FEA and CFD based Simulation Design to Improve Productivity and Enhance Safety in Energy and Power Industry:

Energy industry faces a number of stringent challenges that range from addressing environmental risks, investigating new sources of natural resources, and improving operational performance, while complying with tight technical and regulatory requirements. The past decade has seen increasing explorations for fossil fuels, while research into the alternative energy sources, like wind, solar, and biofuels is taking center stage as governments and companies look to meet the ever-increasing global energy demands. ESimLab offers a Virtual Engineering approach with CFD and FEA tools such as Ansys FluentStarCCM+  for Combustion and flows simulation and FEA based Codes such as ABAQUS, Nastran, AVL Excite and LS-Dyna and the industry-leading fatigue Simulation technology such as Simulia FE-SAFE, Ansys Ncode Design Life to calculate fatigue life of Welding, Composite, Vibration, Crack growth, Thermo-mechanical fatigue and MSC Actran and ESI VA One for Acoustics simulations, encompassing the accurate prediction of in-service and accidental loads, the performance evaluation, and the integrity assessment including the influence of manufacturing the components.

  • Gas Turbine combustion Simulation and optimization
  • Expandable C asing Strings
    • Predict collapse, burst & tensile failure
    • Load required for expansion
    • Metal connectors and threads
  • Coiled tubing & pipe
  • Annular Packers
    • Expandable, inflatable & retractable designs
  • Oil Seals
    • Performance of elastomers
    • Prevent leakage
  • Drilling Oil Risers

Gas turbine combustion Simulation: 1D-System modeling tools coupled with 3D FEA and CFD modeling tools

Gas turbine combustion is a complex process, and it can be a challenge to achieve accurate and reliable CFD simulation results at a reasonable computational cost. Computational efficiency requires appropriate mesh resolution and turbulence, spray, combustion, and emissions models that provide an appropriate level of detail.

ESimLab engineering team use advanced CAE software with special features for mixing the best of both FEA tools and CFD solvers: CFD codes such as Ansys FluentSiemens StarCCM+OpenFOAM and FEA Codes such as ANSYSABAQUSNastranLS-DynaMSC Marc

ComponentQuestionFEA and CFD Simulation
Inlet Systems
  • Fogging and cooling
    • Delivering a uniform temperature to the compressor
    • Ensure complete evaporation of spray
  • Avoiding compressor fatigue caused by non-uniform air flow distribution
  • Icing of air filters
  • Design with virtual prototypes
    • Calculating motion, evaporation, mixing and thermal impact of spray
    • Simulate non-uniformities of inlet coolers or heaters
Shaft and Gear Systems
  • Ensuring rotational stability
  • Avoiding interferences caused by rotation-induced strains
  • Predict critical speeds, whirl, stability, base excitation and transient responses
  • Seamless integration between analysis and optimization tools
    • Including Design for Six-Sigma
Compressors
  • Off-design performance
    • Avoiding surge over a range of power settings
    • Flow separation
  • Flow-induced vibration
  • Understand rotational and flow-induced vibration modes before building physical prototypes
  • Simple extension of quasi-1D tools to full 3D physics for design refinement
    • Turbo design environment
    • Investigation of separation and tip gap characteristics
    • Installation effects
Combustors
  • Maximizing thermal energy generation while minimizing NOx and CO emissions
  • Designing liner and other components for proper thermal load
  • Thermal stresses during “staging” or at partial loads
  • Make early design changes necessary to keep creep and thermal stresses within limits under all operational conditions
  • Optimize combustion and reduce emission levels with virtual prototyping
Turbines
  • Cooling blades sufficiently without sacrificing performance
  • Flexibility in design for partial power loads
  • Flow separation
  • Rotation and flow-induced vibration
  • Gas flow in secondary flow passages
  • Design for non-ideal fluid and structural effects of separation, heat transfer, and blade cooling
  • Flexibility of connecting blade passage analysis with secondary flow passages and cooling effects in a user environment geared towards turbomachinery simulation
  • Design for rotational stability
Acoustic Enclosures
  • Designing ventilation systems to avoid combustible mixtures caused by gas leaks
  • Improve safety and reduce design costs
    • Test and improve ventilation designs under various leakage conditions before manufacturing

FEA and CFD based Simulation for Oil & Gas Industries: Design and Optimization Service

With combination of deep knowledge and experience in FEA and CFD and sophisticated simulation tools, Esimlab engineers can solve any problem with any level of complexity.
ComponentQuestionFEA and CFD Simulation

