HPC for Engineering Simulation of Expandable Liner Hanger ......An Expandable Liner Hanger is a...

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1 HPC for Engineering Simulation of Expandable Liner Hanger Systems Ganesh Nanaware, Tom Gardosik, Leo Gomez

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    HPC for Engineering Simulation of Expandable Liner Hanger Systems

    Ganesh Nanaware, Tom Gardosik, Leo Gomez

  • Agenda

    q  Introduction

    q  About Baker Hughes and Industry Challenges

    q  Expandable Liner Hanger System

    q  HPC Infrastructure

    q  FEA Simulation of Expandable Liner Hanger System

    q  Cost-Benefits Analysis

    q  Summary

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  • q  Leading supplier of oilfield services, products, technology, and systems to the worldwide oil and natural gas industry.

    q  Operates globally with approximately 60,000 employees.

    q  Headquarter in Houston, Texas.

    q  $22.4 billion USD in revenue in 2013

    About Baker Hughes

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    q  Environmental Challenges: o  Offshore deep-water o  Arctic environments o  Shale and hydraulic fracturing o  Stricter environmental and safety regulations

    q  Technological Challenges o  Deeper wells o  Extreme pressures and temperatures o  Unconventional geological variations

    Industry Challenges

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    Source  :  h.p://www.chevron.com/Documents/Pdf/DeepWaterGulfOfMexicoPresentaDon.pdf  

  • q  An Expandable Liner Hanger is a mechanical system used to attach a liner string to the bottom of a previously run casing string during wellbore construction operations within the oil and gas industry.

    q  Expandable liner hanger system consists of a setting tool (running tool) to expand the hanger body, slip ring to hang the liner load, and a packer to seal in a variable-diameter casing.

    q  Offers advanced torsional capability to drill with liner in the problematic formations. Helps to avoid costly NPT.

    q  Used to hang heavier liner under extreme deep-water environment, subsalt plays, or deviated wells.

    Casing

    Liner

    Liner Hanger

    Expandable Liner Hanger

    Expandable Liner Hanger System

    Cement

    Packer Assembly

    Slip Ring

    Setting Tool (Swage assembly, Madrel etc)

    Hanger body

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  • HPC at BHI

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    Enterprise Domain Controller

    Windows Resource Server

    Linux Resource Server

    Linux/Windows Dual-Boot Dual VHD

    Azure

    NFS NIS

    /home Applications

    Scheduler VAS

    /hpc_share Moab/Torque/ViewPoint

    MSHPC Scheduler HiperLogic Portal SQL Server Applications FlexLM

    Compute Resources

    Security

    Services

    Compute

    Visualization  

    Users

  • HPC at BHI : User interface

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  • HPC at BHI : Setup

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    FireWall

    GigE Switch

    10 GigE Switch GigE Switch

    Windows Compute Windows

    Compute Windows Compute

    SQL Server

    Visualization WorkStation

    HPC Head Node

    Windows Resource Servers

    Enterprise Security/Ops

    Tools

    Users

    Enterprise Network

    Admius

    Firewall Router

    (Cisco ISE)

    Attached Storage 35TB

    NAS 24 TB

    HPC Data/MPI HPC Management/NAT Enterprise Network

  • HPC at BHI : Power behind Computation

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    Blade Workstations

    MSHPC 2008r2

    MSHPC 2008r2

    MSHPC 2008r2

    MSHPC 2008r2

    General Purpose 320 Cores 6 GPGPUs

    MSHPC 2012 96 Cores 4 GPGPUs

    HPCGSRV13

    HPCGSRV14

    Scheduler &

    Resource Server 36TB

    Management

    Compute

    Visualization Intel Xeon [email protected] 64GB Memory Windows7 nVidia Quadro FX 2800M

    Intel Xeon [email protected] 32GB Memory nVidia Tesla M2050

    Intel Xeon [email protected] 64 - 128GB Memory

    Intel Xeon E5-2630 0 @ 2.30GHz 48-96GB Memory

  • HPC at BHI : Simulation Job Manager

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  • FEA Simulation and HPC

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    ü  Understand the design limitations, constraints, interactions;

    ü  Accelerate the product development

    ü  Evaluate and optimize performance and improve reliability of the design

    ü  Reduce the development cost and time

    ü  Reduce number of prototypes Why HPC? HPC enables to solve large, complex, and high-fidelity FEA models faster using

    power of parallel processing and faster CPU’s , hence greater FEA simulation

    throughput, less product development time and cost, less number of prototypes,

    and reliable product designs

    FEA Simulation modeling is the process of creating and analyzing a digital prototype of a physical model to predict its performance in the real world  

  • Part  of  typical  mesh  of  Liner  Hanger    Assembly    

    Model  size:    More  than  9MM  elements  and  nodes  

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    FEA Simulation Model

  • Stresses  on  Swage     Segment  Deforma:on  

    Stresses  on  hanger  packer  assembly  

    Simulation Results – Stress and Plastic strain

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  • Refine  the  FEA  Model    to  improve  correla:on  and  minimize  the  error  with  respect    to  physical  test  data  

    Fric:on  Sensi:vity  

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    Simulation Results : Seal Integrity and Friction Sensitivity on Setting Force

    Contact  Pressure  on  Casing  ID    in  Seal  area  

  • Increased the Hanging capacity by 40% with using optimized slip ring design

    Design Of Experiments (DOE) and Reliability Assessment

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    Response  Surface    

    Stochas:c  Analysis  

    DOE  Study  

  • FE Model Size

    q  More than 9 million elements and nodes

    Software

    q  Abaqus/Explicit as Simulation Solver

    q  Hypermesh and Abaqus/CAE to Pre and Post Processing

    q  Hyperstudy to run Design of Experiments (DOE) and Stochastic study

    Hardware

    q  High Performance Computing (HPC) to run jobs;

    q  Cores per Analysis job = 16 cores, 16GB RAM Each

    q  Computational wall-clock time per analysis job: 26h:47m:40s

    Simulation Resource Summary

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    Cost–Benefit Analysis

    Cost  -‐  Benefit  Analysis  of  FEA  Simula:on  using  HPC                  

       

    Project  A  :    where  FEA    simula:ons  were  not  used  

    Project  B  :    where  verified  and  validated  FEA  simula:ons  were  used  

    Project  B  :    where  verified  and  validated  FEA  simula:ons  were  used  

    No  of  Prototype  Tests   35   9   8  %  reduc:on  in  #  of  prototype   0%   74%   77%  Development  Time  (months)   65   30   26  %  reduc:on  in  Development  Time   0   54%   60%  Cost  per  test  (Material  +  Labor)   $33,200   $58,000   $63,840    Total  Test  cost     $1,162,000   $522,000   $510,720  FEA  Simula:on  Cost  ($8000/test)   $0   $280,000   $280,000  Total  Test  cost  If    no  FEA  simula:on  would  have  used  to  develop   $1,162,000   $2,030,000   $2,234,400  

    Cost  Savings  with  using    FEA  Simula:on  to  develop   $0   $1,228,000   $1,443,680  

    %  Cost  Savings  with  using    Simula:on  to  develop   0%   60%   65%  

  • The FEA simulation using HPC environment helped us to:

    ü  Understand    the  physics  of  product  behavior  with  confidence    quickly  

    ü  Accelerate product development to 26 months from 65 month

    ü  Improve reliability and robustness of Expandable Liner Hanger Design.

    ü  Reduce number of prototypes by 60-70%.

    ü  Reduce overall development time and cost.

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    Summary

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    HPC for Engineering Simulation of Expandable Liner Hanger Systems