Advanced Analysis CONSULTING
Consulting Overview “Our customers gain a competitive advantage from our consultants’ proven project experience, leading edge skills and innovative, creative thinking.”
WorleyParsons Consulting is a globally connected network of specialist consulting groups, drawing on world class, cross-industry expertise. We focus on understanding our customers and their challenges, enabling us to bring a unique set of front-end and technical consulting capabilities to bear throughout the entire project lifecycle. We draw on our proven global project delivery capability, and carry our experience across multiple industries to provide innovative solutions during the asset planning phase of the business lifecycle, as well as at an operational and project level.
Global Network We are present in 165 offices in 43 countries around the world. Our renowned consultants work closely with the broader WorleyParsons business to leverage from its proven project delivery record. Our global network of experts develop solutions in the Hydrocarbons, Power, Minerals, Metals, Chemicals, Infrastructure and Environment industries and deliver them locally; close to our customers.
Tradition WorleyParsons has a long tradition of providing world-class consulting services to our customers. This core consulting strength, created from the original company (Wholohan Grill and Partners), has been greatly enhanced by the companies that have joined WorleyParsons as part of our growth over the last 40 years.
Commitment Our organization is driven by a commitment to four enduring principles: • to build and sustain long-term relationships with our customers and consistently deliver on our promise • to continually enhance our knowledge and expertise to support our customers’ challenges • to provide an outstanding home for the best people to work and nurture their talents • to develop and maintain thought-leadership in all of our markets.
Veréna Preston Global Director WorleyParsons Consulting
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asset integrity solutions
Advanced Analysis Consulting The rapidly changing business environment continues to offer us new challenges. At WorleyParsons, we strive to meet these challenges by combining our analytical strengths with our customers’ business know-how. Through understanding and innovation, we don’t develop any solution we develop the best one. Our consultants use complex numerical methods to support our customers’ evolution by solving their problems and optimizing their opportunities. Core capabilities offered by the team include: •
Finite Element Analysis (FEA) – linear, non-linear, dynamic, impact, heat transfer, thermal/structural etc.
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Computational Fluid Dynamics (CFD) analysis – flow assessments/modeling, erosion, thermodynamics etc.
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Numerical methods, often used for asset life extension and applicable in system design, for dynamic systems assessment, noise/acoustic engineering, plant integrity studies, extreme event simulations, fluid structure interaction, multi-physics simulation and equipment verification
We also have an established track record in niche engineering areas including the provision of expert and forensic engineering advice, durability assessments, flood modeling, fracture mechanics-based fatigue assessments, dynamic simulation and modeling of fire, blast and release scenarios.
Shane Donohoo Managing Consultant Advanced Analysis
Additionally, our consultants have developed innovative tools to directly address unmet customer needs. This often involves accessing large amounts of data and presenting it in a way that supports decision-making. These tools represent repeatable and traceable information to ensure system behaviors are understood and that decisions are optimized.
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The challenge Physical testing can be costly, time consuming and wasteful. It also doesn’t always provide a greater understanding of how individual components operate as part of a whole system. Our customers need to improve safety, reliability and efficiency in many different industries where traditional forms of analyses are no longer the best options.
Today’s and Tomorrow’s Challenges Gaining insights into the underlying performance of complex systems Determining optimal configurations of virtual prototypes in order to develop concepts Understanding bottlenecks and optimizing system throughputs in complex supply chains
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Verifying and validating analysis to progress design outcomes that directly address customers’ needs
asset integrity solutions
Our response Our Advanced Analysis Consulting Practice overcomes these challenges by focusing on advanced numerical analysis. It moves away from traditional analysis such as physical testing and provides customers with reduced costs, greater project efficiencies, less time-to-market and less waste.
Advanced Analysis Consulting Solutions Modeling the behavior of complex systems to understand underlying behaviors
eveloping concepts and evaluating their D effectiveness through virtual prototypes to reduce the time required to determine the optimal configuration Creating a dynamic simulation of complex supply chains, enabling the customer to better understand bottlenecks and optimize system throughput I mproving safety, reliability and efficiency through a better understanding of individual component behaviors and the system as a whole Verified and validated numerical methods to obtain design outcomes that once required physical testing, reducing costs and time, and leads to a better product
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asset integrity solutions
Our services Dynamic Simulation Dynamic simulation models logistics and production processes to account for planned and unplanned events. This provides an understanding of the system behavior which can be challenged to achieve the optimal configuration. Modeled events can include maintenance periods, severe weather conditions and late/early arrival of ships. Applications include: mine-rail-port systems, port capacity assessments, shipping and storage modeling and refinery process refinement.
Dynamic Finite Element Analysis (FEA) Dynamic FEA is used to examine how structures behave under changing load conditions. Unexpected scenarios from blast impact to sudden loading from collision can be identified and mitigated, avoiding consequences that are no longer ‘unforeseen’. Response of structures to vibrations, impacts and blasts can be analyzed using dynamic FEA. Applications include: vibration response of onshore and offshore structures, ship impact with marine structures, sacrificial blast wall design, and location and foundations for rotating machinery.
Non-Linear Finite Element Analysis (FEA) Non-linear FEA is used to model structures and equipment where the characteristics of materials change over time. This is demonstrated in the buckling of structural members and the transfer of heat through materials. Applications include: static stress analysis, buckling analysis, collapse/pushover analysis, heat transfer analysis and tunneling simulation.
