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CAE Simulation Driven Product Development for Expandable Liner Hanger
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
- Sensors - Haptic Sensors
Applicable Industries
- Cement
- Oil & Gas
Applicable Functions
- Product Research & Development
- Quality Assurance
Use Cases
- Digital Twin
- Virtual Reality
Services
- System Integration
- Testing & Certification
The Challenge
Baker Hughes, a leading supplier of oilfield services, products, technology, and systems to the worldwide oil and natural gas industry, was facing several environmental and technological challenges. These included operating in offshore deep-water and Arctic environments, dealing with shale and hydraulic fracturing, and adhering to stricter environmental and safety regulations. Technological challenges included drilling deeper wells, dealing with extreme pressures and temperatures, and handling unconventional geological variations. The company was also tasked with the development of an Expandable Liner Hanger System, a mechanical system used to attach a liner string to the bottom of a previously run casing string during wellbore construction operations within the oil and gas industry. This system is used to hang heavier liner under extreme deep-water environment, subsalt plays, or deviated wells.
About The Customer
Baker Hughes is a leading supplier of oilfield services, products, technology, and systems to the worldwide oil and natural gas industry. The company operates globally with approximately 60,000 employees and is headquartered in Houston, Texas. In 2013, the company reported a revenue of $22.4 billion USD. Baker Hughes is known for its innovative solutions to the challenges faced by the oil and natural gas industry, particularly in the areas of offshore deep-water drilling, Arctic environments, shale and hydraulic fracturing, and adherence to strict environmental and safety regulations.
The Solution
To overcome these challenges, Baker Hughes integrated CAE Simulation with Product Development. This approach maximized the probability of product success, product quality & reliability, customer satisfaction, and employee morale. It also minimized the development cost and time by eliminating waste. The integration of CAE Simulation with PDM helped to develop a product with a “Right First Time” strategy, understand the design limitations, constraints, assembly interactions in early stages of development, and reduce the number of prototypes. The company followed a seven-step CAE Simulation methodology that included FE model building, verification, initial validation, refinement or rebuilding, optimization, reliability assessment/improvement, and iteration. This methodology was used to accelerate the development of the Expandable Liner Hanger System design, predict its hanging capacity and sealing integrity, optimize its performance, and improve its reliability.
Operational Impact
Quantitative Benefit
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