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HPC on Cloud for SMEs. The case of
bolt tightening.
A. Gómez, C. Cotelo (CESGA)
G. Rodríguez (Texas Controls), J. Souto (AIMEN)
18/06/2015
To provide high performance computing and advanced
communications resources and services to the scientific
community of Galicia and to the Spanish National Research
Council (CSIC), as well as, to institutions and enterprises
with R&D&I activity.
To promote high quality research in Computational
Science in close collaboration with the research community
from Galicia as well as from other regions or countries all
over the world; contributing in this way to the advancement
of science, to transfer technology to industry and
administrations, and as consequence, to the welfare of
society as a whole.
Mission Statement
Examplesofservices
Simulations for the Regional Weather Office
Examplesof use
Puertos del Estado
Spanish Port Authority
Enrique Álvarez Fanjul
European IBI Area: Ocean Forecasting Service
Examplesof use
Oceanographic simulation to better understand fisheries population
dynamics
ColaborativeResearch with universities
Large scale electromagnetism simulation for
improved radar systems
UVIGO – UNEX – CESGA
Fernando Obelleiro Basteiro
HPC for SMEs
“… HIGHLIGHTS that HPC is a crucial asset for the EU's innovation
capacity and STRESSES its strategic importance to benefit the EU's
industrial capabilities as well as its citizens, by innovating industrial
products and services, increasing competitiveness, and addressing
grand societal and scientific challenges more effectively.”
Draft Council Conclusions on 'High Performance Computing: Europe's place in a
Global Race’” of March 27th, 2013
But for SMEs, HPC does not always mean big supercomputers
What is HPC?
High Performance Computing
(HPC) is the use of servers,
clusters, and supercomputers – plus
associated software, tools,
components, storage, and services
– for scientific, engineering, or
analytical tasks that are particularly
intensive in computation, memory
usage, or data management
Intersec360
Process
Conceptual Model
Mathematical Model
Software
Numerical Resolution
Analysis
Validation
New conditions
SIMULATION IN SMEs in Galicia (2004)
http://simula.cesga.es
Constraints
Training,
V&V, and
consulting
Open Source
External CPUs:
CLOUD
http://simula.cesga.es
http://www.cloudpyme.eu
Centros Tecnológicos
0682_CLOUDPYME2_1_E
Initial solution: Cloud services in net
14 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
End user
HPC Service
Provider
Independen
t Software
Vendor
Research
Software
Provider
Application
Expert
HPC Expert
 Help with M&S and validation
Vertical Applications/Easy interfaces
Confidentiality
Remote storage/HPC/Visualization
Time-to-solution
What do they need?
FORTISSIMO has received funding from the European Union's
Seventh Framework Programme for research, technological
development and demonstration under grant agreement no
609029
Why M&S Tightening?
 TEXAS Controls core business.
 There is no software solution in the market.
 It seems feasible to do it with open source software.
 The SME does not have the required computer capacity.
 A challenge regarding modelling, simulation, and execution.
15 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
FF404: Case of study
FORTISSIMO has received funding from the European Union's Seventh Framework Programme for
research, technological development and demonstration under grant agreement no 609029
16
Headquarters
LA CORUÑA
MADRID
TARRAGONA
BRASIL
(NATAL-RÍO GRANDE
DO NORTE)
Copyright 2014 Members of the Fortissimo Consortium
End User/Company Profile:
18-06-2015
17 -Copyright 2014 Members of the Fortissimo Consortium
Tightening examples
Try to Reduce operational time & the time exposure to radiation.
Nuclear plants
18-06-2015
Copyright 2014 Members of the Fortissimo Consortium 19 -
The process
(Il processo)
18-06-2015
Tightening process
20 -Copyright 2014 - Members of the Fortissimo Consortium
Study and prediction of flanges behavior during tightening process.
What is the best strategy to execute it?
18-06-2015
Copyright 2014 Members of the Fortissimo Consortium 21 -
The Model
(Il modello)
18-06-2015
22
Materials
• Flanges
• Gasket
• Bolts
Design
• Nr bolts
• Groove
• Flange
• Bolts
• Gasket
Sequence
parameters
• Initial load
• Residual
load
• Steps of
tightening
• Groups of
tightening
Parametric simulations: huge number of cases to obtain the optimal design
Contact-Friction model
Copyright 2014 Members of the Fortissimo Consortium14-10-2004
The model
23
Contact-Friction model
Copyright 2014 Members of the Fortissimo Consortium14-10-2004
The model
24 -14-10-2004 Copyright 2014 Members of the Fortissimo Consortium
Taguchi method
The Taguchi method is a standardized approach for determining the best
combination of inputs to produce a product or service.