Computational Fluid Dynamics (CFD) CFD uses numerical methods to model fluid flows. Using CFD modeling allows rapid integration of the system to optimize configuration for cost and efficiency, either as a new prototype or existing system. Such systems include moving fluid, heat transfer and chemical reactions. Applications include: reactions and heat transfer in complex chemical reactors, flood modeling and the interaction between offshore structures and ships.
Specialist Skills and Niche Services In addition to our core business, our Advanced Analysis Consultants have expertise in the following niche areas: •
Certification of pressure vessel equipment for both initial design and subsequent re-certification
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Innovative design of new rolling stock and refurbishment of existing rail carriages
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Forensic advisory services to insurance and legal groups, including acting as an expert witness
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Design and Fatigue Analysis of Iron Ore Cars Customer Fortescue Metals Group Location Western Australia WorleyParsons’ rail group utilized our advanced analysis consultants to design ore cars for Hamersley Iron. Using finite element analysis, the wagons were analyzed under various loading cases, including unloading into a rotary tippler. Fatigue assessments were performed using both US standards and site-specific dynamic test data which provided details such as longitudinal in-train force variations. Finite element analysis allows structures with complex geometries to be analyzed and optimized under a large number of conditions. This is particularly important in the case of mass produced items where a small saving per unit adds up to a considerable saving overall.
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asset integrity solutions
We are increasingly faced by challenges for which there is no precedent. Building from the theoretical base of first principles, we can solve problems where no analogs exist.
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Bondi Sewage Treatment Plant Bypass Channel Customer Sydney Water Corporation Location Sydney, Australia WorleyParsons examined the application of sediment transport theory to a complex real-world problem through the use of CFD modeling. The Bondi Sewage Treatment Plant effluent bypass channel is used only for emergency discharge, however, the channel has a tendency to accumulate significant volumes of sand and other sediments, compromising the discharge capacity. CFD analysis was carried out to enhance understanding of the wave processes occurring in the channel, identify mechanisms for the accumulation of sediments in the channel, and establish a methodology for the assessment of proposed remedial actions. Visualization and understanding of the flow allowed the geometry of the system to be optimized. The end result was lower flow losses and an improvement in system performance.
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asset integrity solutions
Advanced analysis techniques are increasingly used by business to prepare and plan in a rapidly evolving environment.
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Global experience
1. Truss Hydrodynamic Loading Esso Australia Australia A proposed new riser truss for an existing concrete gravity structure (CGS) was modeled to optimize the structural arrangement. The model accounted for the influence of the CGS on the waves, and the hydrodynamic loading on the truss.
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This provided significant value to our customer through accurate load definition and subsequent optimization of the riser truss structure.
2. Life Extension of Oxygen Buffer Vessels BOC New Zealand Four large pressure vessels in an air separation plant had reached the end of their design life. WorleyParsons investigated a life extension of 20 years for the pressure vessels, taking into account the service history and severe cyclic service. This required a fatigue analysis and fracture mechanics assessment to API 579, and FEA of highly stressed areas. An inspection regime which allowed the vessels to continue in operation was established.
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asset integrity solutions
3. Aughinish Production Capital Program Aughinish Alumina Limited Ireland The Aughinish Alumina Refinery upgrade required the simulation of material handling processes to determine optimal ship unloading rates and bauxite storage requirements, accounting for capital and ongoing demurrage costs. A Monte Carlo type dynamic simulation model was developed to represent many years of production. This type of analysis allowed de-bottlenecking, ensured compatibility between the many systems on site, and lead to a reduction in demurrage costs.
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4. Finite Element Analysis (FEA) of Ball Mill for Cement Plant Lafarge Malayan Cement Singapore WorleyParsons analyzed the stress in a ball mill shell for a cement plant during its rotation to solve a problem with shell cracking at the maintenance access doors. A non-linear FEA model was used, including contact surfaces to provide appropriate supports within the model.
5. Roaster Finite Element Analysis (FEA) and Rebuild Inco Limited United States of America The Copper Cliff Smelter’s number two roaster was scheduled for rebuild, minor structural and mechanical modifications, and some changes in refractory lining materials. FEA was used to determine the shell stresses during the roaster operation.
It was determined that the stress range was higher than acceptable. WorleyParsons proposed a number of solutions to reduce the stress level prior to repeating the analysis with the modified design.
Structural weaknesses were identified and potential reinforcements were proposed. The rebuild was successfully implemented and the campaign life improved.
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Global & Australia and New Zealand Shane Donohoo Managing Consultant Level 12, 141 Walker Street North Sydney NSW 2060, Australia Ph: +61 2 8923 6866
Asia & Middle East Clive Ford Principal Consultant 12th Floor, Unit 05 111 Somerset Road Singapore 238164 Ph: +65 6735 8444
USA & Canada Dr Arya Majed Principal Consultant 15600 John F Kennedy Boulevard Houston TX 77032 Ph: +1 713 892 0999
UK, Europe & Africa Luca Chinello Principal Consultant Parkview, Great West Road Brentford, Middlesex London TW8 9AZ Ph: +44 208 326 5000
For further information about our global capability www.worleyparsons.com/consulting