residual weight
high towing force required
operation not possible
floating pipeline
uncontrollable operation
impossible to define
floater size & number
in advance
Key partner inDesignProcess Innovation
CFD Scenario 3D CFD to design filling orifice of tank and verify filling time
1D CFD to simulate whole pipeline & optimize compressors location along the pipeline
Control-Mechanical Scenario Model of a significant pipeline length having wet weight controlled by
standard and active (smart) buoyancy tanks installed along the pipeline
Definition of the control for the smart tanks (the control had to read and to manage the distance of the pipeline from the seabed)
“Design” of a MultiBody model of the pipeline having lumped parameters (mass and stiffness) with:
whole parameterization of the model
interface with Matlab for characterization of control laws
interface with modeFrontier for the organic management of the analyses
DOE analysis (multi-parametric Design of Experiments) for the characterization of the control response in relation to the variation of parameters influencing the control itself (located inside smart Tanks)
Depth Control Analysis for Towing of Horizontal Pipeline in Shallow Water CFD3D & CFD1D - MultiBody+DOE(modeFrontier)
Hydrodynamic effects simulation
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Key partner inDesignProcess Innovation
Supply Pipe
Tank
Common Rail
Mach Number
Compressor 1 Compressor 2
0
20
40
60
80
100
120
140
160
0 100 200 300 400 500 600 700 800
Float Number
Tim
e (
min
)
Choke NoChoke
Tank
Depth Control Analysis for Towing of Horizontal Pipeline in Shallow Water CFD3D & CFD1D - MultiBody+DOE(modeFrontier)
Hydrodynamic effects simulation
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Key partner inDesignProcess Innovation
Controls Analysis
matlab - simulink FORTRAN routines
depth maintenance
stability analysis frequency domain
dynamic analysis time domain
validated multibody model
System with Integral Control
Depth Control Analysis for Towing of Horizontal Pipeline in Shallow Water CFD3D & CFD1D - MultiBody+DOE(modeFrontier)
Hydrodynamic effects simulation
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Key partner inDesignProcess Innovation
PARAMETER 2
PARAMETER 1 PARAMETER 2
STABILITY
AMPLITUDE
PARAMETER 1
Assessment of response for: 2 kinds of valves / dimensions
2 alternative logics of control (integral, proportional)
different environmental conditions
stable
instable
logical flow in modeFrontier
Response
for significant
parameters
variation
over 6000 analysed configurations
Depth Control Analysis for Towing of Horizontal Pipeline in Shallow Water CFD3D & CFD1D - MultiBody+DOE(modeFrontier)
Hydrodynamic effects simulation
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Key partner inDesignProcess Innovation
Take Home Message Looking for Process Integration?
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Virtual Lab motion
Analy
tica
l M
odel
Meta
Model
Drivin
g
Sim
ulin
k
Para
mete
riza
tion
Post
Pro
cess
ing
Str
uct
ura
l Eva
luation
Dynam
ics
Invest
igation
Contr
ols
Syst
em
Post
-Pro
cess
ing
Auto
mation
Key partner inDesignProcess Innovation
COMPANY INFO NETWORK CASE STUDIES BUSINESS MODEL SERVICES & PRODUCTS TECHNOLOGIES & COMPETENCES INDUSTRIES
25
O&G CUSTOMERS
Key partner inDesignProcess Innovation
DOWNSTREAM
OFFSHORE
SUBSEA
PRODUCTION
RESERVOIR AND GEOLOGY
Heat and mass transfer in distillation
columns
Pressure drop evaluation
Mist eliminators
Process furnaces
Fluid dynamic analysis of coker and vacuum
towers
Evaluation of inlet feed devices to reduce