Drilling

  • Drill head design
  • Drilling fluids
  • Horizontal wells
  • Reliable cutting operations in harsh environments
  • Rapid product development cycle
  • Efficiency of cuttings removal is critical to maximize rate of penetration (ROP)
  • Nozzle design plays a major role in cuttings removal
  • Measurements and model visualizations are difficult and expensive
  • Analysis of drill bit and inner row interaction effectiveness
  • Detailed information for the flow field and shear rate characteristics, indicating effective drilling mud removal
  • Optimization
    • Cone cleaning, bottom hole cleaning
    • Cuttings evacuation
  • Erosion prediction
  • Understanding of cutting stresses
  • Ability to design for torque related mechanical stresses
Cementing/Mudflow in Casings
  • Complex flow of non-Newtonian fluid in eccentric gaps
  • Applications are common in directional drilling, cement jobs, and wellbore completion
  • Cutting accumulations in narrow gaps
  • Inconsistent cementing in casing
  • Detailed mapping of fluid including cutting, drilling fluid through the gap
  • Understanding the effect eccentricity and fluid viscosity
  • Evaluation of flow through casing for completion, cement job
  • Study of bore holing
Offshore Structures
Wind and Wave Loading
  • Structural safety for different wave and wind loading
  • Effect of wind direction and the associated forces
  • Fire and gas dispersion
  • Detailed mapping of wind loads on all elements of the structure
  • Ability to study the effect of underwater waves
  • Fluid-induced motion (FIM) studies
  • Studies which can account for extreme loads due to storms, including the effect of wind headings
  • Enhanced understanding of the forces and flow details around helicopter decks
  • Visual illustrations of recirculation and low flow areas for smoke and pollutant dispersion concerns
Offshore Structures and Hydrodynamics
  • Multi-body hydrodynamics
  • Wind/wave forces on offshore structures
  • Global performance
  • Moorings and DP systems
  • Load transfer for structural analysis
  • Fatigue and extreme condition design
  • Structural integrity of floating/fixed platforms
  • Multi-body linear and non-linear hydrodynamics and motion
  • 3D diffraction/radiation analysis
  • Frequency domain analysis
  • Non-linear time-history simulation
  • Analysis of coupled-line dynamics
  • Code compliance
  • Launch and jack-ups
Gas Dispersion
  • Design for safety of operation and crew in case of fire and chemicals leak
  • Account for effect of wind direction, species dispersion
  • Entrainment of exhaust fumes from vessels and flares
  • Evaluate different configurations under various wind direction
  • Predict best locations for crew quarters and evacuation strategies
  • Placement of heli-deck
  • Design and placement of flares
Environmental Pollution Dispersion
  • Understand and eliminate the sources of accidental release of chemicals and pollutants
  • Predict dispersion behavior of pollutants and their downstream movement under various operating conditions and wind effects
  • Design equipment to the right specifications for different operations and for a broad range of applications
  • Simulate pollutant dispersion and what-if conditions for
    • Pool fires
    • Accidental release
    • Cloud dispersion
  • Evaluate different configuration under various wind directions
  • Design equipment to standard specification for pressure and operational requirements
  • Evaluate the structure and performance of stacks/chimneys
Blast Prevention
  • Transport of combustible  products and cargo
  • Study accident scenarios
  • Design integrity for offshore vessels and platform for both structural and safety concerns
  • Perform dynamic system response to accident scenarios
  • Evaluate structural designs and reinforcement options for sustaining blast forces
  • Understand the possible root cause of accidents
  • Evaluate the extent of damage for blast impact scenarios
LNG Plant Site Selection Operation and Design
  • Demand for natural gas has been growing over the last decades
  • Supply points are often far removed from demand centers
  • Impractical to transport in gaseous form
  • Large refrigeration plants built to liquefy the gas prior to shipping
  • Storage tanks and regasification plants built at end use locations
  • Provide efficient air cooling
  • Plant and site selection
  • Plant layout to optimize air intake temperature and velocity
  • The analysis and design is applicable to complex process plant used to produce LNG
  • Engineering simulation software can optimize the required intake temperature margins on air cooled equipment
  • Technique adds significant understanding to flow patterns and entrainment zones specifically
  • Effect of wind direction on entrainment of warmer air is estimated and can be incorporated into design modification

Wind Turbine

In order to test Wind turbine capabilities and assess the risks of failure, numerical modeling is essential for manufacturers. Physical tests are expensive and only possible in limited circumstances due to the size of wind turbines and the lack of control of the wind conditions. ESimLab offers virtual prototyping with FEA and CFD service helping wind energy companies address these challenges and understand the intricacies of design and the interactions of the sub-systems during the different environmental conditions as well as the physics of the materials to manufacture components in a cost efficient way.