Image source: Chapter 7S ©2001 Slides Prepared by Bruce R.
Barringer University of Central Florida S. Thomas
25 -Copyright 2014 Members of the Fortissimo Consortium
Parametric jobs: Taguchi
18-06-2015
TAGUCHI METHOD:
The approach for this experiment corresponds to the Taguchi L’16 orthogonal array (up to 4 levels & 5
parameters), i.e. up to 16 parametric jobs . The runtimes for each of these parametric jobs are very similar.
PARAMETERS:
 Materials for flanges and gaskets
 Number of bolts for each subset (strategy);
 Final load value (minimum load ) .
 Maximum load for each step.
Copyright 2014 Members of the Fortissimo Consortium 26 -
The software
(Il software)
18-06-2015
27 -Copyright 2014 Members of the Fortissimo Consortium
Contact-friction model
18-06-2015
 Code_aster (and Abaqus for initial model verification)
 Taguchi implementation:
 Python script which receives the number of parameters/levels from the web application
and generates the different number of .comm files (input) for the parametric jobs.
 Embedded python in the Code_Aster .comm file for controlling the tightening workflow .
 Job arrays : same job using different .comm file.
 Symmetries, Choices of surfaces main and slaves and Quality of the mesh
 Numerical Resolution:
 Discrete formulation: ALGO_CONT , ALGO_FRO. Options: LAGRANGIAN or GCP algorithm
 Formulation continue: ALGO_RESO_CONT, ALGO_RESO_FROT, ALGO_RESO_GEOM. Options:
POINT_FIX or NEWTON algorithm.
 Solvers: MULT_FRONT, MUMPS, LDLT, PCG, PETSC or FETI
 In case of MPI solvers: PARALLELISME = CENTRALISE, GROUP_ELEM, MAIL_DISPERSE,
MAIL_CONTIGU, SOUS_DOMAINE
28 -Copyright 2014 Members of the Fortissimo Consortium
Contact-friction model
18-06-2015
 Code_aster (and Abaqus for initial model verification)
 Taguchi implementation:
 Python script which receives the number of parameters/levels from the web application
and generates the different number of .comm files (input) for the parametric jobs.
 Embedded python in the Code_Aster .comm file for controlling the tightening workflow .
 Job arrays : same job using different .comm file.
 Symmetries, Choices of surfaces main and slaves and Quality of the mesh
 Numerical Resolution:
 Discrete formulation: ALGO_CONT , ALGO_FRO. Options: LAGRANGIAN or GCP algorithm
 Formulation continue: ALGO_RESO_CONT, ALGO_RESO_FROT, ALGO_RESO_GEOM. Options:
POINT_FIX or NEWTON algorithm.
 Solvers: MULT_FRONT, MUMPS, LDLT, PCG, PETSC or FETI
 In case of MPI solvers: PARALLELISME = CENTRALISE, GROUP_ELEM, MAIL_DISPERSE,
MAIL_CONTIGU, SOUS_DOMAINE
29 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
HPC – Job arrays (
Taguchi)
Case workflow
System architecture
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
GUI: Experiments manager
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
GUI: Define material
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
GUI: Define simulation
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
GUI: Submit simulations
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
Values around the groove are critical to
seal the assembly
GUI: Results in critical points
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
Intermediate results for each tightening step.
Job can be stopped if this results show wrong values.
GUI: Jobs monitor
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
Cancel a parametric job
not the whole simulation
GUI: Remote visualization (I)
VNC client through a browser
18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
39 -Copyright 2014 Members of the Fortissimo Consortium
TurboVNC (high-performance version of VNC)
GUI: Remote visualization (II)
18-06-2015
Copyright 2014 Members of the Fortissimo Consortium 40 -
Validation
(La validazione)
18-06-2015
1º 2º 3º
Group A 67850N 50880N 50880N
Group B 50880N 50880N 50880N
Case validation: Sensorized Flange
1º 2º 3º
Group A 67850N 50880N 50880N
Group B 50880N 50880N 50880N
Copyright 2014 Members of the Fortissimo Consortium
42 -Copyright 2014 Members of the Fortissimo Consortium
Conclusions
18-06-2015
 Configuring the best simulation’s could be a hard work for a no-expert in FEM.
