case study - akselos.com...case study: joint industry project scope •produce more accurate...
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CASE STUDYDigital Twin of Pressure Vessel Joint Industry Project with The Oil and Gas Technology Centre
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• IMPROVE INDUSTRY PRACTICE FOR INSPECTION AND MAINTANANCE OF PRESSURE VESSELS
• UNLOCK THE FULL POTENTIAL OF OGTC’S ROBOTICINSPECTION
• INCREASE ACCURACY/SPEED AND REDUCE COST/CONSERVATISM OF ASSESSMENT
• PRODUCE HIGHLY PREDICTIVE FRAMEWORK - FREQUENT AUTOMATED INSPECTIONS – DETAILED COMPUTATIONAL ANALYSIS
• THROUGH A PHYSICS-BASED INTERPRETATION OF INSPECTION DATA.
• FACILITATED BY AKSELOS STRUCTURAL DIGITAL TWIN TECHNOLOGY
PROJECT DRIVERS
REDUCTION IN EQUIPMENT DOWNTIME
45%
MAINTENANCE COST REDUCTION
25%
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AKSELOS TIES IN PERFECTLY WITH THE FOCUS ON ROBOTICS AND AUTOMATION, HARNESSING THE POWER OF DATA AND TECHNOLOGY TO IMPROVE
OVERALL ASSET EFFICIENCY.
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PRESSURE VESSELS STRUCTURAL DIGITAL TWINS NEXT GENERATION SIMULATION TECHNOLOGY
• 1000x faster than traditional technology
• Parametric
• Cloud
STRUCTURAL DIGITAL TWIN
• Detailed and Physics Based replica of a Physical Asset
• Sensor connected to reflect real world loading and condition
• Continual prediction of structural integrity
CAPABILITIES
• Guide optimization of Inspection, Maintenance & Repair processes
• Operational Scenario Planning Support
• Life extension studies
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PRESSURE VESSELS DIGITAL TWIN
INCREASED ACCURACY
INCREASED SPEED
COST EFFICIENT
STANDARDS BASED
FITNESS FOR SERVICE
ASSESSMENT
SINGLE DIGITAL THREAD FORM
INSPECTION TO CALCULATION
CALCULATIONS BASED ON HIGH FIDELITY,
STRUCTURAL DIGITAL TWIN
AUTOMATED DATA FLOW AND
PROCESS
ROBOTIC INSPECTION THROUGH TO
STRUCTURAL ANALYSIS
CONSISTENT PROCESS BASED ON SIMULATION
(SKIP L1 AND L2 ASSESSMENT)
NEW SIMULATION
TECHNOLOGY
INSPECTION AND REPAIR PLANNING
PHYSICS BASED APPROACH USING STRUCTURAL
DIGITAL TWIN
API 579 ASSESSMENT
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CASE STUDY: JOINT INDUSTRY PROJECT SCOPE
• Produce more accurate predictions for maintenance and inspection - including where and when repairs will be needed.
• Simulate robotics inspection data and flows, to enable accurate validation of the structural integrity (FFS - Fitness For Service),
• Deliver frameworks for a cost-efficient inspection and repair planning based on Digital Twin.• Akselos to demonstrate a new workflow within the API 579 standard that will be much faster than
conventional methods
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CASE STUDY: AKSELOS PROVIDES SUPPORT FOR FAST UPLOAD OF INSPECTION DATA
Workflows are accelerated by Akselos with many steps automated
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CASE STUDY: AKSELOS SUPPORTS A LEVEL 3 ASSESSMENT OF PRESSURE VESSELS IN AN OPERATIONAL CONTEXT• Most detailed evaluation that provides more precise results (within the required API 579 standard)
• Evaluation equipment for plastic collapse, local failure, collapse from buckling and failure from cyclic
loading
General Metal Loss
Elastic Analysis Elastic-plastic Analysis
Local Metal Loss
Elastic Analysis Elastic-plastic Analysis
Assessments
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Data inputs Shell component 2D UV mapping Scan plan
Thickness profileThicknesses mapped to Digital Twin
(a) (b) (c)
(d)
(e)
Automated re-analysis and reporting
(f)
DIGITAL TWIN FOR PRESSURE VESSELS
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DIGITAL TWIN IMPLEMENTATION
Digital Twin model creation for Pressure Vessel
Fitness-For-Service evaluations based on API-579/ASME FFS-1[1]
Full digital thread scenario and automation
REPORT
1X AUTOMATICALLY REPEATED
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Automate Level 1 & Level 2 Assessments of General Metal
Loss
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CASE STUDY: PRESSURE VESSEL AKSELOS ANALYSIS
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AUTOMATE LEVEL 1 ASSESSMENTS OF LOCAL METAL LOSS (2/4)
C-scan Data Marked Local Thin Areas (LTAs) and
Grooves (larger than 50 mm2)
Extracted Thickness Profile of LTAs and
Grooves
• Ignoring areas which are smaller than 50mm2 (7mm x 7mm)
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AUTOMATE LEVEL 2 ASSESSMENT OF GENERAL METAL LOSS• Automatically recognize flaws for an assessment• Ignoring flaws with area smaller than 500mm2 (23mm x 23mm)
#37
#49
C-scan Data Color Coded ContinuousCorrosion
Areas (Flaws)(larger than 500
mm2)
Extracted Thickness Profile of
Flaws
#61
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LEVEL 3 ASSESSMENT – EXAMPLEProtection against Plastic Collapse and Local Failure using Elastic Analysis Method
Elasticity results of the “as-is” (updated thickness) model
Internal Pressure: 13BAR Internal Pressure: 19BAR
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LEVEL 3 ASSESSMENT – IDENTIFICATION OF CRITICAL AREASStress Classification Lines (SCLs) at Critical Locations are identifying manually
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LEVEL 3 ASSESSMENT EXAMPLESStress Classification Lines (SCLs) at Local Thin Areas are identifying manually
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CASE STUDY: PRESSURE VESSEL AKSELOS ANALYSIS
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Pristine Model Shell component 2D UV mapping Scan plan
Thickness profileThicknesses mapped to Digital Twin
(a) (b) (c)
(d)
(e)
Automated re-analysis and reporting
(f)
DIGITAL TWIN FOR PRESSURE VESSELS
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PRESSURE VESSEL DIGITAL TWIN: SUMMARY
• Akselos has demonstrated a new workflow within the API 579 standard that will be much faster than conventional workflows.
• Produce more accurate predictions for maintenance and inspection - including where and when repairs will be needed.
• Integrate robotic inspection data and flows, to enable accurate validation of the structural integrity (FFS - Fitness For Service assessment into operations),
• Deliver frameworks for a cost-efficient inspection and repair planning based on Digital Twin.
• Industry Research estimate that these improvements with be a game changer for Inspection planning saving over £140 million across the UK sector alone.
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