REPORT

ON

SIX MONTHS INDUSTRIAL TRAINING

AT

SYNERGIE INSTITUE OF TRAINING & MODERN

MANUFACTURERES

Submitted to
PUNJAB TECHNICAL UNIVERSITY, JALANDHAR
In partial fulfillment of the requirements for the award of the Degree of
Bachelor of Technology in Mechanical Engineering

By

NAME OF STUDENT
Univ. Roll No. .............................

Under the guidance of

Academic Tutor Industrial Tutor
. ..
(Designation) (Designation)

Department of Mechanical Engineering

CHANDIGARH GROUP OF COLLEGES JHANJERI
,MOHALI (PUNJAB)

1
 CERTIFICATE OF ORIGINALITY OF WORK

I Pankaj Sharma Univ. Roll No. 1348220 student of Mechanical Engineering Branch, 2017
Year have undergone the six month industrial training at Modern Manufacture
& Synergie Institute of Training and Development. I have done the following projects during
my training period: -
1. Soildworks

2. Ansys Workbench

3. Design of Plastic Products

4. Molds

I hereby declare that the work is an original one and has not been submitted earlier to this

university or any other institution for fulfillment of the requirement of a course of study.

NAME OF STUDENT
(Academic Tutor) Univ. Roll No.:1348220
Branch:ME
Semester:8th
CGC,JHANJERI
(Punjab)

2
 CHANDIGARH GROUP OF COLLEGES JHANJERI
,MOHALI (PUNJAB)

Department of Mechanical Engineering

Performa for Evaluation of Student by Industrial Tutor

Industrial Unit :
Name of Industrial Tutor :

Name of Student :
Branch :
Univ. Roll No. :

Title of Project(s) :

Marks Awarded :
As per PTU, Jalandhar, part of the total marks are to be awarded by the industry. Industrial Tutor is
therefore requested to award the marks as per the table given below:

Regularity/ Discipline/ Project Project Viva-

Criteria Punctuality Behaviour Work Report Voce
Total

Max. marks 20 20 20 20 20 100

Marks
Awarded

Comments :

INDUSTRIAL TUTOR

3
 ACKNOWLEDGEMENT

I would like to place on record my deep sense of gratitude to Er. Harshit Dewan ,Industrial
coordinator, Modern Manufacturers for his generous guidance, help, useful suggestions and
continuous encouragement.

I also wish to extend my thanks to MR. Sumit Kumar and other workers for guiding and
providing the knowledge related to machinery and processes.

I am extremely thanks to Prof. Rajneesh Talwar, Principal Chandigarh Group of Colleges

Technical Campus Jhanjeri, Mohali (Punjab) and management for support and
encouragement.

I am extremely thankful to Dr. Kishor Kulkarni, HOD, CGCTC Jhanjeri, Mohali for
valuable suggestions and motivation.

I am also thankful to Mr.Sarabjit Singh and Mr. Sachin Sharma, Training and placement
officers, Chandigarh Group of Colleges Technical Campus Jhanjeri, Mohali (Punjab) for
providing the opportunity to get the knowledge.

Signature of Student

4
 ABOUT THE TRAINING
Software Training :- I did my software training at Synergie Institute of Training &
Development , Mohali for two months. Where I learnt about Soildworks and Ansys.
In soildworks the major content area that I covered are Drawings, 3D Modeling and
Assembly. In Ansys I leant about Static Structural and Hand calculations

Industrial Training :- I completed industrial training at Modern Manufacturers

where I come to know about industry work. In Modern Manufacturers I learnt Design
and Development of Plastic Products, Design Consultancy and Mold/ Die Design.

5
 CONTENTS

Titles Pages No
1. Abstract 7
2. Industrial training &Introduction 8
3. Mold 10
4. Mold basics 12
5. Types of Molds 15
6. Mold base & Cavities 18
7. Part Ejection 19
8. Sprues & Runner 20
9. Gates 22
10.Software Training & Introduction 23
11.Introduction to CAD 26
12.Types of CAD 27
13.Soildworks 29
14.Part of Drawing 33
15.Ansys Workbench 36
16.FEA 38
17.Methods of FEA 39
18.Meshing 40
19.Forces used in Ansys 45
20.Wind load 47
21.Deformation 48
22.Reference 49

1.

6
 ABSTRACT
The main aim of Industrial Training is to expose the student to the industrial technical
problems to which he is to be exposed in the future life. In an organization where Making
Things Right in the first instance is the driving motto, perfection and accuracy are
inevitable.

I have worked for two months at Synergie Institue of Training & Development and four
months in Modern Manufacturers. I have the honour to work as a student of CGCTC
JHANJERI to the extent of my technical capabilities. Doing this tenure, I have acquired a
sufficient knowledge on Soildworks and Ansys and How design is made and produced in
Industry.

I remained actively associated with one of the most demanding field of mechanical. The
time spent in Industry has really proved to be very useful and will remain enduring
throughout my professional career. Brief outline of the work is covered under the
following heads.
We would like to thank our industry guide Er.HARSIT DEWAN who guided us in the
making of a successful work at industry.
We would like to express our gratitude to Dr. KISHORE KULKARNI (H.O.D. ME
Deptt), who motivated us and helped us for industrial training.

7
 Solidworks
Ansys
Design and Development of Plastic Products
8Mold/ Die Design

In conclusion, I must say that the industrial Training has helped me to enhance my working
skills & stamina and to further enlighten me to enter a new phase of life after completion of
the degree program

SECTION A

INDUSTRIAL TRAINING
INTRODUCTION TO COMPANY: - The present work of

experimental investigation was carried out at M/S Modern Manufacturers in collaboration

with SG Engg Works .The company is located at 478, sector-82, Industrial Area, JLPL,
Mohali.. The industry was certified with ISO 9001: 2000 standard in 2004. This industry is
small-scale industry. The total covered area is 40120 sq. feet.
A number of equipments/machines are used for manufacturing the products are listed in
Table 1.2.
Table 1.2: Equipment/Machinery Installed

Name of Equipment / Machine Quality

CNC Turning 01

8
 CNC Milling 02
Capstan and Turret lathe 01
Drilling Machine 02
Milling Machine 01
Surface Grinder 02
EDM 01

Initially all the major production work of industry was carried out through conventional lathe
machines and milling machines. This resulted in overall production being restricted to
approximately 4-5 dies units per annum. In 2008, the industry was modernized and CNC
machines were purchased with a view to increase the production capacity. This resulted in the
overall production capacity increasing to above 8-9 dies units in a single year. Presently the
industry has an installed production capacity of about more 10 dies units. This has been
achieved by continuing improvements in both the installed machinery as well as by
increasing the skills of the work force.
The industry employs over 15 people, which include engineers, technicians, accountants,
skilled draftsmen and unskilled labours. The complete organization structure and the persons
working on different levels are shown in Fig 1.5.