 HPC resources are not only needed for simulations which need a high number
of cores each one. Several multicore’s (~16) simulations are needed for running
parametric jobs (up to 16).
 Troubles appears very often and they are due to different issues: mesh,
contacts definition, algorithms involved, software issues or MPI libraries.
 SMEs need validate their models against real cases.
 End-user prefers a GUI application and it must be flexible to incorporate new
functionalities.
 Remote visualization is desirable. Best tool to visualize data depends on the
output size.
 Value-added services are really needed as FORTISSIMO proposes.
agomez@cesga.es
June 2015
Thanksfor your attention.
HPC on Cloud for SMEs. The case of bolt tightening.

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HPC on Cloud for SMEs. The case of bolt tightening.

  • 1. HPC on Cloud for SMEs. The case of bolt tightening. A. Gómez, C. Cotelo (CESGA) G. Rodríguez (Texas Controls), J. Souto (AIMEN) 18/06/2015
  • 2.
  • 3. To provide high performance computing and advanced communications resources and services to the scientific community of Galicia and to the Spanish National Research Council (CSIC), as well as, to institutions and enterprises with R&D&I activity. To promote high quality research in Computational Science in close collaboration with the research community from Galicia as well as from other regions or countries all over the world; contributing in this way to the advancement of science, to transfer technology to industry and administrations, and as consequence, to the welfare of society as a whole. Mission Statement
  • 4. Examplesofservices Simulations for the Regional Weather Office
  • 5. Examplesof use Puertos del Estado Spanish Port Authority Enrique Álvarez Fanjul European IBI Area: Ocean Forecasting Service
  • 6. Examplesof use Oceanographic simulation to better understand fisheries population dynamics
  • 7. ColaborativeResearch with universities Large scale electromagnetism simulation for improved radar systems UVIGO – UNEX – CESGA Fernando Obelleiro Basteiro
  • 8. HPC for SMEs “… HIGHLIGHTS that HPC is a crucial asset for the EU's innovation capacity and STRESSES its strategic importance to benefit the EU's industrial capabilities as well as its citizens, by innovating industrial products and services, increasing competitiveness, and addressing grand societal and scientific challenges more effectively.” Draft Council Conclusions on 'High Performance Computing: Europe's place in a Global Race’” of March 27th, 2013 But for SMEs, HPC does not always mean big supercomputers
  • 9. What is HPC? High Performance Computing (HPC) is the use of servers, clusters, and supercomputers – plus associated software, tools, components, storage, and services – for scientific, engineering, or analytical tasks that are particularly intensive in computation, memory usage, or data management Intersec360 Process Conceptual Model Mathematical Model Software Numerical Resolution Analysis Validation New conditions
  • 10. SIMULATION IN SMEs in Galicia (2004) http://simula.cesga.es
  • 13.
