on the modeling of industrial processes - cnea€¦ · jump-out of an api 8r connection on the...
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On the modeling of industrial processes
Eduardo N. Dvorkin
1On the modeling of industrial processeswww.simytec.com
On the modeling of industrial processes 2
Industry
Processes Products
• Set-ups• Tooling design
• Mechanical properties• Geometrical tolerances• Integrity requirements
Technological windows
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The Methodology
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Physical Problem
Mathematical Model(PDE + BC + IC)
Numerical Model
Results verification and validation
On the modeling of industrial processes
Engineering Applications1.Structural analysis2.Metal forming3.Heat transfer and metallurgical processes4.Computational fluid mechanics
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On the modeling of industrial processes
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Structural AnalysisCollapse and post-collapse of pipelines (external pressure only)
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0,00
1,00
2,00
3,00
4,00
5,00
6,00
7,00
-5,00E+06 5,00E+06 1,50E+07 2,50E+07 3,50E+07 4,50E+07 5,50E+07 6,50E+07
Int. Vol. Reduction [mm3]
Exte
rnal
Pre
ssur
e [k
g/m
m2]
experimental results (solid line)
finite element curve (line and symbols)
External pressure 1.26 kg/mm2
External pressure 1.19 kg/mm2
External pressure 1.20 kg/mm2
Photo of Pipe After Testing
A B
A B
A B
A B
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Structural AnalysisCollapse and post-collapse of pipelines (pressure-bend tests)
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0
10
20
30
40
50
60
70
80
90
100
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
Strain (%)
Ben
ding
Mom
ent (
t-m)
Clinometers C-FER
FEA
Elastic Theory
Bending moment vs. Average bending strain
A BA B
B->P
Exp. collapse pressure52.3MPa
0
10
20
30
40
50
60
70
80
90
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Strain (%)
Ben
ding
Mom
ent (
t-m)
Clinometers - CFER
Elastic Theory
FEA
External Pressure: 5.14 kg/mm2
Applied external pressure50.4MPa
P->B
On the modeling of industrial processes
Structural AnalysisCollapse and post-collapse of pipelines
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On the modeling of industrial processes
Structural AnalysisCollapse and post-collapse of pipelines
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Strains [%]
35.030.025.020.015.010.05.00.0
On the modeling of industrial processes
Structural AnalysisCollapse of corroded pipes (Repsol-Bolivia)
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Angular position
1.143 mts
78 elementos24 elementos 24 elementos
415.5 mm 415.5 mm312 mm
On the modeling of industrial processes
Structural AnalysisCollapse of corroded pipes (Repsol-Bolivia)
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Ext
erna
lpre
ssur
e(M
pa)
Displacement (mm)
97.91 MPa
81.55 MPa
69.18 MPa
81.84 MPa
69.77 MPa
56.49 MPa
57.39 MPa
y
zAnalyzed node
On the modeling of industrial processes
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Structural AnalysisSalt domes
[1] Lux, K. H., & Heusermann, S. (1983). Creep tests on rock salt with changing load as a basis for the verification of theoreticalmaterial laws. Toronto: Proceedings of 6th Symposium on Salt,vol. I, 1983. p. 417–35.
σh1
a
σh2
σv = γHH
h
b
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12
Structural Analysis Creep parameters
Dis
plac
emen
ts[m
m]
Time (days)
Node 1
Young Modulus=31000 MPaPoisson’s Modulus=0.25
m =-3.27 E-01 MPa-1
k1=-2.54 E-01 MPa-1
k2=-2.67 E-01 MPa-1
Etam*=1.21E+08 Mpa dGk*=1.88E+05 MPaEtak*=4.98E+05 Mpa d
Creep Hardening: StrainHardening
MATERIAL PARAMETERS 1
MATERIAL PARAMETERS 2
Young Modulus=31000 MPaPoisson’s Modulus=0.25
m =-2.54 E-01 MPa-1
K1=-1.22 E-01 MPa-1
k2=-1.61 E-01 MPa-1
Etam*=1.21E+06 Mpa dGk*=8.0E+03 MPaEtak*=1.67E+04 MPa d
Creep Hardening: StrainHardening
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13
Design of casings through salt domes
pa/2
pipe
cavity
Casing detailF.E. mesh
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Structural Analysis
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Dis
plac
emen
t[m
m]
Time [Days]
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Design of casings through salt domes
Structural Analysis
On the modeling of industrial processes
Structural Analysis
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0.0001
0.0050
0.0150
0.0300
0.0500
0.0750
0.1000
Equivalentplasticstrains
Make-up
77.2 tons tensile load
83.6 tons tensile load
87.5 tons tensile load
91.9 tons tensile load
Jump-out of an API 8R connection
On the modeling of industrial processes
Structural Analysis
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Detail of
the seal areaDetail of
the threads
On the modeling of industrial processes
Structural AnalysisOCTG Premium Connections
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When the dope pressure distribution determined in the full-scale test was includedin the finite element model, the numerical results showed a very good agreement
with the experimental ones.