the liquid entrainment and velocity for
improvement of the vapor distribution
Analysis of spray characteristics and target
spray patterns
Baffles simulation studies establishing
criteria for new simulations
Understanding of risers, regenerators and
cyclones for FCC process
Investigation of flow patterns in horizontal
and vertical piping
Flow rate meters/Flow meters
Gravitational separators
Equipment simulation optimization
PRODUCTION SUBSEA OFFSHORE DOWNSTREAM RESERVOIR AND GEOLOGY
26
OIL
& G
AS
ID
US
TR
Y S
EG
ME
NT
S
O&G CHALLENGES PER SEGMENT
Key partner inDesignProcess Innovation
DOWNSTREAM
OFFSHORE
SUBSEA
PRODUCTION
RESERVOIR AND GEOLOGY
Simulation and analysis of fixed
offshore structures
Simulation and analysis of floating
offshore structures
Structural verifications and code
checks
Revamping of existing fixed offshore
structures based on stochastic fatigue
approach
Simulation and analysis of pressure
vessels and pressure components
Dimensional and structural
optimization of floating production
system hulls
Vessel and pipeline dynamic motion
analyses for S-laying or J-laying
pipeline configurations
PRODUCTION SUBSEA OFFSHORE DOWNSTREAM RESERVOIR AND GEOLOGY
27
OIL
& G
AS
ID
US
TR
Y S
EG
ME
NT
S
O&G CHALLENGES PER SEGMENT
Key partner inDesignProcess Innovation
DOWNSTREAM
OFFSHORE
SUBSEA
PRODUCTION
RESERVOIR AND GEOLOGY
Pipeline Lay Analysis
Simulation and Analysis of mechanical-structural components
and devices
Pressure drop evaluation
Stress analysis of pipes, valves and pressure components
Simulation of mechanical-structural components of submarine
pipeline repair systems
Stress analysis and fatigue checks of submarine structures
according to DNV, AISC, API RP2A Rules and Standards
Stress analysis and fatigue checks of pressure components
according to ASME, BS, PED, TEMA, DNV Rules and Standards
Ratcheting and shake-down analysis, creep analysis, simulation
of residual stress in welds, thermo-mechanical analysis for
PHWT operations
Explosion and impact analysis
Fire resistance analysis
Subsea control valves
Subsea flow meters
Oil/water/sand content meters
Pumping and injection systems
Multiphase pumps
Sand control/removal systems
Subsea separation equipment
Flow assurance
Flowlines and risers
Manifolds
PRODUCTION SUBSEA OFFSHORE DOWNSTREAM RESERVOIR AND GEOLOGY
28
OIL
& G
AS
ID
US
TR
Y S
EG
ME
NT
S
O&G CHALLENGES PER SEGMENT
Key partner inDesignProcess Innovation
DOWNSTREAM
OFFSHORE
SUBSEA
PRODUCTION
RESERVOIR AND GEOLOGY
Drilling-related applications
Completion processes
Near-well modeling
Near-well multiphase flow
Liquid/gas production
Well distribution systems
Chemical reservoir treatment
Slug and annular flows
Cyclones
Hydrocyclones
Gravitational separators
Flotation tanks
Separators/tanks internal devices
Electrostatic separators
Vertical and horizontal sloshing
PRODUCTION SUBSEA OFFSHORE DOWNSTREAM RESERVOIR AND GEOLOGY
29
OIL
& G
AS
ID
US
TR
Y S
EG
ME
NT
S
O&G CHALLENGES PER SEGMENT
Key partner inDesignProcess Innovation
DOWNSTREAM
OFFSHORE
SUBSEA
PRODUCTION
RESERVOIR AND GEOLOGY
OIL
& G
AS
ID
US
TR
Y S
EG
ME
NT
S
Reservoir modeling and simulation
Basin modeling and simulation
Well data interpretation
Geological modeling
Microstructural characterization
Scientific visualization
Drilling-related applications
Near-well modeling
Chemical reservoir treatment
Infographic - seismic acquisition and
boundaries
PRODUCTION SUBSEA OFFSHORE DOWNSTREAM RESERVOIR AND GEOLOGY
30
O&G CHALLENGES PER SEGMENT
Offshore Engineering 2015
Vega Field - Single Point Mooring Requalification
Drilling in Unconsolidated Rock – CFD Assistance in Technology Qualification