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
Transcript of HPC for Engineering Simulation of Expandable Liner Hanger ......An Expandable Liner Hanger is a...
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HPC for Engineering Simulation of Expandable Liner Hanger Systems
Ganesh Nanaware, Tom Gardosik, Leo Gomez
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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
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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
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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
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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
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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
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Part of typical mesh of Liner Hanger Assembly
Model size: More than 9MM elements and nodes
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FEA Simulation Model
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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
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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
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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%
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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