9
Fig.1.5: Organization Chart

Managing Director

General Manager Administrator Manager

Production Engineer

Accountant Clerk

General Foreman Supervisor

Manufacturing Section Inspection Store

M/S Modern Manufacturers are manufacturing plastics and rubber products using mouldsl.
These products include a variety of rubber and plastics products according to customers
requirements. Some of the important products are shows in Fig 1.6.

10
 Fig : Platic products of industry

MOLD:-

Mold or Die steel is a cold work steel. It is an ideal and widely used type of hardened steel
which is very economical and dependable for gauging, cutting and blanking tools as well as
can be relied for hardness and good cutting performance. The principle characteristics that are
responsible for the popularity of this material are its ability to retain accurate dimensions at
elevated temperatures, abrasion resistance, toughness and negligible deformation during the
hardening process. It has good wear and rust resisting and better machinability property. It is
commercially machined with conventional method of machining process. Other properties
such as thermal conductivity of die steel at 200C is 30 W/(m. K). Density at 20oC is 7700
g/cm3. Modulus of elasticity is approximately about 2.1x 105 MPa.

Applications of Die Steel

Die steel is a class of carbon and alloy steels commonly used to make tools. Tool steels offer
high hardness, resistance to wear, high toughness and resistance to softening at elevated
temperatures generally attained with a higher content of carbon and other alloying elements.
It is the most widely used die steel material for the manufacture of press tools; cutting dies
and punches for blanking, trimming, flanging and forming operations.

11
 Die steel

Mold basics
At the most basic level, molds consist of two main parts: the cavity and core. The core forms
the main internal surfaces of the part. The cavity forms the major external surfaces.
Typically, the core and cavity separate as the mold opens, so that the part can be removed.
This mold separation occurs along the interface known as the parting line.

The parting line can lie in one plane corresponding to a major geometric feature such as the
part top, bottom or center-line, or it can be stepped or angled to accommodate irregular part
features. Choose the parting-line location to minimize undercuts that would hinder or
prevent easy part removal.

Undercuts that cannot be avoided via reasonable adjustments in the parting line require
mechanisms in the mold to disengage the undercut prior to ejection.

12
Types of Molds
Two-Plate Mold
The two-plate mold, the most common mold configuration, consists of two mold halves that
open along one parting line (see figure 7-1). Material can enter the mold cavity directly via a
sprue gate, or indirectly through a runner system that delivers the material to the desired
locations along the parting line. The movable mold half usually contains a part-ejection
mechanism linked to a hydraulic cylinder operated from the main press controller.

13
 TWO PLATE MOLD

Three- Plate Mold

The three-plate mold configuration opens at two major locations instead of one. Figures 7-
2A through 7-2C show the mold-opening sequence for a typical three-plate mold. Typically,
a linkage system between the three major mold plates controls the mold-opening sequence.
The mold first opens at the primary parting line breaking the pinpoint gates and separating
the parts from the cavity side of the mold. Next, the mold separates at the runner plate to
facilitate removal of the runner system. Finally, a plate strips the runner from the retaining
pins, and parts and runner eject from the mold.

14
 THREE PLATE MOLD

Unlike conventional two-plate molds, three-plate molds can gate directly into inner surface
areas away from the outer edge of parts: an advantage for center-gated parts such as cups or
for large parts that require multiple gates across a surface. Disadvantages include added mold
complexity and large runners that can generate excessive regrind. Also, the small pinpoint
gates required for clean automatic de-gating can generate high shear and lead to material
degradation, gate blemish, and packing problems. Because of the high shear rates generated
in the tapered runner drops and pinpoint gates, three plate molds are not recommended for
shear-sensitive materials such as Cadon SMA and materials with shear-sensitive colorants or
flame retardants.

STACK MOLD
Another configuration, the stack mold, reduces the clamp force required by multi-cavity
molds. Typically, multiple cavities are oriented on a single parting line and the required
clamp force is the sum of the clamp needed by each cavity plus the runner system. In stack
molds, cavities lie on two or more stacked parting lines. The injection forces exerted on the
plate separating parting lines cancel, so the resulting clamp force is the same as for just one
parting line. Stack molds produce more parts per cycle than would otherwise be possible in a
given size molding press.

15
 PRODUCTION OF PLASTIC INJECTION STACK

MOLDS

MOLD BASES AND CAVITIES

The mold base comprises the majority of the bulk of an injection mold. Standard off-the-shelf
mold bases are available for most molding needs. Typical mold bases are outfitted with a
locating ring and provisions for a sprue bushing in the stationary or A half of the mold
and an ejector assembly in the moving B half. Both halves come with clamp slots to affix
the mold in the press. The B half has holes to accommodate bars that connect the press
ejection mechanism to the ejector plate in the mold.

Leader pins projecting from corners of the A half align the mold halves. Return pins
connected to the ejector plate corners project from the mold face when the ejection
mechanism is in the forward (eject) position.

As the mold closes, the return pins retract the ejector plate (if not retracted already) in
preparation for the next cycle Mold cavities, here meaning core and cavity sets, can be
incorporated in the mold three ways: they can be cut directly into the mold plates, inserted in
pieces into the mold base, or inserted as complete cavity units.

Cutting cavities directly into the mold base can be the most economical approach for large
parts and/or parts with simple geometries. When doing so, select the mold base steel
carefully. The physical properties of standard mold base steels may be inadequate for heavy-
wear areas or critical steel-to-steel contact points. Use inserts made of appropriate materials
in these areas

16
Assembling the cavity in the mold base lets you select different metals for the various cavity
components, optimizing the molds durability and performance. It also simplifies and speeds
repairs for worn or damaged cavity components, especially if you maintain spare mold pieces
for vulnerable components. Additionally, assembling the cavities from pieces can simplify
component fabrication. Some of the drawbacks of mold-base cavity assemblies include high
initial mold cost, less-efficient mold cooling, and potential tolerance accumulation problems
with the cavity components. Cavity units offer many of the same advantages found in mold-
base cavity assemblies. Because many cavity units are face-mounted in the mold base for
quick removal, worn or damaged cavities are easily replaced. Some mold bases are designed
to accept standard cavity-insert units for rapid part change while the mold is still in the
molding press. These cavity units typically have independent cooling circuits and ejector
mechanisms that automatically connect to the mold-base ejector system.

