structural integrity seminar at indian institute of science 30-7-2015

www.pro-sim.com engineering your designs1

Indian Structural Integrity Society

Seminar on Structural Integrity Indian Institute of Science Bangalore

30th July 2015

Invited Lecture

Dr S ShamasundarMD, ProSIM R&D Pvt Ltd


Structural Integrity Assessment

for RLA Studies – Indian context

Dr S Shamasundar

ProSIM R&D Pvt Ltd

www.pro-sim.com

small improvement in predictive capabilities will

create huge impact on cost, safety, and reliability.

http://www.pro-sim.com/


Its good to be back!

ProSIM pioneered the discussion on Structural Integrity in 2006.


Structural Integrity Indian Context

– Aerospace– Power Plants

• Nuclear/ Thermal/ Hydel/ Wind

– Oil and Gas– Marine / Naval– Other large assets (Bridges, Heavy Equipment…)


Structural Integrity Indian Context - Design Stage

• Fairly good level of adaptation of SI in design stage

• Significant maturity in Nuclear, Aerospace sectors

– Materials testing and characterisation

– Damage assessment

– Modelling


However, same thing can’t be said about RLA (Remaining Life Assessment)

Significant need (and hence an opportunity)

exists for adapting structural integrity

assessment in the RLA stage.


(Multi) Million Dollar Question

Retire? Or Repair and Reuse???


RLA Studies

Key Concerns

Risk Reliability Cost

Can we invoke R&D, technology to

derive commercial benefit for

operators, users ???


QUESTIONS::: How do we ---

• Assess the extent of damage and life

consumed?

• assess the remaining useful life in a

scientific manner?

• Assess Probability. ensure

reliability?

• minimise risks of failures?

• put confidence?

• do these in a cost effective manner?


An example of similar project


RLA studies on Landing Gear

Main Landing Gear

Challenges

NO INFORMATION ON

Design data

CAD models

Operational history / Load Spectra

Materials


nth block loading

Case 1- x cycles

Case 2- x cycles

Case 3 - y cycles

Case 4- z cycles

1st block loading2nd block loading

Nose Landing Gear


Effect of dwell period on crack growth in an Aero

engine turbine disc – (DMRL)


Creep-Fatigue analysis steam turbine IP turbine shaft

MST Piping Life

Criticality -


Usage Pattern

• Load Spectra

• Damage Inspection

• Failure Histories

Physical Testing

• Material / Damage Characterisation

• Instrumented Strain gauge tests

NDT• Damage

sizing , hot spots

Physics based modelling

• Stress, temperature

• cyclic life

• Time dependent life

• Crack Growth

Statistical Modelling

• Data Analysis

• Neural Network

Computational Intelligence

• Retire Repair

Online data

monitoring


Real Challenge• design and material data is not available from OEM.

• Even the GA and floor drawings are not updated /

‘as-installed’

• RLA work depends on the quality of maintenance

data – not available in proper format

• Our forces and BRDs do not have a track of keeping

these data. Relevant data is not often recorded.

• The data is insufficient, amd

• Operators have to be guided to obtain needed data, in

a proper format.


Real Challenge• In power plants – maintenance period is only 4 to 6

weeks. Within that time frame entire RLA work has

to be completed.

• Eg. Hangar layouts, type are not as what will be in

the drawing.


Some Thoughts on

InSIS activities

• SI study- cross functional, multi-industry, and inter-disciplinary– InSIS to create subgroups

• Create forum for interaction between users/ operators/ R&D/ academia /regulators / technology providers/ and all related groups.

• Involve direct beneficiary industries for problem definition

• Create user / operator education programs and follow-it up with online forums, white boards for interaction

• Generate and define research projects (PhD and MSc engineering / ME)

• Identify major bottlenecks and R&D needs.


To know more, Contact:

ProSIM R&D Pvt. Ltd.,

#4, 1st ‘B’ Main, 1st ‘N’ Block,

Rajajinagar, Bangalore – 560010 , India

Web: www.pro-sim.com

Email: [email protected]

Phone: +91-80- 233 230 20 / 412 777 92 / 412 777 93

http://www.pro-sim.com/

mailto:[email protected]

structural integrity seminar at indian institute of science 30-7-2015

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