Use of FEA to improve the life of plant assets the life of plant - - PowerPoint PPT Presentation

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Sep 23, 2022 42 likes •224 views

Use of FEA to improve the life of plant assets the life of plant assets How a plant saved $5M illion repair cost Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ What is Finite Element Analysis? How do we

SLIDE 1

Use of FEA to improve the life of plant assets

Principal Sponsor

13-15 November 2018 Rotorua, NZ

the life of plant assets

How a plant saved $5M illion repair cost

13-15 November 2018 Rotorua, NZ

SLIDE 2

What

is Finite Element Analysis?

How

do we use it?

Why

use Finite Element Analysis?

When

Principal Sponsor

13-15 November 2018 Rotorua, NZ

When

do we use it?

13-15 November 2018 Rotorua, NZ

SLIDE 3

What

is Finite Element Analysis?

How

do we use it?

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 4

What is FEA?

Principal Sponsor

13-15 November 2018 Rotorua, NZ

Photo by Wes Hicks on Unsplash

13-15 November 2018 Rotorua, NZ

SLIDE 5

How do we use FEA?

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 6

How do we use FEA?

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 7

How do we use FEA?

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 8

What is FEA?

Principal Sponsor

13-15 November 2018 Rotorua, NZ

Photo by Wes Hicks on Unsplash

13-15 November 2018 Rotorua, NZ

SLIDE 9

Why

use Finite Element Analysis?

When

do we use it?

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 10

Why use FEA?

~30% more efficient

Complex geometry
Complex loading

M ore accurate Lighter, stronger, longer lasting… .

High performance

Photo by Samuel Penn on Unsplash

S pare capaci ty

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

~30% more efficient Lighter, stronger, longer lasting… . Reduce development time and cost with virtual prototypes and testing

Save $$$$

S pare capaci ty

SLIDE 11

Issue Pitting corrosion Scope Check maximum allowable working pressure Summary Inspecvtion of an offshore pipe found an area of heavy pitting corrosion. A Level 3 Fitness For Service assessment using FEA was carried out to check allowable pressure Benefit $50,000 repair costs saved

Pitting corrosion FFS

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 12

Issue Weld defect Scope Check acceptability Summary Surface NDT found crack like flaws near a weld

n a vessel interconnect. The crack was to be

removed by grinding. An FE analysis was carried out to determine how much material could safely be removed while maintaining current design conditions. An acceptable profile was developed and issued as a drawing to the technicians carrying out the grinding. Benefit Saving $75,000 repair costs

Local Metal Loss FFS assessment

Principal Sponsor

13-15 November 2018 Rotorua, NZ

Benefit Saving $75,000 repair costs

13-15 November 2018 Rotorua, NZ

SLIDE 13

Local Metal Loss FFS assessment

Issue Large area of localised corrosion Scope Check acceptability Summary An event caused a large area of a very high pressure flange to suffer heavy localised

corrosion. Traditional calculations could not

prove the flange was safe due to the complex shape and loading. A Level 3 FFS assessment using FEA demonstrated the flange was still safe.

Principal Sponsor

13-15 November 2018 Rotorua, NZ

Benefit Saving $5M repair and downtime cost

13-15 November 2018 Rotorua, NZ

SLIDE 14

Dent due to rock fall FFS assessment

Issue Rockfall onto exposed pipeline Scope Determine new maximum allowable working pressure Summary This is an example case of dynamic FE analysis simulation of a large rock hitting a pipe. By approximately modelling the rock and defining its speed when it hit the pipe the simulation can predict the deformed shape of the pipe Benefit Saving $20K repair costs

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

SLIDE 15

Issue Thermocouple readings higher than expected Scope Simulate exhaust gas flow to predict thermocouple readings Summary Thermocouples in a new heat exchanger produced higher than expected readings resulting in reduced flow. CFD showed that the location and mounting of the thermocouples would give readings higher than the actual tube temperatures. The control system was recalibrated based on the CFD results enabling the flow rate restored to the design value and also

Computerised Fluid Dynamics

Principal Sponsor

13-15 November 2018 Rotorua, NZ

restored to the design value and also increasing the predicted lifespan of the heater tubes. Benefit Saving $250,000 replacement costs

13-15 November 2018 Rotorua, NZ

SLIDE 16

Issue Compressor skid package design Scope Optimise piping and supports to minimise vibration issues for a wide range of operating conditions Summary A packaged skid based around a reciprocating compressor required the piping and supports to be designed to minimise vibration and pulsations, as well as meeting standard pressure and temperature static stress requirements.

Rotating equipment

Principal Sponsor

13-15 November 2018 Rotorua, NZ

static stress requirements. Benefit Earlier entry into service reduced teething issues Saving $50,000

13-15 November 2018 Rotorua, NZ

SLIDE 17

The Future of Digital twins

PI TI

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ

What if… .

SLIDE 18

Issue Critical flange joint Scope Create and monitor a “digital twin” of the joint Summary A digital twin of the joint was created and subjected to the actual loads applied to the real joint based on plant readings, maintenance records, manual readings weather records etc. Maintenance schedules adjusted based on predictions. Benefit $500,000 in downtime replacing gaskets

Digital twins

Principal Sponsor

13-15 November 2018 Rotorua, NZ 13-15 November 2018 Rotorua, NZ