Mechanical Components reliability

ESimLab’s FEA and CFD based design and optimization solutions enable the dynamic simulations of the mechanical system (gearbox, transmission) accounting for the flexibility of the supporting structure. This enables to predict the lifetime and the risk of failure for what represents the first cause of loss of Wind turbine.

Noise

Radiated noise is a major concern when planning wind turbines, including noise produced by the blades and the noise radiated from the nacelle. ESimLab proposed solution with using ESI VA ONE and MSC Actran, includes a wide range of modeling options, such as CFD with moving components, SEA (Statistical Energy Analysis), FE (Finite Element), BEM (Boundary Element Method) and hybrid FE/SEA (Finite Element/Statistical Energy Analysis), to determine near and far field radiation from panels and openings.

Wind conditions

Power fluctuation is one of main is one of the main issues in connecting wind farms to the power network. While an increasing number of utilities are requesting from the manufacturers to provide clues about the level of fluctuations, these can usually only be provided after testing full-scale prototypes in real wind conditions. ESimLab use numerical models to simulate natural wind model that matches the statistics of wind profiles and wind gusts that can be applied to realistic models of the Wind turbine to predict the power fluctuations before the first prototype is manufactured.

Manufacturing of blades

With the continuously growing dimensions of Wind turbine, the manufacturing of very large blades has become a serious challenge for the industry. The traditional physical trial-and-error process is becoming financially inefficient. ESimLab ’s FEA and CFD based Virtual Manufacturing solution with combination of advanced numerical tools offers an effective alternate approach to the optimization of the manufacturing of very large blades.

 QuestionsFEA and CFD Simulation
Wind Power
  • Straightforward linear and non-linear vibration analysis
  • Coupled physics for true virtual prototyping
    • Electromagnetics, thermal/structural, fluid/thermal
  • Optimize turbine output and placement
    • Wind speed prediction over complex terrain

Hydro power, Solar power and Biomass

As move to a more sustainable energy future, Solar Power and other renewable sources will play a key role in reducing our energy footprint and ensuring supply is sufficient for a modernizing population. ESimLab’s simulation and optimization consultants support this growing industry. Our core competencies include turbine vortex simulation and prediction, acoustic interpretation and assessment, solar farm siting, composite blade analysis and optimization, and transmission dynamics simulation and optimization.

 QuestionsFEA and CFD Simulation
   
Hydro Power
  • Turbine design
  • Minimizing flow separation in ducts under a wide range of flow rates
  • Fish protection
    • Fish-friendly turbines
    • Maximizing oxygen levels
    • Aeration
    • Fish ladders
  • Dam design
    • Seismic loads
    • Structural stability assessments
  • Understand the impact of installation effects before deployment
  • Optimize performance by determining inlet and outlet flow angles and separation patterns
  • Reduce the number of hardware prototypes needed in the pump design and installation process
  • Allows parametric investigation of scale-up effects for these extremely large pumps, which is not possible through testing, but straightforward with simulation.
Solar Power
  • Wind loads on panels and resulting vibrations
  • The search for cheaper manufacturing methods
  • Designing for thermal loads
  • Maximizing efficiency
  • Design to minimize fluid-structure interaction with virtual prototypes
  • Simulate and optimize manufacturing methods
  • Predict thermal loads to make necessary design refinements before physical prototyping
  • Maximize heat exchanger and power conversion efficiencies for solar-thermal systems
Biomass
  • Understanding the impact of fuel changes
  • Slagging, fouling, and corrosion
  • Air staging and emissions control
  • Grate combustion
  • The capability to design furnaces for a variety of fuels
    • Understanding scale-up implications
  • Understand air staging implications on emissions, heat transfer and ash
    • Access to biomass combustion models
   
Reduced Costs
Easier, earlier, quicker analysis enables design simplification, especially on unusual hull designs. Early design correction avoids costly rework in production.
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Quicker Delivery
Reduce project delays caused by late-emerging design changes and rework. Reduce contingency planning.
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Better Design Quality
Easier analysis workflow promotes more thorough design development.
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Reduce Project Risk
Begin construction work with increased confidence. Reduce the risks and contingencies in tackling unconventional designs.
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CFD based Multi-Body Dynamics simulation of Wind Turbine: Design and Optimization
Optimization of Wind Turbine Composite Fracture Mechanic Damage Design Abaqus Ansys Finite Element CFD ESIMLAB
CFD FEA ABAQUS Ansys Fluent Star-ccm+ Siemens matlab
Wind Turbine CFD based Design and Optimization Ansys Fluent Siemens Star-ccm Numeca Fine Turbo
MultiObjective Design and Optimization of Turbomachinery: Ansys Fluent, Numeca fine turbo, Siemens star-ccm+, simulia abaqus, Ls-dyna, Matlab

Considering complexity and needs to have new procedure and constitutive equation, we must try to develop new FEA and CFD based software to overcome engineering challenges.

