Altair > Case Studies > CAE Simulation Driven Product Development for Expandable Liner Hanger

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

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 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.

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

The integration of CAE Simulation with Product Development resulted in several operational benefits for Baker Hughes. It maximized the probability of product success, product quality & reliability, customer satisfaction, and employee morale. It also helped the company understand the design limitations, constraints, and assembly interactions in the early stages of development, thereby reducing the risk of costly design changes later in the product development process. The “Right First Time” strategy enabled by this approach reduced waste and minimized development cost and time. The seven-step CAE Simulation methodology provided a structured approach to product development, ensuring that all aspects of the product design were thoroughly tested and optimized.

Quantitative Benefit