FEA vs. Strain Gages (with dope pressure)1.28 Turns
-5000
-4000
-3000
-2000
-1000
0
1000
2000
0 20 40 60 80 100 120 140 160
Axial distance from box center [mm]
Hoo
p st
rain
s [u
.strai
ns]
SG pinSG boxFEA box (without D.P.)FEA pin (without D.P.)FEA box (with D.P.)FEA pin (with D.P.)
On the modeling of industrial processes
Structural AnalysisOCTG Premium Connections
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Sphere-cone seal
Cone-cone seal
0
500
1,000
1,500
2,000
2,500
3,000
0123456
Distance along seal area [mm]
Sea
l con
tact
pre
ssur
e [M
Pa]
MU (Cone)100% Pc (Cone)197% Pc (Cone)
0
500
1,000
1,500
2,000
2,500
3,000
0123456
Distance along seal area [mm]
Sea
l con
tact
pre
ssur
e [M
pa]
MU (Sphere)100% Pc (Sphere)
197% Pc (Sphere)
On the modeling of industrial processes
Structural AnalysisOCTG Premium Connections
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disp = 10.60 mm
disp = 16.60 mm
disp = 20.06 mm
disp = 31.91 mm
disp = 46.72 mm
disp = 5.77 mm
disp = 4.10 mm
Make Up
disp = 52.65 mm
EquivalentPlasticStrain
6.72%4.29%2.73%
1.11%0.71%0.45%
1.74%
10.5%
On the modeling of industrial processes
Structural AnalysisOCTG Premium ConnectionsCurve load vs. displacement
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0
50000
100000
150000
200000
250000
0 20 40 60displacement [mm]
load
[kg/
rad]
load flank = 3ºload flank = -4º
disp = 4.6 mm disp =49.7 mm
disp =64.5 mm
On the modeling of industrial processes
Structural AnalysisOCTG Premium Connections
Fatigue analysis: Stress concentration factor
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Min. Load = 130 MpaMax. Load = 220 Mpa
SAF = max [ DPS / || DTS || ](for the whole cycle)
Where :- DPS: Change in the maximum first principal stress- || DTS ||: Absolute value of change in the average stress
applied to the pipe wall
SAFCoefficient
On the modeling of industrial processes
Structural AnalysisOCTG Premium Connections
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2 12 1 . 52 22 2 . 52 32 3 . 52 42 4 . 52 52 5 . 52 60
1 0 0
2 0 0
3 0 0
4 0 0
5 0 0
6 0 0
7 0 0
8 0 0
9 0 0
1 0 0 0
1 -M U
On the modeling of industrial processes
Structural AnalysisSucker Rod Premium Connection
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Detail of thethreaded
area Detail of thethreaded
area
On the modeling of industrial processes
Structural AnalysisSucker Rod Premium Connection
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Relative principal stresses
Tpi/Ty
(Ty = 59,77 kg/mm2)
Detail of thethreaded area
Detail of thethreaded area
API Design
Principal stress I
New Design
Principal Stress I
On the modeling of industrial processes
Structural Analysis
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Sucker Rod Premium Connection
Fatigue Tests Results
Goodman Diagram HS & D Grade Rods
0
10
20
30
40
50
60
70
80
90
100
110
120
0 10 20 30 40 50 60 70 80 90 100 110
Smin (Ksi)
Sm
ax (
Ksi
)
Min YS D Grade (Ksi)
S allowable D Grade (Ksi)
Min YS HS Grade (Ksi)
S allowable HS Grade (Ksi)
Smin (Ksi)
7/8” D PC Rods3/4” D PC Rods
1” D PC Rods
On the modeling of industrial processes
Structural AnalysisUOE pipe manufacturing process
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On the modeling of industrial processes
Structural AnalysisUOE: Process control and Properties assurance
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16” OD x 0.5” WT X60
D/t=32
On the modeling of industrial processes
Structural Analysis
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Steam Assisted Gravity Drainage ( SAGD)
Torsion Test #1
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
22000
24000
26000
28000
30000
32000
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110
Twisted Angle over the slotted section (degrees)
Torq
ue (f
t-lbs
)
Experimental
FEM
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On the modeling of industrial processes 29
μ (pipes/well)=0.0
DrillFem
μ (pipes/well)=0.1
Comparison at the central cross section
Structural Analysis
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DrillFemStructural Analysis
Deviated Well - Data
ID well = 250.825 mmPipes MD= 720mts
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DrillFemStructural Analysis
Deviated Well - µ=0.3
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Structural Analysis
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Waterhammer
Waterhammer experiment. The valve is closed at t=0; the pipe dimensions areL=100m; ID=0.016m and OD=0.018m. Fluid: water (blue)