  • 14. 14 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium End user HPC Service Provider Independen t Software Vendor Research Software Provider Application Expert HPC Expert  Help with M&S and validation Vertical Applications/Easy interfaces Confidentiality Remote storage/HPC/Visualization Time-to-solution What do they need? FORTISSIMO has received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement no 609029
  • 15. Why M&S Tightening?  TEXAS Controls core business.  There is no software solution in the market.  It seems feasible to do it with open source software.  The SME does not have the required computer capacity.  A challenge regarding modelling, simulation, and execution. 15 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium FF404: Case of study FORTISSIMO has received funding from the European Union's Seventh Framework Programme for research, technological development and demonstration under grant agreement no 609029
  • 16. 16 Headquarters LA CORUÑA MADRID TARRAGONA BRASIL (NATAL-RÍO GRANDE DO NORTE) Copyright 2014 Members of the Fortissimo Consortium End User/Company Profile: 18-06-2015
  • 17. 17 -Copyright 2014 Members of the Fortissimo Consortium Tightening examples Try to Reduce operational time & the time exposure to radiation. Nuclear plants 18-06-2015
  • 18. Copyright 2014 Members of the Fortissimo Consortium 19 - The process (Il processo) 18-06-2015
  • 19. Tightening process 20 -Copyright 2014 - Members of the Fortissimo Consortium Study and prediction of flanges behavior during tightening process. What is the best strategy to execute it? 18-06-2015
  • 20. Copyright 2014 Members of the Fortissimo Consortium 21 - The Model (Il modello) 18-06-2015
  • 21. 22 Materials • Flanges • Gasket • Bolts Design • Nr bolts • Groove • Flange • Bolts • Gasket Sequence parameters • Initial load • Residual load • Steps of tightening • Groups of tightening Parametric simulations: huge number of cases to obtain the optimal design Contact-Friction model Copyright 2014 Members of the Fortissimo Consortium14-10-2004 The model
  • 22. 23 Contact-Friction model Copyright 2014 Members of the Fortissimo Consortium14-10-2004 The model
  • 23. 24 -14-10-2004 Copyright 2014 Members of the Fortissimo Consortium Taguchi method The Taguchi method is a standardized approach for determining the best combination of inputs to produce a product or service. Image source: Chapter 7S ©2001 Slides Prepared by Bruce R. Barringer University of Central Florida S. Thomas
  • 24. 25 -Copyright 2014 Members of the Fortissimo Consortium Parametric jobs: Taguchi 18-06-2015 TAGUCHI METHOD: The approach for this experiment corresponds to the Taguchi L’16 orthogonal array (up to 4 levels & 5 parameters), i.e. up to 16 parametric jobs . The runtimes for each of these parametric jobs are very similar. PARAMETERS:  Materials for flanges and gaskets  Number of bolts for each subset (strategy);  Final load value (minimum load ) .  Maximum load for each step.
  • 25. Copyright 2014 Members of the Fortissimo Consortium 26 - The software (Il software) 18-06-2015
  • 26. 27 -Copyright 2014 Members of the Fortissimo Consortium Contact-friction model 18-06-2015  Code_aster (and Abaqus for initial model verification)  Taguchi implementation:  Python script which receives the number of parameters/levels from the web application and generates the different number of .comm files (input) for the parametric jobs.  Embedded python in the Code_Aster .comm file for controlling the tightening workflow .  Job arrays : same job using different .comm file.  Symmetries, Choices of surfaces main and slaves and Quality of the mesh  Numerical Resolution:  Discrete formulation: ALGO_CONT , ALGO_FRO. Options: LAGRANGIAN or GCP algorithm  Formulation continue: ALGO_RESO_CONT, ALGO_RESO_FROT, ALGO_RESO_GEOM. Options: POINT_FIX or NEWTON algorithm.  Solvers: MULT_FRONT, MUMPS, LDLT, PCG, PETSC or FETI  In case of MPI solvers: PARALLELISME = CENTRALISE, GROUP_ELEM, MAIL_DISPERSE, MAIL_CONTIGU, SOUS_DOMAINE
  • 27. 28 -Copyright 2014 Members of the Fortissimo Consortium Contact-friction model 18-06-2015  Code_aster (and Abaqus for initial model verification)  Taguchi implementation:  Python script which receives the number of parameters/levels from the web application and generates the different number of .comm files (input) for the parametric jobs.  Embedded python in the Code_Aster .comm file for controlling the tightening workflow .  Job arrays : same job using different .comm file.  Symmetries, Choices of surfaces main and slaves and Quality of the mesh  Numerical Resolution:  Discrete formulation: ALGO_CONT , ALGO_FRO. Options: LAGRANGIAN or GCP algorithm  Formulation continue: ALGO_RESO_CONT, ALGO_RESO_FROT, ALGO_RESO_GEOM. Options: POINT_FIX or NEWTON algorithm.  Solvers: MULT_FRONT, MUMPS, LDLT, PCG, PETSC or FETI  In case of MPI solvers: PARALLELISME = CENTRALISE, GROUP_ELEM, MAIL_DISPERSE, MAIL_CONTIGU, SOUS_DOMAINE
  • 28. 29 -18-06-2015 Copyright 2014 Members of the Fortissimo Consortium HPC – Job arrays ( Taguchi) Case workflow
  • 29. System architecture 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 30. GUI: Experiments manager 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 31. GUI: Define material 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 32. GUI: Define simulation 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 33. GUI: Submit simulations 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 34. Values around the groove are critical to seal the assembly GUI: Results in critical points 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium Intermediate results for each tightening step. Job can be stopped if this results show wrong values.