MOLDING UNDERCUTS
Undercuts, part features that prevent straight ejection at the parting line, tend to increase
mold complexity and lead to higher mold construction and maintenance costs. Whenever
feasible, redesign the part to avoid undercuts. Minor part design changes can often eliminate
problematic undercuts in the mold. For example, adding through holes can give access to the
underside of features that would otherwise be undercuts . Likewise, simple modifications
enable the mold to form a hole in the sidewall with bypass steel rather than with a side-action
mechanism. For more information on design alternatives to avoid undercuts, see the section
on undercuts in Chapter 2 of this manual. Undercut features that cannot be avoided through
redesign require mechanisms in the mold to facilitate ejection. These types of mechanisms
include side-action slides, lifter rails, jiggler pins, collapsible cores and unscrewing
mechanisms.
Side-action slides use cam pins or hydraulic (or pneumatic) cylinders to retract portions of
the mold prior to ejection. Cam-pin-driven slides retract as the mold opens (see figure 7-5).
As the mold closes, the cam pins return the slides to their original position for the next
injection cycle. Slides driven by hydraulic or pneumatic cylinders can activate at any time
17
during the molding cycle, an advantage in applications requiring the slides to actuate prior to
mold opening or closing. Shallow undercuts can often be formed by spring-loaded lifters or
lifter rails attached to the ejector system. These lifters move with the part on an angle during
mold opening or ejection until the lifter clears the undercut in the part. A variation on this
idea, the jiggler pin , has angled surfaces to guide the pin away from the undercut during
ejection, then return it to the molding position as the ejector system retracts.

Features such as internal threads, dimples, slots, or grooves on the inside of holes or caps
may require collapsible cores. These complex cores are made in segments that collapse
toward the center as they retract during mold opening (see figure 7-8). Available in a variety
of standard sizes from various mold component suppliers, these specialty cores are typically
modified to produce the desired undercut shape. The number and complexity of individual
core components limit the minimum size of collapsible cores. Collapsible cores are rarely
used for inside diameters less than 0.625 inches. Unscrewing mechanisms are commonly
used to produce internal threads. A variety of devices can drive the rotation of the threaded
cores, including rack and- pinion devices actuated by mold opening, motors, or hydraulic
cylinders; or motor-driven gear and chain mechanisms. The mold design should include
provisions to lubricate the various moving parts of the unscrewing mechanism. Slides, cams,
collapsible cores, and unscrewing mechanisms add to the cost and complexity of the mold, as
well as the mold maintenance cost. Investigate options that avoid complex mold mechanisms.
Clever part design can often eliminate troublesome undercuts. Some undercuts are most

18
economically produced as secondary operations, particularly if they can be automated or
performed within the cycle at the press.

COLLAPSIBLE CORE

PART EJECTION
Typically, molds have ejector systems built into the moving B half. The ejection unit of the
molding press activates these systems. Rods linking the press-ejector mechanism to an ejector
plate in the mold enable the press controller to control the timing, speed, and length of the
ejection stroke. Reverse injection molds eject parts from the stationary side of the mold via
independent ejection mechanisms operated by springs or hydraulic cylinders. This
configuration facilitates direct injection onto the inside or back surface of cosmetic parts. The
added complexity of reverse-injection molds adds to the mold cost. Specialized ejection
components, such as knockout (KO) pins, KO sleeves, or stripper plates, project from the
mold ejector plate to the part surface where they push the part out of the mold. These topics
are discussed in this section. The common, round knockout pin provides a simple and
economical method for part ejection. Manufactured with high surface hardness and a tough
core, these inexpensive, off-the-shelf items resist wear and breakage. The mold maker selects
the desired diameter and shank length from the vast array of standard sizes and machines it to
fit. The fit of the ejector pin into the round ejector hole must be held to a tight tolerance to
avoid flash. Worn ejector holes can be refitted with 0.005 inch oversized pins available for
standard diameters. Ejector blades, KO pins with a rectangular cross section, operate much
the same as standard round pins, but can be more difficult to fit and maintain. Typically, they
are used on the edges of ribs or walls that are too thin for standard round pins. KO pins
usually extend to the surfaces lying parallel to the mold face. If KO pins push on angled
surfaces, consider adding grooves to the part design to prevent pin deflection. KO pins
19
extending to narrow walls and edges can be stepped or positioned, so that only a portion of
the pin contacts the molded part (see figure 7-9). This avoids using small-diameter KO pins
that are more difficult to maintain and can deflect or bend. KO pins leave witness marks,
small indentations or rings where the pin contacts the part that could be objectionable on
cosmetic surfaces. Additionally, they can read-through to the opposite surface if the part is
difficult to eject, or if the ejector area is too small. Many factors determine the amount of
ejector area needed, including the part geometry, mold finish, material-release characteristics,
and part temperature at the time of ejection. To prevent damage during ejection, thin-walled
parts generally require larger ejectors and greater ejector area than comparable parts with
thicker walls.

PART EJECTION IN MOLD

20
SPRUES, RUNNERS AND GATES
Standard horizontal clamp presses deliver molten resin to the mold through a hole in the
center of the stationary press platen. A material delivery system usually consisting of a
sprue, runners, and gates then leads the resin through the mold and into the cavity. These
components of the material delivery system are discussed in this section.

SPRUES
The sprue, oriented parallel to the press injection unit, delivers resin to the desired depth into
the mold, usually the parting line. Though they can be cut directly into the mold, sprue
bushings are usually purchased as off-the-shelf items and inserted into the mold (see figure 7-
18). The head end of the sprue bushing comes pre-machined with a spherical recess
typically 0.5- or 0.75 inch radius to receive and seal off against the rounded tip of the
press injection nozzle. The sprue bushing flow-channel diameter typically tapers larger
toward the parting line at a rate of 0.5 inch per foot. This eases removal of the molded sprue.
The sprue orifice size, the diameter at the small end, comes standard in odd 1/32s from 5/32
to 11 /32 inch.Sprue design can affect molding efficiency and ease of processing. In many
molds, the greatest restriction to material flow occurs at the press nozzle tip and sprue orifice.
These areas see the highest volumetric flow rate of the entire system. An excessively small
sprue orifice can generate large amounts of material shear and lead to material degradation,
cosmetic problems, and elevated filling pressure. The problem can be worse in the press
nozzle tip because the tip orifice must be slightly smaller than the sprue orifice to avoid
forming an undercut. The volumetric flow rate used during filling largely determines the
correct sprue orifice size. Shot size and filling speed, as well as the flow properties of the
specific resin, govern the required flow rate.

