www.cd-adapco.com
Flow Assurance By Design
Multi-Fidelity Simulation for Improved Design, Development, and Validation of Subsea Pipelines and Equipment
What You Need to Know… The importance of “Up-Front” and “Multi-Fidelity” simulation Examples and Benefits of 3-D Flow and Thermal Simulation The Software Behind the Benefits: STAR-CCM+ The Company Behind the Solutions: CD-adapco
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Ocean Temperature
Slugging/Hydrates
Ocean Pressure
Inhibitors
Well Fluid Temp/pressure
Accessibility for Repair/Replacement
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The Importance of 3D Simulation in Engineering Design •
“The deeper you go, the less you know” –
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Engineers need to know if proposed equipment and system designs will function properly under increasingly harsh operating offshore/subsea conditions Past experience and “gut feel” become less reliable in new and unfamiliar environments Physical testing of components/equipment is increasingly expensive and less reliable due to scaling assumptions
3D Simulation is rapidly moving from a troubleshooting tool into a leading position as a design tool: “Up-Front” numerical/virtual testing to validate and improve designs before they are built and installed
The Importance of Using the Right Numerical Tools •
To be effective, simulations must be – –
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Fast enough to provide answers within the design timeframe Accurate enough to provide sufficiently insightful answers for better design decisions
Choice and use of a judicious mix of tools for Multi-Fidelity Simulation to meet these effectiveness requirements, e.g. – –
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1-D simulations (e.g., OLGA) for long pipeline systems 3-D simulations (STAR-CCM+) for 3D equipment, transition regions A user-friendly computing environment for activating the right mix of tools for the situation being examined: co-simulation
Flow Assurance Toolkit: 1D, 3D & Test 1D codes such as OLGA:
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Fast, for overall networks & long pipelines But…limits to physics/geometry, tuned from empiricism
3D CFD with STAR-CCM+ / coupled 1D-3D: – – –
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Higher fidelity physics/geometry Detailed simulation More computing resource required (but getting cheaper)
Test: – –
Includes all physics Costly, time-consuming, lack of facility availability, scaling, data acquisition
It’s cheaper to be wrong in the virtual world-Failure in the real world is not an option!
Example Areas for Use of 3D Flow and Thermal Simulation in Deep Offshore Engineering
Subsea and topside: Separators/Slugcatchers/FWKO Jumpers/errosion Advanced thermal /flow modeling
Subsea processing Sand transport Coldspots
Split nodes Pumps
VIV of risers/umbilicals
Component Errosion
Drill Bits/Sand Control ICV/Valves 7
Further Relevant Topside 3D Flow and Thermal Simulation Application Areas
Tankers/LNG Ships: Seakeeping, Sloshing, Propulsion
Flare Combustion/Radiation VIM of Spars Offshore Platforms: Wave Slamming, Wind Loading
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Subsea Applications (partial list)
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Gas lift Equipment sizing Operating procedures Cool-down times/ insulation Solid transport Displacement problems Hydrate remediation Testing of assumptions (e.g. wax during pigging)
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VIV Heat transfer coefficinets In-pipe heating Installation (component loads) Equipment optimization (weight reduction) Erosion Heavy oils Inhibitors, top-line wetting Sulfur transport/melting
Troubleshooting with 3D Simulation •
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Deeper insight into operation of existing equipment Greater spatial/temporal resolution Confidence that you’ll get it right the first time! Failure is not an option Example: pipeline VIV
Carryover in Separator: Dynamic Free-Surface Tracking
Riser section of long pipeline: 3D CFD Captures Transition of Flow Regimes Around Sharp Bends
Effects of Cooling in Transportation of Viscous Oil •
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When heavy/viscous oil is cooled along the pipe, expect density and viscosity to increase as temperature drops. 3D simulation is used to capture the cross-sectional effects.
Effects of Cooling in Pipeline Flow of Viscous Oil •
Temperature, density and viscosity after 200m
Viscosity
Temperature
Density
Pressure drop along pipe
Isothermal
With cooling
Multiphase Flow in Pipe Bends
Large bubbles Medium bubbles Small bubbles
Liquid
4-phase model for more accuracy
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Example: Riser Section
Example: Thermal Study (1) • Identify possible occurrence and location of cold spots in open loop electrically-heated sub-sea pipeline. • Identify three-dimensional heat transfer effects important during the pipeline cool down. • Sub-sea pipeline –wellhead to platform • Sections are electrically heated and unheated – e.g., riser unheated.
Blue – unprotected pipeline section Red – heated pipeline section Orange – riser (unheated)
Example: Thermal Study (2) • Initial start-up oil, water & gas pumped into the pipeline until an approximate steady-state condition is reached (Duration: 2 hrs). • Shutdown fluids within the pipeline are allowed to settle and redistribute (Duration: 1hr). • Cool down fluid in pipeline allowed to cool down. Electrical heating is activated when the fluid temperature in the pipeline reaches 25oC. (Duration: 36 hrs) • Start-up oil, water & gas pumped into the pipeline until an approximate steady-state condition is reached (Duration: 2 hrs).