100 m
WaterTank
12.5 bar
Re: 5700
Fast Closing Valve
Pipeline
p
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Normalized pressure at the valve. Comparison of calculated and experimental results
Structural AnalysisWaterhammer
On the modeling of industrial processes
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Air Tank200 bar
Fast Opening Valve
Pipeline
Wall
2 m Lv 100 m
0.8 m
Dp0 Dp1 Dp2
Non-miscible fluids test. The valve is opened at t=0.02; the water pipeline dimensions areL=100m; ID=0.0893m and OD=0.01143m. Fluid: air (red), water (blue)
Structural AnalysisWaterhammer
On the modeling of industrial processes
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Structural AnalysisWaterhammer
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Air mesh refinement results for the interface position
On the modeling of industrial processes
Metal FormingRolling Processes
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2.14
2.16
2.18
2.20
2.22
2.24
2.26
2.28
2.30
2.32
0 100 200 300 400 500 600 700
Distance from the stand center [mm]Th
ickn
ess [
mm
]
Measurements
METFOR
On the modeling of industrial processes
Metal Forming
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The Mannesmann piercing process
On the modeling of industrial processes
Metal Forming
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The Mannesmann piercing process
On the modeling of industrial processes
On the modeling of industrial processes 39
Localization
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On the modeling of industrial processes 40
EquivalentPlasticStrain
6.72%4.29%2.73%
1.11%0.71%0.45%
1.74%
10.5%
EquivalentPlasticStrain
External pressure
Compression
Overtorque
EquivalentPlasticStrain
Overtorque
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Localization
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Localization
On the modeling of industrial processes 42
EquivalentPlasticStrain
6.72%4.29%2.73%
1.11%0.71%0.45%
1.74%
10.5%
EquivalentPlasticStrain
External pressure
Compression
Overtorque
EquivalentPlasticStrain
Overtorquewww.simytec.com
LocalizationFinite element modeling and mesh dependency
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LocalizationFinite element modeling and mesh dependency
On the modeling of industrial processes 44
The width of the localized zone is forced to be in the elements size scale
Mesh dependent results
Special techniques need to be developed to solve this problem
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LocalizationFinite element modeling and mesh dependency
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LocalizationFinite element modeling and mesh dependency
46
Plasticity + Damage
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LocalizationFinite element modeling and mesh dependency
Heat transfer
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Welding
HAZ Liquid pool zone
Numerical values
Experimental values
On the modeling of industrial processes
Heat transfer
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CCAST System: Thermal model of the continuous casting process
CCAST – SIDERAR v3.0
CCAST – SIDOR v1.0
CCAST – SIDERCA v1.1
CCAST – DALMINE v1.0
We perform Inverse Analysis Inverse Analysis to determine the heat transfer coefficients
Slab continuous casting process Round continuous casting process
On the modeling of industrial processes
CFD
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Free Flow Kinetic Hydropower Turbine
On the modeling of industrial processes
CFD
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Free Flow Kinetic Hydropower Turbine
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CFD
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Free Flow Kinetic Hydropower Turbine
Flow lines
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CFD
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Free Flow Kinetic Hydropower Turbine
On the modeling of industrial processes
CFD
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Dispersed two phase flow: liquid and gas
Photograph of the
biphasic plume[ABC-88]
z* = 0.8
-100-50
050
100150200250300
0 0.2 0.4 0.6 0.8 1r*
v*
axia
l
[JB-88]Computac.[ABr-90][MG-85][SG-82]
v [m/s]max
minGAS
INJECTIONVelocity distribution
Coanda effect
On the modeling of industrial processes
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