21
Runners
Unlike sprues, which deliver material depth-wise through the center of the mold plates,
runners typically transport material through channels machined into the parting line. Runner
design influences part quality and molding efficiency. Overly thick runners can lengthen
cycle time needlessly and increase costs associated with regrind. Conversely, thin runners can
cause excessive filling pressures and related processing problems. The optimum runner
design requires a balance between ease of filling, mold design feasibility, and runner volume.
Material passing through the runner during mold filling forms a frozen wall layer as the mold
steel raw heat from the melt. This layer restricts the flow channel and increases the pressure
drop through the runner. Round cross-section runners minimize contact with the mold surface
and generate the smallest percentage of frozen layer cross-sectional area. As runner designs
deviate from round, they become less efficient (see figure 7-20). Round runners require
machining in both halves of the mold, increasing the potential for mismatch and flow
restriction. A good alternative, the round-bottomed trapezoid, requires machining in just
one mold half. Essentially a round cross section with sides tapered by five degrees for
ejection, this design is nearly as efficient as the full-round design. The runner system often
accounts for more than 40% of the pressure required to fill the mold. Because much of this
pressure drop can be attributed to runner length, optimize the route to each gate to minimize
runner length. For example, replace cornered paths with diagonals or reorient the cavity to
shorten the runner. Runner thickness has a direct effect on filling pressure, cycle time,
packing, and runner volume. The optimum runner diameter depends on a variety of factors
including part volume, part thickness, filling speeds and pressure, runner length, and material
viscosity.

For sufficient packing, make runners at least as thick as the part nominal wall thickness.
Increase runner thickness for long runners and runners subjected to high volumetric flow
rates.
Amorphous resins typically require larger runners than semi crystalline resins.

Hot Runner Injection Mold

22
GATES
Except for special cases, such as sprue-gated systems which have no runner sections, gates
connect the runner to the part. Gates perform two major functions, both of which require the
thickness to be less than the runner and part wall. First, gates freeze-off and prevent
pressurized material in the cavity from backing through the gate after the packing and holding
phases of injection.

Applied pressure from the press injection unit can stop earlier in the cycle, before the part or
runner system solidifies, saving energy and press wear-and-tear. Secondly, gates provide a
reduced thickness area for easier separation of the part from the runner system. A variety of
gate designs feed directly into the parting line. The common edge gate typically projects from
the end of the runner and feeds the part via a rectangular gate opening.

When designing edge gates, limit the land length, the distance from the end or edge of the
runner to the part edge, to no more than 0.060 inch for LANXESS plastics. Edge gates
generate less flow shear and consume less pressure than most self-degating designs. They are
therefore preferred for shear-sensitive materials, high-viscosity materials, highly cosmetic
applications, and large-volume parts.

Fan gates and chisel gates, variations of the edge gate, flare wider from the runner (see figure
7-29) to increase the gate width. Chisel gates can provide better packing and cosmetics than
standard edge gates on some thick-walled parts. Like the standard edge gate, the land length
for fan gates should not exceed 0.060 inch at the narrowest point.

Chisel gates taper from the runner to the part edge with little or no straight land area. Edge
gates can also extend to tabs (see figure 7-30) that are removed after molding or hidden in
assembly. These tab gates allow quick removal of the gate without concern about gate
appearance.

23
 SECTION-B
SOFTWARE TRAINING

ABOUT THE COMPANY:- SYNERGIE Institute of Industrial Training &

Development, Mohali is a training division of NIPUNN ENGINEERING AS (An European
Company) and commits itself for the successful implementation of the prestigious
development projects and conducting trainings of international standards to lead the vision of
development of individuals to develop competences/resources required in engineering.

NIPUNN Engineering AS is basically a Norwegian Engineering, Procurement and

Construction contractor catering its services to subsea, offshore/Onshore Oil & Gas and
marine industry globally. NIPUNN offers complete solutions to its customers from concept
stage to delivery, commissioning, start-up. NIPUNN having its hub office in Lier, Norway
also have subsidiary offices in Ivory Coast (Africa) & Mohali, India.

NIPUNN Engineering sees an opportunity in training & skill development and to address the
same, we have launched SYNERGIE (Skill Development Division of NIPUNN) to develop
and promote competence in R&D sector in India. Training & Development is one of the
topmost visions of the Synergie in India and rightly so, considering the fact that India has
highest youth population of which is unskilled and unemployed. SYNERGIE is therefore
committed to develop university students, recently graduates and corporate professionals for
the availability of skilled workforce for the industry and services sectors to improve quality
of products and services.

SYNERGIE provide services in the following areas:

Detailed Design & Engineering

Education

Research & Development

Consulting

24
Synergie delivers training on wide range of software training programs and also accelerate
and certify the skills with standardized material through every stage of training. The
training can be considered as add on advantage which will enhance the knowledge of students
in an addition to what they learn in their curriculum. All our software courses are industry
oriented.

The entire software Training Program is prepared and shall be delivered by industrial and
well experienced Engineers in field. Training will not only enhance the knowledge of the
students but also nourish them to opt for a pertinent. All skilled development and Software
Training programs are designed and developed in association with Norwegian and European
companies to fulfill competence required to highly paid oil & gas industry in coming years.

The Training program has its lecture content distributed into engineering practices in
engineering (i.e., translating the engineering sciences into engineering design methods,
including following regulated engineering standards) and knowledge synthesis (enabled
through a major design project). Training program also requires a written live project reports,
technical presentations and the use of state-of-the-art software used in engineering industry.

Figure: - Mechanical Modeling

It is no hidden fact that there are limited job opportunities for fresh engineering graduates,
partially due to skewed demand & supply ratio and also because of lack of industrial

25
exposure. To worsen the situation, we observe that students are not even aware about the
opportunities in Research & Development industry that is an ideal start to build their career.

Also, i have observed is that the institutes, in which they are undergoing studies, though are
imparting very good theoretical knowledge but the practical experiences and exposure of the
students towards implementing that theoretical knowledge into practical work is not up to the
mark. The training sessions which are included in the course curriculum of university are not
utilized properly by students to enhance their practical & industrial skills.

So, the main purpose of this training is to impart practical knowledge and to make the
students understand how to apply their vast knowledge database that they have gathered
during being in your prestigious institute. How to apply the knowledge they have gathered to
solve real world engineering problems with the help of modern technology /softwares.

TOOLS & SERVICES OFFERED BY SYNERGIE

Multidiscipline engineering: - SYNERGIE undertakes multidiscipline as well as single

discipline projects and value every project assigned to it with equal importance, irrespective
of size or the quantum of work. Our strength lies in executing projects in core engineering
disciplines like structural, piping, mechanical, process, layout, instrumentation & control,
management and documentation.

(a) Structural:- SYNERGIEs structural group encompasses of specialists with rich

engineering experience in structural design and development simultaneously endeavoring to
uphold international standards in quality. We make our every best effort to rationalize
product design, turnaround time as well as ensure cost effectiveness. Engineering firms have
an added advantage with us in the sense that we offer our services for the smallest part of
your project and can engage us at any stage.