  • 35. GUI: Jobs monitor 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium Cancel a parametric job not the whole simulation
  • 36. GUI: Remote visualization (I) VNC client through a browser 18-06-2015 Copyright 2014 Members of the Fortissimo Consortium
  • 37. 39 -Copyright 2014 Members of the Fortissimo Consortium TurboVNC (high-performance version of VNC) GUI: Remote visualization (II) 18-06-2015
  • 38. Copyright 2014 Members of the Fortissimo Consortium 40 - Validation (La validazione) 18-06-2015
  • 39. 1º 2º 3º Group A 67850N 50880N 50880N Group B 50880N 50880N 50880N Case validation: Sensorized Flange 1º 2º 3º Group A 67850N 50880N 50880N Group B 50880N 50880N 50880N Copyright 2014 Members of the Fortissimo Consortium
  • 40. 42 -Copyright 2014 Members of the Fortissimo Consortium Conclusions 18-06-2015  Configuring the best simulation’s could be a hard work for a no-expert in FEM.  HPC resources are not only needed for simulations which need a high number of cores each one. Several multicore’s (~16) simulations are needed for running parametric jobs (up to 16).  Troubles appears very often and they are due to different issues: mesh, contacts definition, algorithms involved, software issues or MPI libraries.  SMEs need validate their models against real cases.  End-user prefers a GUI application and it must be flexible to incorporate new functionalities.  Remote visualization is desirable. Best tool to visualize data depends on the output size.  Value-added services are really needed as FORTISSIMO proposes.

Notas do Editor

  1. This template is for the WP4xx experiments. The time for the presentation should be 45 minutes, including questions.
  2. 2
  3. During the kick-off, the different processes that can be modelled and simulated where analysed. Finally, the agreement was to model and simulate the most challenged but useful process within the design and service provision: the tightening.
  4. During the kick-off, the different processes that can be modelled and simulated where analysed. Finally, the agreement was to model and simulate the most challenged but useful process within the design and service provision: the tightening.
  5. List the partners and any application software used . Use N/A if not applicable.
  6. Another relevant scope of the project for Texas Controls, have to do with the deep study of the tensional field in flanges. As we mentioned before, typical FEM studies only take into account the final load of the bolts, given by the Engineering Codes. But due to the physical fact that Higher loads are necessary to get residual loads when, risky situations for the components, always happens during the tightening. It is very common in “on site” situations when a flange is leaking, to increase a lot the load applied, producing hidden damages in grooves and bolts. Most of the times, the better solution is to optimize the tightening procedure. Typical failure of flanges are due fatigue situations when high stress are located in the groves where metallic gaskets are compressed. If high temperatures are involved, then Stress corrosion cracking appears. So it is necessary to determine the minimum applied load to achieve the maximum sealing force, with no damages of grooves and bolts.
  7. So, as I have just presented so far in the previous slides, one of our most important activities is focused in getting reliable and safe mechanical joints in the industry, so we could summarize this objective in our lemma: “Leak free Plants” In this slide I would like to explain the problems we have to face day by day in our activity: In our opinion, Bolted joints, in a Refinery or in a PowerGen plant, should be considered as a welded joint in many aspects. Of course there are not melted materials nor phase changes when we talk about a flanged joint…and, at a first sight, it is more simple to face a temporary joint ( for example a flange) than a welded joint, but the responsibility of the people that tighten a Flange it is the same of a welder. If this joint fails, for example in a pipe of hydrogen in a Hydrocracker, the consecuences could be catastrophic. So we have to know more about the behaviour of the elements of the flanges. The big problems appears when we have to face the sealing of a non standard flange in critical applications. Nowadays, Oil Refining Industry have to face problems to refine heavy oils, and, to optimize the production of lighter fractions from heavy oils, (for example tar sands refineries) This this facilities, higher pressure and higher temperatures are necessary. Even, new technologies for energy generation as Thermal Solar Energy, needs new solutions for new problems. So, more frequently than in previous years, designers are finding solutions far away from the standards, using “ad hoc” designs. Furthermore, the optimization of the desings of Heat Exchangers, Pressure Vessels is mandatory for the Heavy Industry in Europe to better compete and to give value to their customers. On the other hand, designer usually obviate during the design process, the tightening itself, without knowing that, in many occasions, damages in main parts occurs during the tightening process and not at the final stage of a tightened flanges. We have detected, then, that engineers usually doesn’t take into account the tightening process itself when designing flanges of pressure vessels, and never considers the time elapsed in such process, thing that in special critical applications or in huge projects should be a critical figure to consider. In our projects or designs, we constantly apply recommendations of entities such as the British Petroleum Institute, the Fluid Sealing Association, the European Sealing Association, ASME, API, Offshore Operators Association of the United Kingdom (UKOOA) and other research committees, and we usually get involved in mechanical simulations, finite element analysis and empirical testings on how it affects the temperature, thermal cycling, or even cryogenic conditions in the sealing products. We have studied in many occasions the differences between applied loads and residual loads, the effects of friction when torque is involve to get a correct tightening, etc…Everything lead us to understand the interaction of different elements of the flanged joints to allow us to face the most critical jobs offering guarantees of implementation and operation of no leaking flanged joints.
