How CAE can provide ROI in Oil and Gas - Subsea UK · 2015-10-07 · How CAE can provide ROI in Oil and Gas 23 September 2015 ... Simulation of mechanical-structural components of

How CAE can provide ROI in Oil and Gas

23 September 2015

Bipin Patel – [email protected]

mailto:[email protected]

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


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


Industry Sectors INDUSTRIES

4


5

BENEFITS

REDUCE TIME

LOWER COSTS

INCREASE QUALITY

ACCELERATE PRODUCT

PERFORMANCE

INCREASE RELIABILITY

Benefits in using virtualization process


CFD Analysis

Foundry Process Optimization

CASE STUDIES

6

Radiator

Ferroli aluminium radiator:

CFD analysis (geometry optimization)

Casting simulation (process optimization)


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

7


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




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


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)


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


12

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


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

13



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

14



15

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


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



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) .

17

beach

4.5 km pipeline

cable

4.5 km

winch

Shallow water field pipelay barge


Key Issues

how many floaters ?

which size?

which spanning?

18

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 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

19

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


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

20


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



21


Controls Analysis

matlab - simulink FORTRAN routines

depth maintenance

stability analysis frequency domain

dynamic analysis time domain

validated multibody model

System with Integral Control



22


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



23


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


COMPANY INFO NETWORK CASE STUDIES BUSINESS MODEL SERVICES & PRODUCTS TECHNOLOGIES & COMPETENCES INDUSTRIES

25

O&G CUSTOMERS


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


DOWNSTREAM

OFFSHORE

SUBSEA

PRODUCTION


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


27

OIL

& G

AS

ID

US

TR

Y S

EG

ME

NT

S



DOWNSTREAM

OFFSHORE

SUBSEA

PRODUCTION


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


28

OIL

& G

AS

ID

US

TR

Y S

EG

ME

NT

S



DOWNSTREAM

OFFSHORE

SUBSEA

PRODUCTION


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


29

OIL

& G

AS

ID

US

TR

Y S

EG

ME

NT

S



DOWNSTREAM

OFFSHORE

SUBSEA

PRODUCTION


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


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31

Upstream to downstream

Offshore Engineering 2015

Vega Field - Single Point Mooring Requalification

Drilling in Unconsolidated Rock – CFD Assistance in Technology Qualification

Thank You

23 September 2015

Bipin Patel – [email protected] / 07711 204002

mailto:[email protected]

Documents

How CAE can provide ROI in Oil and Gas - Subsea UK · 2015-10-07 · How CAE can provide ROI in Oil and Gas 23 September 2015 ... Simulation of mechanical-structural components of