Case Study
                                Zeta-PDM
 
Structural Elastic Analysis of a Gas Vessel Design
 
Company Profile
Independent UK based Zeta-pdm offer multiphase separation equipment often comprising of state of the art separation internals. As part of their services for the oil & gas, water and petrochemical industries, the company offers flexible and entire solutions for Separators, Gas Scrubbers, Flash Drums, Degassers, Slug Catchers and Enhanced Oil Recovery Systems.
With a clientele that spans the globe, Zeta-pdm has sound expertise derived from an extensive background in production facilities troubleshooting, de-bottlenecking and revamping. Boasting an acknowledged capacity to provide operational designs, along with after-sales support, Zeta-pdm is committed to the "whole life" concept. Drawing from experience that has serviced names like BP, Chevron, Shell, Statoil and Maersk to name a few, Zeta-pdm supplies equipment on applications for onshore and offshore static platforms together with those specifically developed for semi-submersibles, TLPs and FPSOs.

Research and development into new products and solutions is an essential part of the motivating force behind the company. In addition to design solutions, Zeta-pdm also provides clients with simulation services such as Computational Fluid Dynamics (CFD) & Finite Element Analysis (FEA).
Background

IDAC were approached by Zeta-pdm to conduct an independent finite element analysis on a compressor suction scrubber vessel design. The primary objective of the analysis was to assess the structural integrity of the assembly under its own dead weight. The geometry consists of a vertical vessel, 4 holding clips, and a support ring. The inlet device rests on 4 clips while the gas outlet system is supported on a fully circumferential ring. Zeta-pdm were most interested in obtaining the Von-Misses stresses acting on the structure and total deformations caused due to these stresses.

The analysis was performed using ANSYS DesignModeler for the geometry modifications and parameterization, while ANSYS Simulation was used to set up, solve and post process the linear static analysis.

Analysis

The inlet device and the gas outlet system are not explicitly modeled, but instead point masses were added at their respective centers of gravity. Using ANSYS' contact technology, welded contacts were modeled in the geometry using fully bonded elements. To ensure that the stresses in the region of interest were most accurately accounted for, the geometry was split in 4 different regions, each using a slightly different mesh setting. A finer mesh was used in the area near the clips and the supporting ring. The entire model was meshed using 3D higher order hexahedral and solid shell elements.

Given the simplicity of the structure and the relative small mesh count as a result, a decision was made to model the entire model instead of using any natural planes of symmetry. To also reflect operating conditions accurately, idac used a combination of fixed, sliding and frictionless supports on the entire structure. For example, the bottom of the vessel, sits on a skirt during daily operations. As a result, fixed supports were used on these surfaces.

In this particular analysis, hydrostatic and buoyancy forces were neglected, as they were determined to be minor in comparison to the operating loads. Gravity however was taken into consideration, as the assembly was being analysed under its own dead weight.

Upon review of the results, it was found that the maximum stresses do occur in the region of the pin supports. However, the design did not need to be edited as both the total deformation and maximum stresses were well under the Yield Limit of the material. As the material did not pass into the plastic part of the stress-strain curve, the design has been verified for use in operation.

 
   
 

Design Benefit

Given the successful completion of this project, Zeta-pdm and idac have now worked on numerous other projects together, where an independent analysis is sought, that cover varying designs and operating conditions. The use of finite element analysis in varying scenarios and under different loads has allowed Zeta-pdm to gain further confidence in their designs and also investigate ways for reducing manufacturing costs and turn-around times. In their own words, "Working with idac has helped us to verify our designs, and has provided us with valuable feedback to assist us with further development. Also, the turnaround period from initial enquiry to completed report, and "quality of service" has been very impressive." Paul Harker, Zeta-pdm Ltd.

 
 
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