3D Modelling and Stress Analysis for Inert Gas & CAF System

Project Overview:

Elixir Engineering  was awarded to perform 3D Modelling and Stress Analysis for Inert Gas & CAF System

Seagreen Wind Energy Limited (SWEL) has received full consent from Marine Scotland and relevant local authorities for its wind farm and offshore transmission elements. Positioned approximately 27 km from the Angus coastline on the East Coast of Scotland, the Seagreen Offshore Wind Farm aims to harness renewable energy efficiently and sustainably.

Offshore Substation Platform (OSP) Design
Electric power generated by the wind farm will be collected on an Offshore Substation Platform (OSP) through a network of 66 kV array cables. The OSP’s primary function is to transform power from 66 kV to 220 kV using a high-capacity grid transformer, facilitating seamless export to the onshore substation for further distribution.

EPC Contract and Fire Safety Systems
M/s Petrofac has been awarded the EPC Contract for the "SEA GREEN OFFSHORE WIND FARM PROJECT" and is overseeing the development of the Offshore Wind Farm platform. The project’s scope includes critical fire safety systems for electrical equipment and components, utilizing an Inert Gas (IG) System and a Compressed Air Foam (CAF) System.

Subcontracting and Engineering Partners
M/s Petrofac subcontracted the EPC of the IG and CAF Systems to M/s TYCO Fire & Security UAE LLC. For this, TYCO engaged Elixir Engineering to perform the design, engineering, and 3D modeling of skids and piping networks for both the IG and CAF Systems. These systems adhere strictly to BS EN 13480 standards, ensuring high-quality design and installation for offshore environments.

Execution Methodology for IG & CAF System Design & Stress Analysis

• Comprehensive Review of System Documentation
  • Review P&ID for IG and CAF Systems to ensure precise alignment with design objectives.
  • Assess Process Design Parameters and Conditions to validate operational efficiency and safety.
• Precise Demand and Capacity Calculations
  • Perform IG and CAF demand calculations for each room, structured in a detailed 3-tier analysis.
  • Re-validate the required number of cylinders and confirm dimensions for optimized space utilization.
• Specification and Material Selection
  • Prepare detailed Piping and Valve Material Specifications to ensure quality and compliance.
  • Execute pipe wall thickness calculations according to EN-13480 standards for reliable system integrity.
  • Select pipe fittings in line with EN-1092 design practice for durability and compatibility.
• Creation of Essential Documentation and System Lists
  • Develop a Line List for clear mapping of system connections and components.
  • Review Petrofac's existing 3D Model for Platform Arrangement and Electrical Equipment to ensure alignment with the current project scope.
• Advanced PDMS Administration and Routing Design
  • Create Administrative Modules in PDMS to streamline Piping Component and Skid Arrangement workflows.
  • Generate preliminary pipe routing layouts for IG and CAF Systems in 3 tiers, ensuring adequate sprinkler coverage.
• Comprehensive Support Drawings and Schedule Development
  • Prepare detailed Support Drawings and Support Schedules to reinforce system stability.
  • Identify critical piping setups for targeted Pipe Stress Analysis.
• Accurate Pipe Modeling and Preliminary Analysis
  • Model piping components as per General Arrangement (GA) drawings in specialized software.
  • Define fluid and material properties and environmental conditions according to project specifications.
• Stress Analysis for System Load Conditions
  • Perform rigorous Stress Analysis across multiple load cases, including Thermal, Sustained, Hydro, Occasional, and Transportation.
  • Validate stress, deflection, and displacement values within allowable limits for structural integrity.
• Strategic Skid Nozzle Load Assessment
  • Include Skid Nozzle Loads in the allowable check, finalizing anchor points inside and outside the skid for system stability.
• Iterative Analysis for Compliance Assurance
  • Re-perform analysis if stress or deflection limits are exceeded, adjusting pipe support and routing as needed.
  • Extract and submit the Stress Summary and Restraint Summary upon validation.
• 3D Model Review and Clash Detection
  • Participate in 3D Model Reviews at 30%, 60%, and 90% stages, preparing comprehensive review reports.
  • Ensure clash detection for piping networks, verifying constructability with other arrangements.
• Structural Load Coordination and Verification
  • Define and provide Piping Loads (Axial, Vertical & Friction) at all support locations to the Structural Team.
  • Confirm that structural arrangements can sustain the specified component loads for long-term safety.
• Comprehensive Report Preparation and Submission
  • Compile a complete report with detailed stress analysis results, including software summaries.
  • Submit the finalized 3D model alongside GA drawings, Isometric drawings, Spool preparation, and Bulk MTO for client review
• Additional Procurement Support and As-Built Modelling
  • Provide continuous support to vendors, addressing procurement queries.
  • Deliver As-Built 3D model support based on redline markups, ensuring a seamless transition to final construction.
• Deliverables
  • GA Drawings & Isometric Drawings: Precision layouts for project implementation.
  • Support Schedules: Primary and secondary support specifications for construction.
  • Bulk Material Take-Off (MTO): Comprehensive list of materials for procurement.
  • 3D Model Submission: Complete as-built and preliminary models for verification.

