Hill, Roger

Stapf, Sean

NASA Technical Reports Server

SE Corp. Case Study 
Helping NASA evaluate safety hazards with SolidWorks Flow Simulation 
After working as an engineer for two decades, Sean Stapf founded SE Corp. in 2008. Making his analysis 
consulting business a success required hard work, as well as access to highly capable design, analysis, 
and engineering applications. 
The type of work that Stapf targeted-advanced simulations in CAD and Computational Fluid Dynamics 
-demanded robust, cost-effective engineering tools. Fortunately, Stapfs engineering history had 
exposed him to commercial analysis systems. "I was familiar with all of the world-class FEA (finite 
element analysis) packages, having used them throughout my career," Stapf recalls. "However, for my 
consulting company, I conducted a cost-benefit analysis. I needed analysis power and speed at the most 
attractive price." 
Stapf chose SolidWorks® Simulation Premium software as SE Corp.'s analysis package because of its 
CAD integration, extensive set of capabilities, and fast solvers. "I selected SolidWorks Simulation 
Premium and SolidWorks Flow Simulation software because they provide structural, thermal, and 
computational fluid dynamics (CFD) analysis tools within the SolidWorks parametric modeling 
environment," Stapf says. "It has three to four times the capabilities of other packages and can run my 
simulations two to three times faster, at half the price." 
Integrated CFD tools were also important. "Some of the features that stood out were the ability to work 
with parametric solids inside the CFD domain, to improve the analysis mesh through the use of smart 
elements, and to run grid-independent calculations," Stapf explains. "These features remove the barriers 
between the engineer and t~e physics. With SolidWorks Flow Simulation, I can do within minutes what 
others may spend days or weeks refining." 
https://ntrs.nasa.gov/search.jsp?R=20120013421 2019-08-30T21:54:02+00:00Z
SE Corp. Case Study 
Page2 
Preparing for the next chapter in space flight 
SE Corp. found the type of challenge it was seeking when it undertook a flow simulation of the Vehicle 
Assembly Building (V AB) at NASA's Kennedy Space Center in 2010 for NASA partner SAIC. NASA 
needed to assess potential uses for the V AB, where all of the shuttles were prepped for launch. NASA 
specifically wanted to evaluate facility safety and emergency escape procedures in the event of a rocket 
fuel ignition accident to determine if the V AB would remain viable for future projects. 
SE Corp. modeled a broad array ofV AB configurations, including those with the massive 480-foot-tall 
vehicle doors opened and closed, and with the incident occurring in any of the V AB's four work bays. 
Using SolidWorks Flow Simulation, Stapf simulated how thousands of feet ofhigh-temperature exhaust 
gases from the ignition and subsequent explosion would be driven throughout the V AB at hundreds of 
feet per second. 
"The CFD model predicted where and when these exhaust gases would become lethal in and around the 
V AB," Stapf notes. "By quantifying the time and severity of structural and personnel exposures to 
exhaust temperature, velocity, pressure, and concentration, NASA could improve safety and emergency 
response planning." 
Fast solution aids safe facility reuse 
Using SolidWorks Flow Simulation, SE Corp. quickly simulated the behavior of exhaust gases and 
ground-level thermal radiation. The study also examined the effects of the sea breeze coming off the 
Atlantic Ocean. With this study, NASA was able to identify the operational bays with the greatest 
potential hazards, calculate personnel egress times during an incident, and establish distances from the 
V AB at which personnel would be safe. 
SE Corp. Case Study 
Page3 
"I was able to turn the CFD solution around in 24 hours," Stapf says. "Although the model and mesh 
were large-roughly 200,000 elements-! was able to accelerate solution time by using smart elements. 
The model would have required millions of elements and a month of solution time in another CFD 
package. With SolidWorks Flow Simulation software, I was able to produce grid-independent solutions 
and report multiple flow gradients with high fidelity and detail in a single day." 
Winning Space Flight Awareness Team Award 
In recognition of SE Corp.'s contribution, NASA recognized the project with its "Space Flight 
Awareness Team Award." The award specifically cites the team "For significant contributions in the 
implementation of a Maximum Credible Event safe siting approach allowing NASA a cost avoidance and 
continued use ofthe John F. Kennedy Space Center Vehicle Assembly Building for future programs." 
"It was an honor to receive this award, perform this work, and know that the V AB will continue to 
contribute to the US space program for another 50 years," Stapf says. "I'm more than satisfied with 
SolidWorks simulation solutions and glad that my customers are happy with my work." 
[sidebar] 
Sean Stapf founded SE Corp., which specializes in providing high-end analysis consulting, after working 
for two decades as a civilian mechanical engineer at the US Department of Defense. The Consultancy's 
work, which involves advanced simulations for prestigious clients like NASA, demands engineering tools 
that are both robust and cost-effective. 
Stapf chose SolidWorks® Simulation Premium and SolidWorks Flow Simulation software as SE Corp.'s 
analysis platform because of their CAD integration; structural, thermal, and computational fluid 
dynamics (CFD) analysis capabilities; and fast solvers. By selecting SolidWorks Flow Simulation 
software, SE Corp. was able to complete a CFD study on NASA's Vehicle Assembly Building in just 24 
hours, replace millions of elements with smart elements to shorten solution time, produced results that 
SE Corp. Case Study 
Page4 
helped NASA improve safety planning, and was recognized with NASA's Space Flight Awareness Team 
Award. 
Challenge: 
To simulate and analyze incredibly large and increasingly complex physical phenomena and 
engineering problems, such as the impact of an inadvertent rocket fuel ignition inside the Vehicle 
Assembly Building (V AB) at NASA's Kennedy Space Center. 
Solution: 
Implement the multiphysics analysis capabilities of SolidWorks Simulation Premium software and 
. SolidWorks Flow Simulation computational fluid dynamics (CFD) analysis tools. 
Results: 
+ Completed NASA V AB CFD simulation in just 24 hours 
+ Shortened solution time with smart elements 
+ Produced results that helped NASA improve safety planning 
+ Won NASA's Space Flight Awareness Team Award 
SE Corp. 
1581 S. Orlando Ave. 
Cocoa Beach, FL 32931 
USA 
Phone: +1321 536 5544 
V AR: Modern Tech Mechanical, Orlando, FL, USA 
[standard end matter] 
SolidWorks is a registered trademark ofDassault Systemes SolidWorks Corp. All other product names are 
trademarks or registered trademarks of their respective owners. ©2012 Dassault Systemes. All rights reserved. 
MKSECCSENG0612 
. . . 


Helping NASA Evaluate Safety Hazards with SolidWorks Flow Simulation

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