CASE STUDY
50 Configurations Overnight, 70% Cost Savings
Client: Mid-market offshore engineering firm (Houston)
Industry: Oil & Gas
Location: Gulf of Mexico deepwater field
Duration: 2 weeks
Software: OrcaFlex, Python
Analysis Type: Steel Catenary Riser sensitivity
A 25-engineer offshore engineering firm faced a common challenge: their largest client requested a comprehensive riser sensitivity study with 50 configuration variations to optimize touchdown point location, hang-off angle, and buoyancy module placement. Traditional manual approach would require 100+ engineer-hours and 2-3 weeks of calendar time.
Each OrcaFlex model required 30 minutes of manual setup to modify geometry, buoyancy, and environmental parameters. With 50 variations, setup alone would consume 25 engineer-hours.
Post-processing each simulation required 30 minutes to extract maximum stress, fatigue damage, dynamic amplification factors, and create comparison plots. Another 25 engineer-hours for extraction.
Only two senior engineers had OrcaFlex expertise. Running sensitivity studies meant pulling them from other billable projects, creating opportunity cost beyond direct labor.
The operator needed results within 2 weeks to meet their FEED milestone. Traditional approach would barely fit the schedule with no margin for error or iteration.
| Model Setup (50 configs x 30 min) | 25 hours |
| Simulation Runtime | 40 hours |
| Results Extraction (50 configs x 30 min) | 25 hours |
| Report Compilation | 10 hours |
| Total Engineer Hours | 100 hours |
| Traditional Cost (@ $500/hr) | $50,000 |
Python scripts read the design matrix Excel file and automatically generated all 50 OrcaFlex model files with correct geometry, buoyancy distribution, and environmental loading combinations.
All 50 simulations queued and executed overnight. Engineers submitted jobs at 6 PM; results were waiting at 8 AM the next morning.
Post-processing scripts extracted all required outputs (max stress, fatigue damage, effective tension, curvature) and populated standardized comparison tables automatically.
Final deliverable compiled automatically with sensitivity plots, optimization recommendations, and configuration comparison matrix ready for client review.
# Batch OrcaFlex Sensitivity Analysis
import orcaflex_batch as ofx
# Load design matrix from Excel
design_matrix = ofx.load_matrix("sensitivity_matrix.xlsx")
# Generate all 50 model configurations
for config in design_matrix:
model = ofx.generate_model(
base_model="SCR_baseline.dat",
tdp_offset=config['tdp_offset'],
hangoff_angle=config['hangoff_angle'],
buoyancy_length=config['buoyancy_length'],
current_profile=config['current']
)
ofx.queue_simulation(model)
# Run overnight batch
ofx.run_batch(parallel_jobs=8)
# Extract results and generate report
results = ofx.extract_all_results()
ofx.generate_sensitivity_report(results)
| Metric | Traditional Approach | A&CE Automation | Improvement |
|---|---|---|---|
| Model Setup Time | 25 hours | 2 hours (script development) | 92% reduction |
| Results Extraction | 25 hours | 30 minutes (automated) | 98% reduction |
| Report Compilation | 10 hours | 1 hour (review only) | 90% reduction |
| Total Engineer Hours | 100 hours | 8 hours | 92% reduction |
| Calendar Time | 2-3 weeks | 3 days | 85% faster |
| Project Cost | $50,000 | $15,000 | 70% savings |
Received design matrix with 50 configuration variations. Adapted existing automation framework to client's baseline OrcaFlex model. Validated single-run results against manual analysis.
Submitted all 50 simulations at 5 PM. Jobs ran overnight on 8 parallel cores. All simulations completed by 6 AM with no failures.
Automated post-processing extracted all results. Generated sensitivity plots and comparison tables. Delivered final report by 2 PM--10 days ahead of traditional schedule.
"We submitted the design matrix Friday afternoon and had validated results Monday morning. This would have taken our team 2-3 weeks. The cost savings let us include additional load cases the operator originally cut from scope."
Following this project, the client has engaged A&CE for:
Annual savings: Estimated $200K+ in engineering hours
| Riser Type: | Steel Catenary Riser (SCR) |
| Water Depth: | 5,500 ft (1,680 m) |
| Sensitivity Parameters: | TDP offset (+/-500 ft), hang-off angle (+/-3 deg), buoyancy length (+/-200 ft) |
| Environmental Cases: | 10-year, 100-year hurricane, loop current |
| Load Combinations: | Operating, extreme, survival |
See how batch processing can deliver 60-80% cost savings for your next sensitivity study.
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