Critical Equipment Life Extension Assessment
Project Overview
PDL was engaged by an undisclosed manufacturing client following the discovery of a crack in a critical production asset during an active manufacturing campaign. The equipment had already undergone an emergency repair, but before production could restart, the client needed an independent assessment to determine whether the machine could continue operating safely and for how long. PDL delivered a structured structural integrity and fracture mechanics assessment to provide the technical evidence required for operational decision-making.
Our Solution
Our engineers deployed a comprehensive suite of simulation tools, including ANSYS Mechanical for structural analysis and ANSYS Fluent for thermal-fluid interaction. We developed a detailed 3D model of the component, applying realistic boundary conditions and material properties. Key aspects of our solution included:
Material Characterization : Incorporating advanced material models to accurately represent behavior under irradiation and high temperatures
Topology Optimization : Identifying optimal material distribution to reduce weight while maintaining structural integrity.
Thermal-Structural Coupling : Simulating the interaction between temperature fields and structural deformation.
Fatigue Life Prediction : Performing high-cycle and low-cycle fatigue analysis to predict component lifespan.
The assessment demonstrated that while one of the repair plates was effective in reducing crack growth, the repair did not provide a permanent solution and the component would ultimately require replacement. PDL recommended component replacement as the preferred course of action but also identified a safe temporary operating strategy. By defining a reduced duty cycle supported by targeted inspection intervals and additional verification activities, the client was able to continue production long enough to fulfil its immediate customer commitments while maintaining safety as the overriding priority. The project provided the client with the technical assurance needed to make informed operational decisions, maintain short-term production capability and justify investment in replacement equipment.
Client: Undisclosed
Sector: Other
Service Provided: Fracture Mechanics (LEFM), Fitness-for-Service Assessment
Challenge: Determine the safety and remaining life of cracked production equipment during an active manufacturing campaign
Outcome: Safe short-term operation achieved through a controlled reduced-duty strategy, while providing technical justification for long-term component replacement
