Customer: Italian company Drillmec S.p.A.
Object of optimization: The tower of mobile unit (see Fig. 1).The unit is intended for carrying out of technological operations during drilling, well development, repair, running and pulling-out of tubing strings and drill strings.
Fig.1 – Object of optimization
Goals of optimization: It is necessary to reduce the tower weight and preserve its strength.
Parameters of optimization: Geometrical structure of tower, parametres of beams (14 parametres in total). It means that to reduce the weight of the tower we can modify its structure and beams parameters.
Process of simulation:
a. We created the 3D parametric model of the tower with the famous finite element analysis software ANSYS (Fig. 2);
Fig.2 – 3D model of tower in the ANSYS system
b. Every type of beam has its identification number. Besides, every type of beam has a set of geometrical parametres according to its ID number (Fig. 3 and 4);
Fig.3 – Types of beams their identification numbers
Fig.4 – Types of beams with their geometrical parametres and ID numbers
c. We created two configuration parametres of tower. These parametres change the number of sections in the tower structure (Fig. 5 and 6);
Fig.5 – The configuration parameter n1
Fig.6 – The configuration parameter n2
Now, to get any configuration of the tower in ANSYS software the user must modify the tower parametres. We calculated the number of possible alternate designs of the tower construction – it is 210000000000000000000000.
d. We created four calculations models according to various loading conditions (Fig. 7,8,9,10).
Fig.7 – The wind pressure (frontal direction)
Fig.8 – The wind pressure (lateral direction)
Fig.9 – Pulling out mode
Fig.10 – Installation mode
Integration with optimization technology:
We performed integration of four calculation models (Fig. 7,8,9,10) with the optimization software – IOSO NM (Fig. 11).
Fig.11 – The optimization scheme
Each model has an input file with geometrical parametres of the tower and an output file with the results of simulation. During the first stage the IOSO NM starts calculation for all models; the models perform necessary simulation and create output files with results. During the second stage the IOSO NM performs analyses of output files and modifies parameters (change 3D model of the tower) in input files. Then this cycle repeats many times until optimal solutions are found.
The best solution was found for 380 iteration (Fig. 12) - but we cannot show you the 3D image of the best solution because we have no rights:
Fig.12 – Weight reduction graph
As a result, we reduced the tower weight by more than 27%!
Interesting facts of this optimization:
- 14 independent parametres
- 10 restriction (constrains)
- 210000000000000000000000 possible alternate designs of the tower construction
The best solution of tower construction was found for 380 iteration – but just imagine, how much time it iakes the designer of the tower to find the best solution out of 210000000000000000000000 possible alternate designs without our help? – we can say thousands of years......this is the reason why you should think about our services!