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

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 use it? Why use Finite Element Analysis? When When do we use it? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

What is Finite Element Analysis? How do we use it? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

What is FEA? Photo by Wes Hicks on Unsplash Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

How do we use FEA? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

How do we use FEA? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

How do we use FEA? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

What is FEA? Photo by Wes Hicks on Unsplash Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Why use Finite Element Analysis? When do we use it? Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Why use FEA? M ore accurate • Complex geometry • Complex loading • High performance Photo by Samuel Penn on Unsplash S S pare pare capaci ty capaci ty Lighter, stronger, longer lasting… Lighter, stronger, longer lasting… . . ~30% more efficient ~30% more efficient Reduce development time and cost with virtual prototypes and testing S av e $$$$ Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Pitting corrosion FFS 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 Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Local Metal Loss FFS assessment Issue Weld defect Scope Check acceptability Summary Surface NDT found crack like flaws near a weld on 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 Benefit Saving $75,000 repair costs Saving $75,000 repair costs Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

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. Benefit Saving $5M repair and downtime cost Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

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 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Computerised Fluid Dynamics 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 restored to the design value and also increasing the predicted lifespan of the heater tubes. Benefit Saving $250,000 replacement costs Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Rotating equipment 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. static stress requirements. Benefit Earlier entry into service reduced teething issues Saving $50,000 Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

The Future of Digital twins x PI TI What if… . Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ

Digital twins 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 Principal Sponsor 13-15 November 2018 13-15 November 2018 Rotorua, NZ Rotorua, NZ