FEA and CFD based Programming needs experience and deep knowledge in both Solid or fluid mechanics and programming language such as Matlab, Fortran, C++ and Python.

Esimlab’s engineering team use advanced methodology and procedure in programming and correct constitutive equation in solid, fluid and multiphysics environment based on our clients needs.

We use subroutine’s with programming languages such as Fortan, C and Python in CFD and FEA sofware such as Abaqus, Ansys, Fluent and Star-ccm+ to add new capability and Constitutive equation.

ESimLab use Mathematical Methods and Models for Engineering Simulation. We, focuses on numerical modelling and algorithms development for the solution of challenging problems in several engineering sectors specialized in the development of software for the numerical discretization of partial differential equations, linear algebra, optimization, data analysis, High Performance Computing for several engineering applications.

Together, we enable customers to reduce R&D costs and bring products to market faster, with confidence.

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A world-class consultancy for engineering, technology, innovation, our industry know-how and technical expertise is unrivalled.

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We use advanced virtual engineering tools, supported by a team of technical experts, to global partners in different industries.

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Our Software team is made up of developers, industry experts and technical consultants ensuring we can respond to each client’s individual needs

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Advanced Simulation & Analysis

Calling upon our wide base of in-house capabilities covering strategic and technical consulting, engineering, FEA and CFD based manufacturing and analytical software development – we offer each of our clients the individual level of support they are looking for, providing transparency, time savings and cost efficiencies.

Real World Simulation

ESimLab engineers participate in method development, advanced simulation work, software training and support. Over experiences in engineering consulting and design development enables ESimLab’s engineering team to display strong/enormous client focus and engineering experience. The ESimLab team supports engineering communities to leverage CFD-FEA simulation softwares and methodologies. It leads to the creation of tailored solutions, aligned with the overall product development process of ESimLab clients.

metal forming simulation: ansys abaqus simufact forming
Metal Forming Simulation
Automotive Engineering: Powertrain Component Development, NVH, Combustion and Thermal simulation, Abaqus, Ansys, Ls-dyna, Siemens Star-ccm EsimLab
Crash Test and Crashworthiness
Finite Element and CFD Based Simulation of Casting esi procast
Casting Simulation
Additive Manufacturing: FEA Based Design and Optimization with Abaqus, ANSYS and Nastran
Additive Manufacturing
MultiObjective Design and Optimization of Turbomachinery: Ansys Fluent, Numeca fine turbo, Siemens star-ccm+, simulia abaqus, Ls-dyna, Matlab
Design of Turbomachinery
CFD Heat Thermal simulation: Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab
CFD Heat Transfer
Fluid Structure Interaction FSI with Ansys Abaqus, Fluent Star-ccm Comsol
Hydrodynamics
Fluid Structure Interaction FEA CFD FSI Abaqus Ansys Comsol LS-dyna Wind Turbine EsimLab
Fluid Strucure Interaction
Exhaust Acoustics and vibration: ESI va one, msc actran, abaqus, ansys, fluent, star-ccm , nastran
Acoustics & Vibration
Aerodynamic Simulation CFD Ansys Fluent Siemens Star-ccm+ Numeca xflow cradle
Aerodynamic Simulation
Ansys Fluent, Siemens Star-ccm+ Numeca fine , Avl Fire, Matlab
Combustion Simulation
Multiphase Flow Simulation Abaqus, Ansys, Fluent, Siemens Star-ccm+, Matlab
MultiPhase Flow Simulation
Fatigue Simulation Abaqus Ansys FE-Safe NCode Design Life FEA Finite Element ESimLab
Creep & Fatigue
Multibody dynamics MBD Abaqus, Ansys Fluent, Star-ccm+, Ls-dyna, Matlab, fortran , C++, Python
Multi-Body Dynamics (MBD)
composite impact simulation , Comsol Abaqus, Ansys, Fluent, Siemens Star-ccm+, Aerospace and defenceMatlab, Fortran, Python CFD FEA
Composite Design
welding FEA Simulation Simufact Welding ESI Sysweld Abaqus Ansys ESIMLAB
Welding Simulation
Optimization of Wind Turbine Composite Fracture Mechanic Damage Design Abaqus Ansys Finite Element CFD ESIMLAB
Multi-Objective Optimization
CFD and FEA based Fortran, C++, Matlab and Python Programming
Advanced Fortran, C++, Matlab & Python Programming