Design and engineering of offshore platforms and top-sides

Design, engineering and analysis of skids and modular structures
Stress and fatigue analysis of structures using finite element analysis

26
 Design documentation (GA/ fabrication drawings, material specifications, procedures,
manuals etc.)

Introduction to CAD

Computer-aided design (CAD), also known as computer-aided drafting and design (CADD),
is the use of computer technology for the development of design and design-documentation.
Computer Aided Design describes the way in which technology is folded into a design
process. Computer Aided Drafting describes the process of drafting with a computer. CADD
software, or environments, provides the user with input-tools for the purpose of streamlining
design processes; drafting, documentation, and manufacturing processes. CADD output is
often in the form of electronic files for print or machining operations. The development of
CADD-based software is in direct correlation with the processes it seeks to economize;
industry-based software (construction, manufacturing, etc.) typically uses vector-based
(linear) environments whereas graphic-based software utilizes raster-based (pixelated)
environments.

CADD environments often involve more than just shapes. As in the manual drafting of
technical and engineering drawings, the output of CAD must convey information, such as
materials, processes, dimensions, and tolerances, according to application-specific
conventions.

CAD may be used to design curves and figures in two-dimensional (2D) space; or curves,
surfaces, and solids in three-dimensional (3D) objects. CAD is an important industrial art
extensively used in many applications, including automotive, shipbuilding, and aerospace
industries, industrial and architectural design, prosthetics, and many more. CAD is also
widely used to produce computer animation for special effects in movies, advertising and
technical manuals. The modern ubiquity and power of computers means that even perfume
bottles and shampoo dispensers are designed using techniques unheard of by engineers of the
1960s. Because of its enormous economic importance, CAD has been a major driving force
for research in computational geometry, computer graphics (both hardware and software),
and discrete differential geometry.

The design of geometric models for object shapes, in particular, is often called computer-
aided geometric design (CAGD).

27
Types of CAD

There are several different types of CAD. Each of these different types of CAD systems
requires the operator to think differently about how he or she will use them and he or she
must design their virtual components in a different manner for each.

There are many producers of the lower-end 2D systems, including a number of free and open
source programs. These provide an approach to the drawing process without all the fuss over
scale and placement on the drawing sheet that accompanied hand drafting, since these can be
adjusted as required during the creation of the final draft.

3D wireframe is basically an extension of 2D drafting. Each line has to be manually inserted

into the drawing. The final product has no mass properties associated with it and cannot have
features directly added to it, such as holes. The operator approaches these in a similar fashion
to the 2D systems, although many 3D systems allow using the wireframe model to make the
final engineering drawing views.

3D "dumb" solids (programs incorporating this technology include AutoCAD) are created in
a way analogous to manipulations of real world objects. Basic three-dimensional geometric
forms (prisms, cylinders, spheres, and so on) have solid volumes added or subtracted from
them, as if assembling or cutting real-world objects. Two-dimensional projected views can
easily be generated from the models. Basic 3D solids don't usually include tools to easily
allow motion of components, set limits to their motion, or identify interference between
components.

3D parametric solid modeling requires the operator to use what is referred to as "design
intent". The objects and features created are adjustable. Any future modifications will be
simple, difficult, or nearly impossible, depending on how the original part was created. One
must think of this as being a "perfect world" representation of the component. If a feature was
intended to be located from the center of the part, the operator needs to locate it from the
center of the model, not, perhaps, from a more convenient edge or an arbitrary point, as he
could when using "dumb" solids. Parametric solids require the operator to consider the
consequences of his actions carefully.

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Some software packages provide the ability to edit parametric and non-parametric geometry
without the need to understand or undo the design intent history of the geometry by use of
direct modeling functionality. This ability may also include the additional ability to infer the
correct relationships between selected geometry (e.g., tangency, concentricity) which makes
the editing process less time and labour intensive while still freeing the engineer from the
burden of understanding the models design intent history. These kind of non-history based
systems are called Explicit Modelers. The first Explicit Modeling system was introduced to
the world at the end of 80's by Hewlett-Packard under the name Solid Designer. This CAD
solution, which released many later versions, is now sold by PTC as "Co Create Modeling"

Draft views are able to be generated easily from the models. Assemblies usually incorporate
tools to represent the motions of components, set their limits, and identify interference. The
tool kits available for these systems are ever increasing; including 3D piping and injection
mould designing packages.

Mid-range software are integrating parametric solids more easily to the end user: integrating
more intuitive functions (Sketch Up), using the best of both 3D dumb solids and parametric
characteristics (Vector Works), making very real-view scenes in relative few steps
(Cinema4D) or offering all-in-one (formZ).

Top end systems offer the capabilities to incorporate more organic, aesthetics and ergonomic
features into designs (Catia, Generative Components). Freeform surface modeling is often
combined with solids to allow the designer to create products that fit the human form and
visual requirements as well as they interface with the machine.

Effects using CAD

Beginning in the 1980s Computer-Aided Design programs reduced the need of draftsmen
significantly especially in small to mid-sized companies. Their affordability and ability to run
on personal computers also allowed engineers to do their own drafting work eliminating the
need for entire departments. In Todays world most if not all students in universities do not
learn drafting techniques because they are not required to do so. The days of mechanical
drawings are almost obsolete.[4] Universities such as New Jersey Institute of Technology no

29
longer require the use of protractors and compasses to create mechanical drawings, instead
there are several classes that focus on the use of CAD software such as Pro Engineer or
IDEAS-MS.

Another consequence had been that since the latest advances were often quite expensive,
small and even mid-size firms often could not compete against large firms who could use
their computational edge for competitive purposes.[citation needed] Today, however,
hardware and software costs have come down. Even high-end packages work on less
expensive platforms and some even support multiple platforms. The costs associated with
CAD implementation now are more heavily weighted to the costs of training in the use of
these high level tools, the cost of integrating a CAD/CAM/CAE PLM using enterprise across
multi-CAD and multi-platform environments and the costs of modifying design work flows
to exploit the full advantage of CAD tools. CAD vendors have effectively lowered these
training costs. These methods can be split into three categories:

Improved and simplified user interfaces. This includes the availability of role specific tailor
able user interfaces through which commands are presented to users in a form appropriate to
their function and expertise.

Enhancements to application software:- One such example is improved design-in-context,

through the ability to model/edit a design component from within the context of a large, even
multi-CAD, active digital mock-up.

User oriented modeling options. This includes the ability to free the user from the need to
understand the design intent history of a complex intelligent model.

2. SOFTWARES/TOOLS LEARNT
During training period till now we learnt and practiced different softwares of Autodesk like AutoCAD,
Inventor, Naviswork resp. Brief description of all these softwares is mentioned below

2.1 SOLIDWORKS

SolidWorks (stylized as SOLIDWORKS), is a solid modeling computer-aided design (CAD) and computer-aided
engineering (CAE) computer program that runs on Microsoft Windows. SolidWorks is published by Dassault
Systmes.

