Computational Engineering at Rolls-Royce
Terry Hewitt
EDS, an HP Company
Agenda
EDS, an HP Company & Rolls-Royce
Why do Rolls-Royce need HPC?
What are the business benefits?
HPC architecture
Future Challenges
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Who
EDS, an HP Company
Division of HP that provides IT services
• Some customers
• GM, Department of Work & Pensions (UK), MOD, SKF, Rolls-Royce
•Acquired
• Me: April 2008
• EDS: September 2008
• Computational Engineering
• HPC + visualization, data management, gird computing, engineering
applications, workflow, ….
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WHY DO ROLLS-ROYCE NEED HPC?
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Speed-up (schematic)
What is HPC?
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Speed-up
Task takes time t on 1 processor
By running on n processors:
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•Solve problem in the shortest turnaround
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time (~t/n)
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— capability
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computing
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Number of processors
Run time vs # processors
•Solve bigger and more complex problems
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in same time (t)
computing
•Run several jobs of same capability (t)
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Run time
— capacity
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— Parameter
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space searching (e.g., range of
operating conditions)
—
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capacity computing
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Number of Processors
Design
Combustion
Two-phase combusting flow
External aerodynamics
Fuel injector and combustor
CFD is used an analysis tool
cooling flows
CFD is used as a Design and Optimisation Tool
Nacelle
Exhaust
Aerodynamics
Afterbody flow
Crosswind effects
Nozzle, mixer,
Installed engine/pylon/
jet flow
wing interaction
Fan
Aerodynamics
Fan flutter
Fan/OGV/pylon interaction
Turbine
IGV forced response
Multistage aerodynamics
Inverse design and optimisation
End wall and blade heat transfer
Compressor
Film cooling
Multistage aerodynamics
Unsteady rotor/stator flow
Engine Systems
Annulus leakage flow
Rotating disc cavity flows
Rotor shroud leakage
Rim seals
Unsteady vane/rotor flow
Brush and labyrinth seals
Forced response
Secondary air system losses
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Nozzle/Afterbody Design
Flow incidence
Empirical Methods
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Ideal for conceptual/preliminary design
Rapid to apply
scope limited to tested configurations
Accuracy - set by available data-base
Experimentation
Horizontal/vertical
tail interactions
• Expensive :
— Wind Tunnel - £500,000 - £ 1 M
— Radar Range - £100,000 200,000
— Static Thrust Stand - £300,000
• Accuracy - Definitive
• Limitations - effects of scale, support
systems, tunnel interference, and gas
temperature
Computational Fluid Dynamics
• Proven ability to predict trends and
increments
• No limitations of model scale, gas
temperature
• No support system interference
• Absolute accuracy currently limited
• Costs falling
• Valuable complement to empirical and
test approaches
Computational Engineering at Rolls-Royce - IDC
IR and RCS
emissions
Thick boundary
layer - strong
viscous influences
Nozzle/afterbody
contouring
Thrust Vectoring
Plume interaction
Combat aircraft afterbody drag makes up
between 30% to 50% of total aircraft
drag
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Hydra Noise Applications
Rotor Alone Tone Noise
Steady Non-linear CFD
Low Noise Rotor Design
Intake Acoustic Liner
Bypass
Mean Flow Calculation for
ACTRAN-DGM
Buzz-Saw
Full Annulus
Non-Linear
Radiation
Mean Flow for
ACTRAN
Fan Broadband
Rotor Alone,
Fan-OGV Interaction
Turbulent
RANS (PROBAND, ISVR)
LES (PROBAND, UCAM)
Computational Engineering at Rolls-Royce - IDC
Jet
Non-linear unsteady,
Turbulent
LES
Fan/OGV Tone
Wake-OGV
interaction
Unsteady, Linear
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LP Turbine
Tones
Multi-Stage,
Unsteady
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SC03 – Finite Element Analysis
Company Standard FE Code
Most widely used technical program in
Rolls-Royce
~20,000 runs/month
~1,800 users
~400 full-time equivalent
Used & improved for last 15 years
Built on Rolls-Royce’s 30+ years of FE
expertise
Used for:
• Thermo-Mechanical Analysis
• Linear & Non-Linear Structural
analysis
• Vibration Analysis
• Input Generation & Output
Processing for Whole Engine
Structural Analysis
• Creep / Fatigue Lifing
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Whole Engine Modelling