Piping Engineering and Design Documentation Deliverables

• Pipe Wall Thickness Calculation
  • Detailed calculations ensuring precise wall thickness for optimal pressure management and flow efficiency.
• Pipe Material Specification
  • Material specifications are tailored to withstand specific environmental and operational conditions, enhancing durability.
• Valve Material Specification
  • Comprehensive details on valve materials aligned with system requirements, maximizing resilience and compatibility.
• Line List
  • A complete line list outlining each pipe segment, ensuring clarity in identification and compliance with design standards.
• Primary Support Schedule
  • Schedule of primary supports for critical load management and stability, essential for safe and durable system operations.
• Secondary Support Schedule
  • Secondary support schedules complement primary supports, providing added reinforcement and longevity.
• Piping Stress Analysis Report
  • In-depth stress analysis report, ensuring piping system integrity under various load and thermal conditions.
• Extracted GA Drawing
  • Accurate GA drawings that offer an overview of pipe arrangement for seamless system understanding.
• Extracted Piping Isometric Drawings
  • Detailed isometric drawings enable precise layout visualization and facilitate installation and maintenance.
• Extracted Sprinkler Coverage Drawing
  • Clear sprinkler coverage drawings for safety assurance and effective fire control measures.
• Painting Specification
  • Comprehensive painting specifications to ensure corrosion resistance and compliance with aesthetic and safety standards.
• Pipe Spool Drawings
  • Spool drawings detailing pipe fabrication, enabling accurate and efficient assembly and installation processes.
• Transportation Philosophy
  • A logistics-focused transportation philosophy outlining efficient methods for moving materials and completed structures.
• Bulk MTO (Material Take Off)
  • Comprehensive Bulk MTO listing all materials required, streamlining procurement and resource allocation.

Conclusion

The Seagreen Offshore Wind Farm Project exemplifies Elixir Engineering's expertise in delivering precise 3D modeling and stress analysis for critical fire safety systems like Inert Gas (IG) and Compressed Air Foam (CAF) piping. By meeting stringent BS EN 13480 standards and ensuring robust system integrity, Elixir Engineering has contributed to advancing offshore safety and reliability.

Why Choose Elixir Engineering?

As a trusted partner for offshore engineering solutions, Elixir Engineering brings:
✅ Proven expertise in 3D Modelling, Piping Design, and Pipe Stress Analysis
✅ Compliance with international standards, including BS EN 13480
✅ Advanced software utilization, including PDMS for efficient design workflows
✅ Experience with offshore facilities such as Offshore Substation Platforms (OSP)
✅ Commitment to safety, quality, and efficiency in complex engineering environments

Ready to Enhance Your Offshore Safety Systems?
Explore our in-depth expertise in piping design, 3D modeling, and stress analysis for offshore fire safety systems. Contact Elixir Engineering to discuss how we can support your project’s engineering needs with cutting-edge solutions and exceptional results.