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According to the publisher, over 2 million engineers and designers at more than 165,000 companies used
SolidWorks as of 2013. Also according to the company, fiscal year 201112 revenue for SolidWorks totaled $483
million.

SolidWorks Corporation was founded in December 1993 by Massachusetts Institute of Technology graduate Jon
Hirschtick. Hirschtick used $1 million he had made while a member of the MIT Blackjack Team to set up the
company. Initially based in Waltham, Massachusetts, USA, Hirschtick recruited a team of engineers with the goal of
building 3D CAD software that was easy-to-use, affordable, and available on the Windows desktop. Operating later
from Concord, Massachusetts, SolidWorks released its first product SolidWorks 95, in November 1995. In 1997
Dassault, best known for its CATIA CAD software, acquired SolidWorks for $310 million in stock.

SolidWorks currently markets several versions of the SolidWorks CAD software in addition to eDrawings, a
collaboration tool, and DraftSight, a 2D CAD product.

SolidWorks was headed by John McEleney from 2001 to July 2007 and Jeff Ray from 2007 to January 2011. The
current CEO is Gian Paolo Bassi from Jan 2015. Gian Paolo Bassi replaces Bertrand Sicot, who is promoted Vice
President Sales of Dassault Systmes Value Solutions sales channel.

Modeling method

SolidWorks is a solid modeler, and utilizes a parametric feature-based approach to create models and assemblies.
The software is written on Parasolid-kernel.

Parameters refer to constraints whose values determine the shape or geometry of the model or assembly. Parameters
can be either numeric parameters, such as line lengths or circle diameters, or geometric parameters, such as tangent,
parallel, concentric, horizontal or vertical, etc. Numeric parameters can be associated with each other through the use
of relations, which allows them to capture design intent.

Design intent is how the creator of the part wants it to respond to changes and updates. For example, you would want
the hole at the top of a beverage can to stay at the top surface, regardless of the height or size of the can. SolidWorks
allows the user to specify that the hole is a feature on the top surface, and will then honor their design intent no
matter what height they later assign to the can.

Features refer to the building blocks of the part. They are the shapes and operations that construct the part. Shape-
based features typically begin with a 2D or 3D sketch of shapes such as bosses, holes, slots, etc. This shape is then
extruded or cut to add or remove material from the part. Operation-based features are not sketch-based, and include
features such as fillets, chamfers, shells, applying draft to the faces of a part, etc.

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 Screen shot captured from a SolidWorks top-down design approach

Building a model in SolidWorks usually starts with a 2D sketch (although 3D sketches are available for power
users). The sketch consists of geometry such as points, lines, arcs, conics (except the hyperbola), and splines.
Dimensions are added to the sketch to define the size and location of the geometry. Relations are used to define
attributes such as tangency, parallelism, perpendicularity, and concentricity. The parametric nature of SolidWorks
means that the dimensions and relations drive the geometry, not the other way around. The dimensions in the sketch
can be controlled independently, or by relationships to other parameters inside or outside of the sketch.

In an assembly, the analog to sketch relations are mates. Just as sketch relations define conditions such as tangency,
parallelism, and concentricity with respect to sketch geometry, assembly mates define equivalent relations with
respect to the individual parts or components, allowing the easy construction of assemblies. SolidWorks also
includes additional advanced mating features such as gear and cam follower mates, which allow modeled gear
assemblies to accurately reproduce the rotational movement of an actual gear train.

Finally, drawings can be created either from parts or assemblies. Views are automatically generated from the solid
model, and notes, dimensions and tolerances can then be easily added to the drawing as needed. The drawing module
includes most paper sizes and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC).

2.1.2 File format

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SolidWorks files (previous to version 2015) use the Microsoft Structured Storage file format. This means that there
are various files embedded within each SLDDRW (drawing files), SLDPRT (part files), SLDASM (assembly files)
file, including preview bitmaps and metadata sub-files. Various third-party tools (see COM Structured Storage) can
be used to extract these sub-files, although the subfiles in many cases use proprietary binary file formats.

2.1.3 3-D Modeling

After learning the concept of 2-D sketches we learnt how to do 3-D modeling in SolidWorks 2010 by using
different features like extrude, revolve etc. and also sketched and converted many drawings into 3-D
models. Some of the snapshots of 3-D models are shown below:-

2.1.4 Assembling:-

SolidWorks have this phenomenal feature of assembling different parts together .So we can sketch parts
individually convert them into 3-D models and then assemble them using different constraints and fix them
together to make one single assembly. Some of the assemblies we made during practice session are
specified below.

2.1.5 GENERAL ARRANGEMENT DRAWING:-

Arrangement drawings include information about the self-contained units that make up the system: table of
parts, fabrication and detail drawing, overall dimension, weight/mass, lifting points, and information
needed to construct, test, lift, transport, and install the equipment.

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2.1.6 PARTS OF A DRAWING
a. Title Block: The title block contains the drawing number and all the information required to identify the
part or assembly represented. Approved military prints will include the name and address of the
Government Agency or organization preparing the drawing, the scale, the drafting record, authentication,
and the date.
b. Revision Block: Each drawing has a revision block which is usually located in the upper right corner.
All changes to the drawing are noted in this block. Changes are dated and identified by a number or letter.
If a revision block is not used, a revised drawing may be shown by the addition of a letter to the original
number.
c. Drawing Number: All drawings are identified by a drawing number. If a print has more than one sheet
and each sheet has the same number, this information is included in the number block, indicating the sheet
number and the number of sheets in the series.
d. Reference Numbers and Dash Numbers: Reference numbers that appear in the title block refer to
other print numbers. When more than one detail is shown on a drawing, dashes and numbers are frequently

34
used. If two parts are to be shown in one detail drawing, both prints will have the same drawing number
plus a dash and an individual number such as 7873102-1 and 7873102-2.
e. Scale: The scale of the print is indicated in one of the spaces within the title block. It indicates the size
of the drawing as compared with the actual size of the part. Never measure a drawing--use dimensions.
The print may have been reduced in size from the original drawing.
f. Bill of Material: A special block or box on the drawing may contain a list of necessary stock to make an
assembly. It also indicates the type of stock, size, and specific amount required.
2.1.7. CONSTRUCTION LINES
a. Full Lines: Full lines represent the visible edges or outlines of an object.

b. Hidden Lines: Hidden lines are made of short dashes which represent hidden edges of an object.
c. Center Lines: Center lines are made with alternating short and long dashes. A line through the center of
an object is called a center line.
d. Cutting Plane Lines: Cutting plane lines are dashed lines, generally of the same width as the full lines,
extending through the area being cut. Short solid wing lines at each end of the cutting line project at 90
degrees to that line and end in arrowheads which point in the direction of viewing. Capital letters or
numerals are placed just beyond the points of the arrows to designate the section.

