Finite Element Analysis (FEA) Services

Our engineers have worked on large structural skids, pipe racks, and support frames that operate under heavy mechanical loads and variable foundation conditions.

One challenge involved a modular skid system where uneven pile reactions caused stress concentrations in the lifting frame. Through nonlinear contact modeling and optimization of beam cross-sections, we achieved proper load redistribution and reduced the total structural weight by 12% without compromising safety factors.

In another project, we evaluated concrete foundations supporting rotating equipment to ensure compliance with vibration and deflection limits, resolving alignment issues that had previously led to repeated field rework.

Our team has supported oil & gas and energy operators in assessing pressure vessels, storage tanks, and process equipment under extreme conditions. Using nonlinear finite element simulations, we evaluated buckling, fatigue, and weld integrity to ensure API 579 Fitness-for-Service compliance.

In one case, a vertical heat exchanger exhibited localized shell distortion near the saddle supports. We performed a detailed elastic–plastic FEA including weld residual stresses and identified that excessive clamp loads during installation were the cause. After re-qualifying the support design, the client avoided unplanned downtime and extended the unit’s service life by over 5 years.

Similarly, for a large storage tank subjected to settlement and wind loading, we provided local shell reinforcement recommendations that restored its structural stability within regulatory limits.

Dynamic simulations are critical when components experience fluctuating loads, machinery-induced vibration, or potential seismic events.

For one offshore compressor skid, the piping system exhibited excessive pulsation due to compressor harmonics. Our vibration analysis, including modal and transient response studies, identified resonant frequencies and guided a redesign of supports and dampers, reducing vibration amplitudes by over 60%.

In another project, we performed a nonlinear explicit dynamic analysis to evaluate the response of an equipment enclosure under blast pressure. The results enabled the client to optimize material thickness and stiffener spacing, achieving weight savings while maintaining safety margins required by blast design codes.

Several clients have engaged ENA2 after repeated failures in welded pressure components and rotating parts. In one case, we conducted a fatigue assessment on a process pipeline that experienced cyclic thermal loading. By integrating temperature-dependent material models and performing strain-life fatigue analysis, we pinpointed the exact zones prone to crack initiation.

The redesign, which included geometry smoothing and material upgrades, resulted in a 40% improvement in fatigue life.

We have also supported forensic investigations involving fracture propagation in riser clamps and lifting lugs. Through fracture mechanics FEA and stress-intensity evaluations, we helped determine root causes, validate corrective actions, and prevent recurrence of similar failures in service.

ENA2 specializes in simulating coupled thermal and structural behaviors where temperature changes significantly influence stress response.

In a project involving a gas-fired process heater manifold, extreme temperature gradients led to repeated flange leaks and gasket failures. We developed a fully coupled thermal-stress model that captured the transient heating cycles and identified differential expansion effects. Design modifications to the flange geometry and bolt preload achieved a 70% reduction in thermal stress range and eliminated recurring leakage incidents.

For another client, we performed fluid–structure interaction (FSI) analysis to evaluate flow-induced vibrations in a heat exchanger tube bundle. The study accurately predicted the vibration modes and guided design adjustments that prevented premature wear and cracking.

Accurate material modeling is essential for simulating the real performance of welded, composite, or polymer-based systems.

For a welded offshore structure, ENA2 performed weld distortion and residual stress analysis using thermal-mechanical coupling to predict post-weld deformations. The findings allowed the fabrication team to pre-compensate critical weld sequences, reducing alignment deviation by over 50%.

In another case, we modeled FRP and polymer piping systems under combined pressure and temperature to verify allowable stresses and creep behavior. By integrating nonlinear viscoelastic material properties into the FEA model, we validated long-term performance and supported client certification requirements for composite equipment.