  8. So, as I have just presented so far in the previous slides, one of our most important activities is focused in getting reliable and safe mechanical joints in the industry, so we could summarize this objective in our lemma: “Leak free Plants” In this slide I would like to explain the problems we have to face day by day in our activity: In our opinion, Bolted joints, in a Refinery or in a PowerGen plant, should be considered as a welded joint in many aspects. Of course there are not melted materials nor phase changes when we talk about a flanged joint…and, at a first sight, it is more simple to face a temporary joint ( for example a flange) than a welded joint, but the responsibility of the people that tighten a Flange it is the same of a welder. If this joint fails, for example in a pipe of hydrogen in a Hydrocracker, the consecuences could be catastrophic. So we have to know more about the behaviour of the elements of the flanges. The big problems appears when we have to face the sealing of a non standard flange in critical applications. Nowadays, Oil Refining Industry have to face problems to refine heavy oils, and, to optimize the production of lighter fractions from heavy oils, (for example tar sands refineries) This this facilities, higher pressure and higher temperatures are necessary. Even, new technologies for energy generation as Thermal Solar Energy, needs new solutions for new problems. So, more frequently than in previous years, designers are finding solutions far away from the standards, using “ad hoc” designs. Furthermore, the optimization of the desings of Heat Exchangers, Pressure Vessels is mandatory for the Heavy Industry in Europe to better compete and to give value to their customers. On the other hand, designer usually obviate during the design process, the tightening itself, without knowing that, in many occasions, damages in main parts occurs during the tightening process and not at the final stage of a tightened flanges. We have detected, then, that engineers usually doesn’t take into account the tightening process itself when designing flanges of pressure vessels, and never considers the time elapsed in such process, thing that in special critical applications or in huge projects should be a critical figure to consider. In our projects or designs, we constantly apply recommendations of entities such as the British Petroleum Institute, the Fluid Sealing Association, the European Sealing Association, ASME, API, Offshore Operators Association of the United Kingdom (UKOOA) and other research committees, and we usually get involved in mechanical simulations, finite element analysis and empirical testings on how it affects the temperature, thermal cycling, or even cryogenic conditions in the sealing products. We have studied in many occasions the differences between applied loads and residual loads, the effects of friction when torque is involve to get a correct tightening, etc…Everything lead us to understand the interaction of different elements of the flanged joints to allow us to face the most critical jobs offering guarantees of implementation and operation of no leaking flanged joints.
