Design Optimisation through Value

Engineering of Fluid Machinery

Programme and Registration Brochure

12 November 2008

IMechE, 1 Birdcage Walk, London

www.imeche.org/events/S1367

Supported by Aerospace Industries Division, Manufacturing Industry Division, Safety & Reliability Group
and Tribology Group

Co-Sponsored by:
Design Optimisation through Value Engineering of Fluid Machinery
This event will cover the full design optimisation of fluid machinery using the latest value engineering techniques. It will cover the
latest multi-disciplinary, multi-functional approaches, together with specific, practical examples drawn from industry.
Major themes will be country sourcing, cost reduction and the use of advanced low-cost leading competitive techniques – all key
strategic areas for commercial companies to increase sales/profit margins.

Attending will help you:

• Operate at the cutting edge; learn the latest value engineering techniques
• Engineer for value: increase functionality, reduce costs
• Strike the perfect balance between performance and costs
• Run fluid machines at optimum level; reduce fluid machinery costs
• Make machines more robust; minimise lead time delays
• Improve global competitiveness
• Develop improved costing methods including factory parameterised models with real-time costs for each design code
• Study cost engineering methodologies: detailed analogous or parametric estimating
• Learn total life-cycle costing techniques
• Acquire usable statistics from complex situations
• Examine cost and risk modelling for complex products
• Improve use of design in manufacturing, assembly, installation and maintenance
• Examine low-cost country sourcing
• Learn lessons from Asian and Eastern European supply chains
• Hear the latest thinking in gas turbine technology
• Reduce exhaust emissions in diesel engines
• Further continued professional development
• Meet, greet and network with key industry players

Who should attend

• Design engineers
• Manufacturing engineers
• Cost estimating engineers
• Advanced sourcing specialists
• University staff
• Consultants
• Value engineering specialists

Exhibition and sponsorship

If you have a product or service to promote, you can enhance brand awareness through our range of exciting
sponsorship/exhibition opportunities.
For details of how we can tailor a package to suit your needs, please contact Aman Duggal on
tel: + 44(0)20 7973 1309 or email: sponsorship@imeche.org

