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


  • 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



    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


    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.



    Liner Hanger

    Expandable Liner Hanger

    Expandable Liner Hanger System


    Packer Assembly

    Slip Ring

    Setting Tool (Swage assembly, Madrel etc)

    Hanger body


  • HPC at BHI


    Enterprise Domain Controller

    Windows Resource Server

    Linux Resource Server

    Linux/Windows Dual-Boot Dual VHD



    /home Applications

    Scheduler VAS

    /hpc_share Moab/Torque/ViewPoint

    MSHPC Scheduler HiperLogic Portal SQL Server Applications FlexLM

    Compute Resources






  • HPC at BHI : User interface


  • HPC at BHI : Setup



    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



    Enterprise Network


    Firewall Router

    (Cisco ISE)

    Attached Storage 35TB

    NAS 24 TB

    HPC Data/MPI HPC Management/NAT Enterprise Network

  • HPC at BHI : Power behind Computation


    Blade Workstations

    MSHPC 2008r2

    MSHPC 2008r2

    MSHPC 2008r2

    MSHPC 2008r2

    General Purpose 320 Cores 6 GPGPUs

    MSHPC 2012 96 Cores 4 GPGPUs



    Scheduler &

    Resource Server 36TB



    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


  • FEA Simulation and HPC


    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  


    FEA Simulation Model

  • Stresses  on  Swage     Segment  Deforma:on  

    Stresses  on  hanger  packer  assembly  

    Simulation Results – Stress and Plastic strain


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

    Fric:on  Sensi:vity  


    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


    Response  Surface    

    Stochas:c  Analysis  

    DOE  Study  

  • FE Model Size

    q  More than 9 million elements and nodes


    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


    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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    HPC for Engineering Simulation of Expandable Liner Hanger Systems