  9. So, as I have just presented so far in the previous slides, one of our most important activities is focused in getting reliable and safe mechanical joints in the industry, so we could summarize this objective in our lemma: “Leak free Plants” In this slide I would like to explain the problems we have to face day by day in our activity: In our opinion, Bolted joints, in a Refinery or in a PowerGen plant, should be considered as a welded joint in many aspects. Of course there are not melted materials nor phase changes when we talk about a flanged joint…and, at a first sight, it is more simple to face a temporary joint ( for example a flange) than a welded joint, but the responsibility of the people that tighten a Flange it is the same of a welder. If this joint fails, for example in a pipe of hydrogen in a Hydrocracker, the consecuences could be catastrophic. So we have to know more about the behaviour of the elements of the flanges. The big problems appears when we have to face the sealing of a non standard flange in critical applications. Nowadays, Oil Refining Industry have to face problems to refine heavy oils, and, to optimize the production of lighter fractions from heavy oils, (for example tar sands refineries) This this facilities, higher pressure and higher temperatures are necessary. Even, new technologies for energy generation as Thermal Solar Energy, needs new solutions for new problems. So, more frequently than in previous years, designers are finding solutions far away from the standards, using “ad hoc” designs. Furthermore, the optimization of the desings of Heat Exchangers, Pressure Vessels is mandatory for the Heavy Industry in Europe to better compete and to give value to their customers. On the other hand, designer usually obviate during the design process, the tightening itself, without knowing that, in many occasions, damages in main parts occurs during the tightening process and not at the final stage of a tightened flanges. We have detected, then, that engineers usually doesn’t take into account the tightening process itself when designing flanges of pressure vessels, and never considers the time elapsed in such process, thing that in special critical applications or in huge projects should be a critical figure to consider. In our projects or designs, we constantly apply recommendations of entities such as the British Petroleum Institute, the Fluid Sealing Association, the European Sealing Association, ASME, API, Offshore Operators Association of the United Kingdom (UKOOA) and other research committees, and we usually get involved in mechanical simulations, finite element analysis and empirical testings on how it affects the temperature, thermal cycling, or even cryogenic conditions in the sealing products. We have studied in many occasions the differences between applied loads and residual loads, the effects of friction when torque is involve to get a correct tightening, etc…Everything lead us to understand the interaction of different elements of the flanged joints to allow us to face the most critical jobs offering guarantees of implementation and operation of no leaking flanged joints.
  10. Embebed python in the Code_Aster .comm file (input) for controling the tightening workflow -> Nos permite: Poner como variables ciertos valores que vendrán del formaulario web (valores para el material, nº de vueltas, nºde tornillos, fuerzas a aplicar) => tener una plantilla .comm para usar con cualquier número de tornillos , vueltas…, gracias al uso de variables y bucles python. Nos permite también acceder a la tabla de desplazamientos que se va escribiendo, tomar el último valor de desplazamiento de un apriete e imponerlo como condición inicial en la siguiente vuelta.
  11. So, as I have just presented so far in the previous slides, one of our most important activities is focused in getting reliable and safe mechanical joints in the industry, so we could summarize this objective in our lemma: “Leak free Plants” In this slide I would like to explain the problems we have to face day by day in our activity: In our opinion, Bolted joints, in a Refinery or in a PowerGen plant, should be considered as a welded joint in many aspects. Of course there are not melted materials nor phase changes when we talk about a flanged joint…and, at a first sight, it is more simple to face a temporary joint ( for example a flange) than a welded joint, but the responsibility of the people that tighten a Flange it is the same of a welder. If this joint fails, for example in a pipe of hydrogen in a Hydrocracker, the consecuences could be catastrophic. So we have to know more about the behaviour of the elements of the flanges. The big problems appears when we have to face the sealing of a non standard flange in critical applications. Nowadays, Oil Refining Industry have to face problems to refine heavy oils, and, to optimize the production of lighter fractions from heavy oils, (for example tar sands refineries) This this facilities, higher pressure and higher temperatures are necessary. Even, new technologies for energy generation as Thermal Solar Energy, needs new solutions for new problems. So, more frequently than in previous years, designers are finding solutions far away from the standards, using “ad hoc” designs. Furthermore, the optimization of the desings of Heat Exchangers, Pressure Vessels is mandatory for the Heavy Industry in Europe to better compete and to give value to their customers. On the other hand, designer usually obviate during the design process, the tightening itself, without knowing that, in many occasions, damages in main parts occurs during the tightening process and not at the final stage of a tightened flanges. We have detected, then, that engineers usually doesn’t take into account the tightening process itself when designing flanges of pressure vessels, and never considers the time elapsed in such process, thing that in special critical applications or in huge projects should be a critical figure to consider. In our projects or designs, we constantly apply recommendations of entities such as the British Petroleum Institute, the Fluid Sealing Association, the European Sealing Association, ASME, API, Offshore Operators Association of the United Kingdom (UKOOA) and other research committees, and we usually get involved in mechanical simulations, finite element analysis and empirical testings on how it affects the temperature, thermal cycling, or even cryogenic conditions in the sealing products. We have studied in many occasions the differences between applied loads and residual loads, the effects of friction when torque is involve to get a correct tightening, etc…Everything lead us to understand the interaction of different elements of the flanged joints to allow us to face the most critical jobs offering guarantees of implementation and operation of no leaking flanged joints.