35
e. Dimension Lines: Dimension lines are fine full lines ending in arrowheads. They are used to indicate
the measured distance between two points.

f. Extension Lines: Extension lines are fine lines from the outside edges or intermediate points of a drawn
object. They indicate the limits of dimension lines.

g. Break Lines: Break lines are used to show a break in a drawing and are used when it is desired to
increase the scale of a drawing of uniform cross section while showing the true size by dimension lines.
There are two kinds of break lines: short break and long break. Short break lines are usually heavy, wavy,
semiparallel lines cutting off the object outline across a uniform section. Long break lines are long dash
parallel lines with each long dash in the line connected to the next by a "2" or sharp wave line.

2.1.8. Welding Symbols:

Welding cannot take its proper place as an engineering tool unless means are provided for conveying the
information from the designer to the workmen. Welding symbols provide the means of placing complete
welding information on drawings. The scheme for symbolic representation of welds on engineering
drawings used in this manual is consistent with the "third angle" method of projection.

The joint is the basis of reference for welding symbols. The reference line of the welding symbol (as
shown in figure) is used to designate the type of weld to be made, its location, dimensions, extent, contour,
and other supplementary information. Any welded joint indicated by a symbol will always have an arrow
side and another side. Accordingly, the terms arrow side, other side, and both sides are used herein to
locate the weld with respect to the joint.

The tail of the symbol is used for designating the welding and cutting processes as well as the welding
specifications, procedures, or the supplementary information to be used in making the weld. If a welder
knows the size and type of weld, he has only part of the information necessary for making the weld.

The process, identification of filler metal that is to be used, whether or not peening or root chipping is
required, and other pertinent data must be related to the welder. The notation to be placed in the tail of the
symbol indicating these data is to be establishing by each user. If notations are not used, the tail of the
symbol may be omitted.

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2.2 ANSYS WORKBENCH

ANSYS v 13.0: - ANSYS v 13.0 is software developed by Ansys Inc. Pennsylvania (USA).
ANSYS offers engineering simulation solution sets in engineering simulation that a design
process requires. Companies in a wide variety of industries use ANSYS software. The tools
put a virtual product through a rigorous testing procedure (such as crashing a car into a brick
wall, or running for several years on a tarmac road) before it becomes a physical object.
So in Ansys v 13.0 we are learning on static structural module. Here is brief information
about static structural module of Ansys v 13.0
Structural Analysis Software

The ANSYS v 13.0 structural analysis software suite is trusted by organizations around the
world to rapidly solve complex structural engineering problems with ease.

ANSYS Structural software addresses the unique requirements of pure structural analysis
without the need for extraneous tools. The product delivers all the power of nonlinear
structural capabilities as well as all linear capabilities to deliver high-quality, reliable
structural simulation results.

Figure 9: - A analyzed structure

37
FEA analysis (finite element) tools from ANSYS provide the ability to simulate every
structural aspect of a product:

Linear static analysis that simply provides stresses or deformations.

Modal analysis that determines vibration characteristics.
Advanced transient nonlinear phenomena involving dynamic effects and complex
behaviors.

All users, from designers to advanced experts, can benefit from ANSYS structural analysis
software. The fidelity of the results is achieved through the wide variety of material models
available, the quality of the elements library, the robustness of the solution algorithms, and
the ability to model every product from single parts to very complex assemblies with
hundreds of components interacting through contacts or relative motions.

Figure 10: - A still from Ansys V 13.0 home screen

ANSYS FEA tools also offer unparalleled ease of use to help product developers focus on the
most important part of the simulation process: understanding the results and the impact of
design variations on the model.

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Finite Element Analysis:-Finite element of analysis or (FEM) is a program that uses the finite
element method to analyses a material or object and find how applied stress will affect the material or
design FEA can help determine any points of weakness in a design before it is manufacture. The
analysis is done by creating a mesh of points in the shape of the object that contains information about
the material and the object at each point for analysis.

There are two common methods of solving problems within finite element programs. These methods
are the h-method and the p-method. With each method the geometry to be analyzed is broken into
finite elements. The difference between the two methods lies in how these elements are treated. The
h-method uses many simple elements, whereas the p-method uses few complex elements.

Methods in FEA:-

H-method
P-method

H-method: - The simplest type of element has a linear shape function. This means that the
function for displacement across the element is linear. With the h-method, the shape function of
the element will usually be linear. In an actual part, it is quite uncommon for the displacement to
vary linearly. The h-method accounts for this by increasing the number of elements. More
accurate information is obtained by increasing the number of elements.

The name for the h-method is borrowed from mathematics. The finite element method was
originally developed by the work of mathematicians, particularly those who worked in the
area of numeric integration. The variable h is used to specify the step size in numeric
integration. This variable name carried over into finite element analysis.

The upside to only using linear shape functions is that it easy to solve the element equations.
The downside is that the strain across the element must be constant. Strain is defined as the
change in displacement divided by the original length. Since the displacement function is
linear, strain must be constant throughout the element. Stress is derived from strain by using
the modulus of elasticity, which is a constant. Therefore, stress in an element with a linear
shape function must be constant.

39
If a part is modeled with a very course mesh, then the stress distribution across the part will be very
inaccurate. In order to more accurately find the stress distribution across the part, we will need to
increase the number of elements

To save computing time, it is most beneficial to increase the number of nodes only in the
areas where more nodes are necessary. If a large section of the part is under a constant stress,
then only a few elements will be required. This will save a lot of computing time.

The number of elements must only be increased in areas where the stress is changes quickly
over a small distance. This could be the area where a load is applied, around a hole, or where
geometry is changing. In these areas the stress can change dramatically over a very small
distance. It is up to the user to determine where more elements will be required to obtain an
accurate solution.
P-method: - With p-elements, once a mesh is created, it does not need to be changed. Rather
than changing the number of elements, the shape function of the element will be changed to
handle non-linear displacement functions. In areas where the stress is changing quickly, the
complexity of the shape function is changed rather than changing the size of the elements.
More accurate information is obtained by increasing the complexity of the shape function.

The p in p-method stands for polynomial. Increasing the polynomial order of the shape
function changes the accuracy of the p-method. This allows a very complex displacement
function to be approximated across a large element.

If the shape function is second order, then the strain across the element will be linear. Using
the same example stress distribution as before the results would be represent by the bars in
Figure 3.

If this does not accurately reflect the strain in the element, then the order of the shape function can be
increased to third order. This will allow strain over the element to be a second order function. The
results would be represented by the bars

Often with p-method programs, the polynomial order can be increased as high as nine. This
allows for an eighth order strain function over the element.

40
The upside to the p-method is that high ordered shape function can approximate the strain
distribution in an element very closely. The downside is that it requires a lot of computing
time to solve a high order shape function. In order to save computing time, it is beneficial to
only increase the polynomial order in the elements where more complex shape functions are
needed.