Example: Thermal Study (3)
Examples: Solid Transport / Erosion
Examples: Solid Transport / Erosion
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The optimized case (right) has 67% less erosion than the original case (left)
Testimonial to the Benefits of 3D CFD “These applications demonstrate that CFD offers the potential for huge advancements in drilling, especially under more challenging conditions. CFD gives design engineers the ability to easily and accurately analyze fluid flow, making it possible to rapidly evaluate alternatives and also provides comprehensive diagnostic information. The result is that design engineers can optimize the drilling bit from a fluid flow perspective during the design phase.” --Dr. Michael Wells, Director of Research and Development, Hughes Christensen Division of Baker Hughes
The optimized case (right) has 67% less erosion than the original case (left) 23
The Software Behind the Benefits:
STAR-CCM+
The Integrated Flow, Thermal and Stress Process
Accelerated Pre-Processing with Surface Wrapping Geometry Import & CAD –Embedded Front End
Automated Volume Meshing
Advanced Physics Solutions
Some Further Examples of 3D Flow/Thermal Simulation Solutions…
Pig Insertion Slug Catcher Top-side Separator
2m Christmas Tree: Bubble Simulation
Pipe Junction: flow regime disruption Your CAE Partner for Success
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CD-adapco: The Company Behind the Solutions
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The world’s largest independent flow/thermal-focused provider of 3D transient engineering simulation solutions (CFD) – software, consulting (20% of turnover), mentoring, training – STAR-CCM+ : the world’s best 3D simulation environment ~30 years of providing flow, thermal, and stress solutions across industries from oil & gas, nuclear, chemical, automotive, to aerospace & defense Independence allows flexibility in meeting engineering challenges Over US$100 million p.a. end-user spend, 17-20% current growth rate 450+ employees across 21 offices in 8 countries – 90% postgraduate degrees; 40% PhDs More than 8000 users in over 3500 companies Multiphase process equipment CFD knowhow:
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Individuals who have help shape today’s CFD world:
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Prof. Gosman, Prof. Lo, Prof. Peric 27
A Selection of our Oil and Gas Clients
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CD-adapco and SPT established a partnership in 2008 to develop/ integrate tools for Up-Front (Multi-Fidelity) Computational Flow Assurance. Both companies are fully committed. Very close working relationship between management and engineers. To develop and enhance the STAR-OLGA Link: CD-adapco engineers from New York and London offices visit &work with SPT experts in SPT Oslo headquarters. CD-adapco and SPT are partners in European TMF and FACE research consortia, US (U. Of Tulsa) Hydrates JIP.
OLGA-STAR Coupling for Co-Simulation: The Concept Study 3D effects of in-line equipment: valves, junctions, elbows, risers, obstacles, jumpers, separators, slug catchers, compressors, ...
OLGA <-> STAR: Flow rates/pressure
One-way
STAR <-> OLGA: Flow rates/pressure
or two-way, one end or multiple ends of 3D in-line equipment
OLGA-STAR Link Example: Slugcatcher Investigation •
Slugcatcher undersized? • •
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Questions: • • •
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Original design with 5 tanks Built with only two (cost saving) what happens during pigging? carryover? hydrate/wax particles melt?
Gas/oil/water flow: co-simulation with OLGA for upstream pipeline input
SLUG CATCHER (Upstream Olga Model)
(200m)
(24 Km)
SLUG CATCHER: Oil Surface Olga Oil Flow Rate Blue graph below (BC to CFD Model)
Jumper Experimental Setup (U. of Tulsa Hydrates JIP: ¼ scale)
Talk to Us About Next Steps… •
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More detailed technical presentations on specific topics/examples of interest (live or via Webex) STAR-CCM+ demonstration (live or Webex) Trial licenses, Training, Mentoring Benchmarks/pilot project(s)
In Particular, Come to the
SPT Dynamic Partnership Showcase Wednesday, May 5
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Event details Date: Wednesday May 5th 9:00 am – 8:00 pm Location: Directors Club in Reliant Stadium (enter Reliant Stadium through the Coca Cola entrance and take the elevator to the 7th floor) Schedule: – Continental Breakfast 9:00 am – 10:30 am – Lunch (by invitation only—contact SPT directly) 12:15 am – 1:45 pm – SPT’s CEO Tom Even Mortensen will speak during lunch – Networking Happy Hour 5:00 pm – 8:00 pm Partner Showcase Demonstration Area: STAR-OLGA Link
Come to CD-adapco’s 2nd Annual STAR Global Forum 2010: Simulation for Energy Engineering
Professor Philip J. Smith, Director Institute for Clean and Secure Energy (ICSE) University of Utah
A. Michael Schaal, Director Oil and Gas Division Office of Integrated Analysis and Forecasting Energy Information Administration (DOE)