Organising Committee
Brian Haller Director Retrofit Concepts, ALSTOM Power Systems
Kam Chana Head of Instrumentation QinetiQ
Colin Scrivener Consultant Rolls-Royce
PROGRAMME
12 November 2008
09:30 Registration and Coffee
SESSION 1
10:00 Chairman’s Welcome
Brian Haller, Director, Retrofit Concepts, ALSTOM
Power Systems
10:10 Keynote: Demonstrating Value from Value Engineering
Dr David Clark, Principal Fellow, Warwick Manufacturing
Group
• Adding value can be interpreted as adding functionality
or removing cost, yet there is a danger that adding
functionality can come at the expense of increased
complexity
• Examples will be given from the work at Warwick
Manufacturing Group, where value engineering has
required a fresh look at complexity and a radical re-
appraisal of product perception
10:30 ‘Design for Cost’ of ALSTOM Large Steam Turbine Retrofits
Brian Haller, Director, and Gareth Thomas, Manager –
Product Cost, Retrofit Concepts, ALSTOM Power
Systems
ALSTOM is a world leader in the retrofitting of large steam
turbines for fossil and nuclear-fuelled machines (both full
and half speed). However, to remain competitive it must
achieve a better balance for its products between the
main issues of cost and performance. This paper
describes a new ‘(Re-) Design for Cost’ (DFC)
programme launched to achieve these aims. The
following aspects will be covered:
• The processes used to launch and drive the ‘(Re-)
Design for Cost’ programme
• Some examples of DFC projects and the results
achieved
• Ingraining the value engineering culture within the
company
• Development of improved costing methods, including
factory parameterised models and real-time material
costs in each design code
• Use of automated design and optimisation methods to
produce cost-effective solutions
• Use of low-cost country sourcing and localisation
10:50 Deployment of Cost Engineering Methods in Value
Engineering
Dr Paul Baguley, Research Fellow, Cranfield University
• Value engineering frameworks and their use of cost
information
• Cost engineering methodologies as detailed,
analogous or parametric estimating
• Cost and risk modelling for complex products
• Full-life cost and affordability concepts, methods and
a case study
• A word on advanced cost modelling methods
11:10 Discussion
11:25 Coffee
SESSION 2
11:45 Integrated Design and Supply Chain Engineering: an Air-
Cooled Chillier Axial Flow Fan
Paul Wenden, Head of Engineering, Anthony Geoffrey
Sheard, Vice President – Fan Technology, Keith John
Elkington, Group Sourcing Manager, Flakt Woods Ltd
In an ongoing drive for competitive advantage over the last
20 years, organisations have progressively focused on
their core competences, outsourcing non-core activity.
Once an organisation has restructured around its core
competences, however, the opportunity for further gains
through outsourcing in-house activity are reduced.
Another strategy is needed to build and maintain
competitive advantage.
In this paper the authors describe an integrated design
and supply chain engineering strategy and its application
to an air-cooled chillier axial fan. A three-part process will
be described.
12:05 Applying Statistical Methods to Generate Cost Models in
the Early Phase of ALSTOM Gas Turbine Development
Hans Peter Knoepfel, Principal Engineer Design
Analysis Combustor, ALSTOM
• Advantages of cost models
• Model structure and area of application
• Data collection and preparation
• Statistical methods
• Example
• Summary
There is a long tradition of expertise in the power plant
business at our locations in Switzerland. Today, ALSTOM
is one of the leading providers of all-round power
generation solutions. We develop, produce, install,
modernise and service power plants all over the world.
Not only do we supply all the components for a power
plant, but our products, systems and services guarantee
success for our customers in today’s dynamically
changing energy markets, which are characterised by
liberalisation, deregulation and privatisation. We can draw
on a unique wealth of experience – ALSTOM has
supplied over 25% of the world’s installed power-
generation capacity.
12:25 Discussion
12:40 Lunch
SESSION 3
13:25 Gas Turbine Engines: a Quieter, Leaner, More-Efficient Burn
Professor Peter Bryanston-Cross, Optical Engineering
Laboratory, University of Warwick
Each day in the UK 30,000 tonnes of fuel is used for
transport, 10,000 tonnes for aviation and 40,000 tonnes
of coal for power and generation. The majority of this fuel
is imported and forms a large cost to the economy, as
well as a possibly unstable supplier dependency.
Combustion efficiency – the minimisation of pollution
from its burning products and the use of sustainable
combustion materials – is crucial to British industry.
 It is unlikely that in the short term the process of
combustion for power generation will change
significantly. This paper reviews the possible changes in
gas turbine technology available to the manufacturer
and user.
Examples will be shown of significant noise reduction,
weight reduction with the implementation of new design
and manufacturing processes, and methods for
measuring and controlling combustion efficiency directly.
13:45 Design of an IP Nozzle Guide Vane Cooling System Using
Robust Optimisation Methodology
Peter Ramwell, Technologist, Turbine Systems
Engineering, Thermofluids, Rolls-Royce
The presentation will detail the design problems tackled
in this particular case and general cooling style of IP
guide vanes. It will discuss how the design process was
automated and integrated into a system that enabled
robust optimisation to be performed. This will lead into a
description of what optimisation techniques were used
and what the outcome and implications were.
14:05 Saving Energy, Saving Water and Saving the Planet through
the use of Affordable, Premium Bi-Directional Pumping
Rings
Alan Roddis, Engineering Director, AESSEAL plc
With increasing environmental legislation, energy
consumption and water conservation are at the forefront
of every plant engineer’s mind. API Plan 23 and Plan 53
are two of the most influential seal piping plans available
to plant engineers to affect rotating equipment energy
and water consumption, yet in many plants and industrial
areas around the world the benefits are not realised.
This presentation will cover the following:
• Typical energy and water savings of Plans 23 and 53
• Value engineering developments of innovative
pumping rings
• Design optimisation – the next-generation API682-
compliant pumping rings and their wider use in hybrid
seal support systems
14:25 Discussion
14:40 Tea
SESSION 4
15:00 The Effect of Variations of Intake Pressure and
Temperature on a Heavy-Duty Diesel Engine
Mofid Gorji Bandpy, Associate Professor, Davood
Domiri Ganji, Associate Professor and Sajjad Soleimani
Amiri, MS Student, Department of Mechanical
Engineering, University of Mazandaran
Diesel engines exhausting gaseous emissions and
particulate matter have long been regarded as one of the
major air pollution sources, particularly in metropolitan
areas, and have been a source of serious public concern
for a long time.
The choosing of various injection strategies is not only
motivated by cost reduction, but is also one of the
potentially effective techniques to reduce exhaust
emission from diesel engines. The purpose of this study
is to investigate the effect of different injection angles
on a heavy-duty diesel engine and its emission
characteristics. The varieties of injection angle were
simulated and the emissions calculated. The
comparison between the different injection strategies
was also investigated.
This presentation explains the results and findings of
the study.
15:20 The Optimisation of Internal Pump Geometry to Extend
Impeller Life
Roy Spence, Senior Renewable Energy Consultant,
SgurrEnergy Limited and T Purdom, Principal Engineer
Stress/FEA, Clyde Pumps Ltd
CFD simulations have been employed to perform a
parametric study of the geometric variables within a
complete hydraulic pump, to assist the understanding of
flows and pressure pulsation effects. A taguchi statistical
approach allows the percentage contributions of each
geometry feature to pressure pulsations to be evaluated.
It is clear that the cutwater and vane arrangement are the
dominant parameters, albeit their effect varies with flow
rate. The situation is complex but it is possible to identify
and recommend certain key features of an ‘optimised’
design.
The CFD results for pressure distributions across the
impeller have been used as input to an FEA, which
allows stress distributions to be derived and compared
with existing design methods. Areas of high stress are
shown to be consistent with locations that have been
associated with fatigue.
The work opens up considerable potential for improved
hydraulic design in pumps, together with a more rational
approach to structural integrity.
15:40 Optimisation of a Set of Improved-Performance Cyclic
Geometry Fan Outlet Guide Vanes for a High Bypass Ratio
Turbofan
Olivier Bron, Technologist, Fans and Compressors,
Rolls-Royce
• Aerodynamic redesign of fan outlet guide vanes
needed as consequence of customer requirement for
increased specific thrust
• Impact of complete redesign estimated to be about
£650,000 for tooling costs and obsolete
manufactured parts
• Unacceptable delays, costs and risks in lead time and
manufacturing
• Alternative design strategy available from recent
developments in computer capabilities and resources
• CFD optimisation performed on full assembly using
state-of-the-art 3D Reynolds Averaged Navier-Stokes
solver
• Optimised solution finely tuned to increase robustness
and performance around full operating range
• Cost-effective solution reached
• Risks related to manufacturing processes eliminated
• Lead time delays minimised
16:00 Discussion
16:15 Summary
16:30 Close of Seminar
The programme is subject to amendment.
Design Optimisation through Value Engineering of Fluid Machinery
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12/11/2008 S1367
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