Automated acquisition of geometry (2D
IGES)
Automated acquisition of
materials properties data
Automated acquisition
of temperature data
Automated acquisition of
engine distributed thrust
loading
Automated acquisition of
non-structural mass data
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Design System
Dyna3D Model of Whole Engine
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Applications in Aerospace, Marine and Energy
Rotor
performance
Aerospace Applications
Energy
Applications
20 degrees cut
Marine
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BUSINESS BENEFITS
Business Benefits & Requirements
Reduce the following
•Time to market of an engine design
•Component costs
•Design and certification costs
•Number of destructive tests of components and engines
Increase the quality of the engine (via better fidelity of the simulations)
• reduces service & maintenance costs
Ensure the integrity of the design
Optimise their return on investment in HPC
• Integration with existing estate
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HPC ARCHITECTURE
A brief note on status
The material presented is in one of the following
states
• Installed & working
• On Order (delivery within some weeks)
• Planned (have the money but must do above 1st)
• Aspirational (we haven’t got the money yet)
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Islands
Orthogonal
High performance connectivity
Scale-up
Scale-out
Integrate with each other
Integrate with rest of the estate
Roll-out to different geographies
Ethernet interconnect not shown
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Administration/Information Island
Hosts Sun Grid Engine Master – Job management
Hosts resource management
• allocation, modification, reporting
Must provide failover
Provide an Information Service
• availability of nodes
No user logins!
More commonly know as Head nodes
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Pre/Post Processing Island
Applications run interactively
Remote display
Can handle LARGE files from the
simulations
High performance graphics cards
Examples
Pre Processing: mesh generation
Post Processing: results
visualization
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Visualization Island
High performance server with
High performance graphics cards
Capable of handling large displays
Capable of parallel visualization
DCV
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High Performance File Store
Supports Parallel activity
High Performance
Resilience
GPFS Node
GPFS Node
SAN
switch
GPFS Node
GPFS Node
GPFS Node
...
GPFS
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SAN
switch
Backup/Archive
Expected volumes mean corporate LAN & data
store won’t cope, hence
• “behind” High Performance Filestore
• independent solution
Work in progress
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Compute Island
Each Compute Island may have different
processor architectures to reflect
different application requirements
different purchase points
Differences
• Processor (sockets/node, # cores, clock frequency)
• Memory
• Interconnect
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WHY DOES HPC WORK?
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What made HPC successful?
Champions in Rolls-Royce
•Vision
•Develop a suitable business case
•Management prepared to take a risk
Applicable software available
•Relationship with academia to fill gaps
Some problems can’t be solved any other way
Expertise in EDS
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FUTURE PROBLEMS
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Internal Problems
• Space & Power
Maintain coherency as architectures change
Join the islands together around the world
Use desktops overnight to supplement capacity
ISV vs in-House codes
•reduce s/w development/maintenance costs by
using ISV in lieu of in-house codes
•possible lack of competitive edge (in-house codes
contain features not in ISVs)
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Speed-up (schematic)
Must increase
performance of in-house
codes (and ISVs)
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We must move the
“elbow” to the right
• to 100’s or 1,000s
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Speed-up
It’s a software issue
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Number of processors
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THANK YOU FOR LISTENING
EDS
5400 Legacy Drive
Plano, TX 75024
+1 972 605 6000 (optional)
[email protected] or eds.com
EDS and the EDS logo are registered trademarks of Hewlett-Packard Development
Company, LP. HP is an equal opportunity employer and values the diversity of its
people. ©2008 Hewlett-Packard Development Company, LP.
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