  12. The critical distances are around the groove, but the values of flexion and torsion of the flanges are important too. It is necessary to control the values around the groove to seal the assembly.
  13. The critical distances are around the groove, but the values of flexion and torsion of the flanges are important too. It is necessary to control the values around the groove to seal the assembly.
  14. VNC client through a browser. This is adequate for small-medium cases (4- 8 bolts) because the outputs are ~ 4GB each parametric job
  15. TurboVNC is a high-performance version of VNC. Big case (24 bolts) generates big outputs > 8.5GB first step 24 bolts: 10h * 16MPI * 8.5GB of output
  16. So, as I have just presented so far in the previous slides, one of our most important activities is focused in getting reliable and safe mechanical joints in the industry, so we could summarize this objective in our lemma: “Leak free Plants” In this slide I would like to explain the problems we have to face day by day in our activity: In our opinion, Bolted joints, in a Refinery or in a PowerGen plant, should be considered as a welded joint in many aspects. Of course there are not melted materials nor phase changes when we talk about a flanged joint…and, at a first sight, it is more simple to face a temporary joint ( for example a flange) than a welded joint, but the responsibility of the people that tighten a Flange it is the same of a welder. If this joint fails, for example in a pipe of hydrogen in a Hydrocracker, the consecuences could be catastrophic. So we have to know more about the behaviour of the elements of the flanges. The big problems appears when we have to face the sealing of a non standard flange in critical applications. Nowadays, Oil Refining Industry have to face problems to refine heavy oils, and, to optimize the production of lighter fractions from heavy oils, (for example tar sands refineries) This this facilities, higher pressure and higher temperatures are necessary. Even, new technologies for energy generation as Thermal Solar Energy, needs new solutions for new problems. So, more frequently than in previous years, designers are finding solutions far away from the standards, using “ad hoc” designs. Furthermore, the optimization of the desings of Heat Exchangers, Pressure Vessels is mandatory for the Heavy Industry in Europe to better compete and to give value to their customers. On the other hand, designer usually obviate during the design process, the tightening itself, without knowing that, in many occasions, damages in main parts occurs during the tightening process and not at the final stage of a tightened flanges. We have detected, then, that engineers usually doesn’t take into account the tightening process itself when designing flanges of pressure vessels, and never considers the time elapsed in such process, thing that in special critical applications or in huge projects should be a critical figure to consider. In our projects or designs, we constantly apply recommendations of entities such as the British Petroleum Institute, the Fluid Sealing Association, the European Sealing Association, ASME, API, Offshore Operators Association of the United Kingdom (UKOOA) and other research committees, and we usually get involved in mechanical simulations, finite element analysis and empirical testings on how it affects the temperature, thermal cycling, or even cryogenic conditions in the sealing products. We have studied in many occasions the differences between applied loads and residual loads, the effects of friction when torque is involve to get a correct tightening, etc…Everything lead us to understand the interaction of different elements of the flanged joints to allow us to face the most critical jobs offering guarantees of implementation and operation of no leaking flanged joints.
  17. The first step showed bigger displacements, the remaining steps involve adjustments over the compression. This behaviour matches with reality, where the last tightening uses smaller force over pre-tensioned material. The distribution of the stress over the flange and gasket showed a higher peak of stress over the groove zone and in the contacts between flange and gasket. The local compression distance between the flanges determined by the prediction of the numerical model and the experimental test (Figure Local Distance ) was compared. In the graphic it can be seen how the tendency between both methodologies is the same, but the absolute values were different. The differences are due to geometric tolerances: Positioning and surface texture. The positioning in the FEM model is perfect due to the need for a good surface contact between the flange and the gasket to properly achieve initial values for the contact algorithm. The FEM model sometimes exhibits some minor penetration between parts, which never happens in the experimental tests.. The surface texture implies roughness which is not taken into account in the FEM model. The roughness does not explain 1mm difference, but any defect in the surface of contact could generate that difference. The final results obtained by FEM methodology were validated by TEXAS because the methodology applied and the tendencies obtained were correct. The results from FEM method will be comparatives between different parameters.