Summary: - In terms of computing time, the h and p methods will have about the same
requirements. In each case you are solving for about the same number of nodes. The h-
method increases the number of nodes by adding more elements. The p-method increases the
number of nodes by increasing the order of the shape function.

Terms Related to FEA:-

Element
Contacts
Mesh
Equivalent Stress (von Mises stress)
Degree of freedom

Meshing: - Mesh generation is one of the most critical aspects of engineering simulation.
Too many cells may result in long solver runs, and too few may lead to inaccurate results.
ANSYS Meshing technology provides a means to balance these requirements and obtain the
right mesh for each simulation in the most automated way possible. ANSYS Meshing
technology has been built on the strengths of stand-alone, class-leading meshing tools. The
strongest aspects of these separate tools have been brought together in a single environment
to produce some of the most powerful meshing available.

Features:-

It provides a scalable solution.

Solve model complexity. Desired mesh quality and type and time available to perform
meshing.
Provide efficient tools to quickly generate a high quality mesh to simplify the physics.

41
 The highly automated meshing environment makes it simple to generate the following
mesh types:

Tetrahedral
Hexahedral
Hexahedral core
Body fitted Cartesian

Degree of freedom: - the degree of freedom can be defined as the minimum number of
independent coordinates that can specify the position of the system completely.

Material of the CIU skid: - I have structural steel as the default material for the skid of CIU.
As it is easily available. Also it possesses good strength & corrosion resistive properties.
Functional loads: - Self-Weight: -These include the weight of structural members, including
main framework and secondary structures and plating and grating. Protective coatings, etc.
paints and passive fire protection materials.
Dry Equipment: - These include the weight of equipments and bulk weights e.g.
Pressure vessel, pumps, piping, mechanical equipment, cables and tanks.
Loads during operation:-
Fluid loads: - These will include the operating inventory of vessels, tanks and pipes.
Some vessels and systems will be subject to hydro test during fabrication and possibly on
station.
Live loads: - These arise on the structure from personnel, maintenance, temporary lay
down or storage. No weight growth contingency is applied to live loads.

Load cases: - In CIU skid analysis; we have to do different load cases. Those are listed
below:

1. Operational case.

2 Transportation case with wind in transverse direction.

3. Transportation case with wind in longitudinal direction.

4 Earthquake case.

42
5. Lifting case.

OPERATIONAL CASE: - Various loads & masses acting on the skid are to be given in
mechanical module of static structural. So in this case we have given various masses acting
on the skid and the various other loads those will act on the skid.

Meshing of the model: - Meshing is the process of breaking up the model into smaller
pieces that can be solved by the software using advanced matrix math and then merged
together to show the correct result for the whole. Figure 5 shows the meshed CIU skid
model.

Mesh size: - Mesh size is the size of the elements that we have to set before the solution.
Generally we take coarse size mesh. After that we refine the results in order to analyze the
results difference. In CIU skid I have given 10 mm size to the every element.

Figure 15: - Meshing of the CIU skid

Various masses acting on the skid:-

Tank weight
Pump weight
Heater Weight

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 Drip tray
Miscellaneous
Grating weight

Various forces acting on the skid: -

standard earth gravity

Wind forces

After giving the total equipment weight acting on the system, I had given 0 displacements to
the pads of the CIU skid model I all three directions in order to fix it. Then I gave standard
earth gravity. Along these I had also given the wind force acting in the transverse direction
taking as a worst case according to the calculations done on wind speed as shown in .

Solution: - The results obtained from Ansys v 13.0 are in the form of numbers as well as in
animated form. Figure 8 is showing Total deformation & Equivalent stress in animated form:
-

Figure 18: - Results showing total deformation & equivalent stress

44
LIFTING CASE: - In lifting case we analyze the stress produced in the skid when it is lifted
up from ship or from other platform in order to transport it or to fix it on its proper location.
Lifting is done with the help of crane or other lifting device with the cables attached to the
body. So in Ansys to give lifting effect to the structure we insert springs on the exact
locations as shown in the figure. To give springs on proper location we have to make lifting
pads on which the springs got fitted. Lifting pads are made in geometry of Ansys 13.0
software.

In lifting case the masses acting on the system remains the same as in operational case. I have
assumed that the 4 spring of stiffness 100000000 N/mm will lift the CIU skid.

Forces acting on the CIU skid during lifting: - only acceleration will act on the CIU skid
when we lift it. I took a value of acceleration = 2.5G (2.5 times of standard earth gravity).

45
 Figure 20: - Acceleration acting during lifting

Solution:-

I have only checked maximum von Mises stress produced in the structure. We do not
consider total deformation as we considered in operational case.

46
 Figure 22: - Elements under von Mises stress

From results it was found that the element is not fully fail under von Mises stress, So the
design is safe in case of lifting.

TRANSPORTATION CASES: -

Transportation loads will also act on the structure of the CIU. Transportation loads are
calculated from the maximum heave, pitch & roll motions of the ship on which the assembly
is carried to the offshore location.

WIND LOADS: -

This case is done on the Chemical injection unit when it is transported from the fabrication
site to the offshore location. The wind loads are calculated from the wind speeds of that area
where the project will be mounted actually & also from the speeds of wind in the sea from
where it is to be transported. From wind speeds by applying different formulas the wind load
is calculated in terms of force. Then that force is applied in appropriate directions in order to
get the results. Transportation loads will also act on the structure .

TRANSPORTATION CASE WITH WIND IN TRANSVERSE DIRECTION: -It is the

load of wind which will act on the CIU structure when the wind is flowing along the
transverse direction of the CIU structure. Long side of the structure is taken as transverse side

47
of that structure. In wind loading the speed of wind is taken as the 47m/s as the design speed.
From this speed wind load in terms of force is calculated by considering various factors.
Weight of the equipment is kept as it. During transportation accelerations will also act on the
structure. Those are also applied to the structure.

Wind load after appropriate calculations is applied on the CIU structure. In this we always
take the worst take of failing. So in this case tanks situated on the CIU skid are having the
maximum area exposed to wind than any other equipment. So the wind load is applied on the
CIU tank as a remote force at the centroid of exposed surface area of the tank.

Figure 23: - Wind & acceleration loads acting on the CIU skid

Note: - In transverse case the wind will act in Z direction according to the geometry of the
object.

48
Results: -

Deformation: -

Figure 24: - Deformation induced in the CIU Skid structure

The deformation produced in the CIU skid structure is 10.216 maximum. So it is well
with in the allowable limits of L/500 that is 15.02. So our deformation is well below the
allowable criteria so our structure is safe.

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7. References: -

www.nipunn.com
www.synergie.no
www.wikipedia.org
www.autodesk.com
www.solidworks.in

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