up front flow assurance(looping)otc2010
Post on 03-Jun-2018
215 Views
Preview:
TRANSCRIPT
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 1/38
www.cd-adapco.com
Flow Assurance By DesignMulti-Fidelity Simulation for
Improved Design, Development, and Validationof Subsea Pipelines and Equipment
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 2/38
What You Need to Know…
2
The importance of “Up-Front” and
“Multi-Fidelity” simulation
The Company Behind the Solutions:CD-adapco
Examples and Benefits of 3-D Flow andThermal Simulation
The Software Behind the Benefits:STAR-CCM
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 3/38
3
Ocean Temperature
Ocean Pressure
Well Fluid Temp/pressure
Slugging/Hydrates
Inhibitors
Accessibility for Repair/Replacement
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 4/38
The Importance of 3D Simulation in Engineering Design
• “The deeper you go, the less you know”
– Engineers need to know if proposed equipment and systemdesigns will function properly under increasingly harshoperating offshore/subsea conditions
– Past experience and “gut feel” become less reliable in newand unfamiliar environments
– Physical testing of components/equipment is increasinglyexpensive 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 designsbefore they are built and installed
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 5/38
The Importance of Using the Right Numerical Tools
• To be effective, simulations must be
– Fast enough to provide answers within the design timeframe
– Accurate enough to provide sufficiently insightful answers forbetter design decisions
• Choice and use of a judicious mix of tools for Multi-FidelitySimulation to meet these effectiveness requirements, e.g.
– 1-D simulations (e.g., OLGA) for long pipeline systems
– 3-D simulations (STAR-CCM+) for 3D equipment, transitionregions
– A user-friendly computing environment for activating the rightmix of tools for the situation being examined: co-simulation
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 6/38
Flow Assurance Toolkit: 1D, 3D & Test
• 1D codes such as OLGA: – Fast, for overall networks & long pipelines
– But…limits to physics/geometry, tuned from empiricism
• Test:
– Includes all physics
– Costly, time-consuming, lack of facility availability, scaling, dataacquisition
• 3D CFD with STAR-CCM+ / coupled 1D-3D:
– Higher fidelity physics/geometry – Detailed simulation
– More computing resource required (but getting cheaper)
It’s cheaper to be wrong in the virtual world--
Failure in the real world is not an option
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 7/38
Example Areas for Use of 3D Flow and Thermal
Simulation in Deep Offshore Engineering
7
ICV/Valves
Jumpers/errosion
Sand transport Coldspots
Split nodes Pumps
Advanced thermal /flow modeling
Subsea processing
Component Errosion
Subsea and topside:
Separators/Slugcatchers/FWKO
VIV of risers/umbilicals
Drill Bits/Sand Control
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 8/38
Further Relevant Topside 3D Flow and Thermal
Simulation Application Areas
8
Tankers/LNG Ships: Seakeeping, Sloshing, Propulsion
Offshore Platforms: Wave Slamming, Wind Loading
VIM of Spars
Flare Combustion/Radiation
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 9/38
Subsea Applications (partial list)
• Gas lift
• Equipment sizing
• Operating procedures
• Cool-down times/insulation
• Solid transport
• Displacement problems
• Hydrate remediation• Testing of assumptions
(e.g. wax during pigging)
• VIV
• Heat transfer coefficinets
• In-pipe heating
• Installation (componentloads)
• Equipment optimization (weightreduction)
• Erosion
• Heavy oils• Inhibitors, top-line wetting
• Sulfur transport/melting
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 10/38
Troubleshooting with 3D Simulation
• 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
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 11/38
Carryover in Separator:Dynamic Free-Surface Tracking
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 12/38
Riser section of long pipeline: 3D CFD Captures
Transition of Flow Regimes Around Sharp Bends
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 13/38
Effects of Cooling in Transportation of Viscous Oil
• When heavy/viscous oil is cooled along the pipe, expectdensity and viscosity to increase as temperature drops.
• 3D simulation is used to capture the cross-sectional effects.
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 14/38
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 15/38
Pressure drop along pipe
With cooling
Isothermal
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 16/38
Multiphase Flow in Pipe Bends
Large bubbles
Mediumbubbles
Small bubbles
Liquid
4-phase model for
more accuracy
16
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 17/38
Example: Riser Section
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 18/38
• 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.
Example: Thermal Study (1)
Blue – unprotected pipeline section
Red – heated pipeline sectionOrange – riser (unheated)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 19/38
• Initial start-up oil, water & gas pumped into the pipeline until anapproximate 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 (2)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 20/38
Example: Thermal Study (3)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 21/38
Examples: Solid Transport / Erosion
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 22/38
Examples: Solid Transport / Erosion
2222
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 23/38
“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) The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left)
The optimized case (right) has 67% less erosion than the original case (left)
The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left)
Testimonial to the Benefits of 3D CFD
23
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 24/38
The Software Behind the Benefits:
STAR-CCM
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 25/38
The Integrated Flow, Thermal and Stress Process
Geometry Import &CAD –EmbeddedFront End
AcceleratedPre-Processingwith SurfaceWrapping
AutomatedVolumeMeshing
AdvancedPhysicsSolutions
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 26/38
Your CAE Partner for Success 26
Pipe Junction: flow regime disruption
2m
Some Further Examples of
3D Flow/Thermal Simulation Solutions…
Slug Catcher
Christmas Tree:
Bubble Simulation
Pig Insertion
Top-side Separator
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 27/38
• 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:
• Individuals who have help shape today’s CFD world:» Prof. Gosman, Prof. Lo, Prof. Peric
27
CD-adapco: The Company Behind the Solutions
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 28/38
A Selection of our Oil and Gas Clients
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 29/38
• 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-adapcoengineers from New York andLondon offices visit &work withSPT experts in SPT Osloheadquarters.
• CD-adapco and SPT arepartners in European TMF andFACE research consortia, US(U. Of Tulsa) Hydrates JIP.
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 30/38
OLGA-STAR Coupling for Co-Simulation:
The Concept
OLGA <-> STAR:
Flow rates/pressure
STAR <-> OLGA:
Flow rates/pressure
Study 3D effects of in-line equipment: valves, junctions, elbows, risers, obstacles, jumpers,separators, slug catchers, compressors, ...
One-way or two-way, one end or multiple ends of 3D in-line equipment
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 31/38
OLGA-STAR Link Example:
Slugcatcher Investigation
• Slugcatcher undersized?• Original design with 5 tanks
• Built with only two (cost saving)
• Questions:
• what happens during pigging?
• carryover?• hydrate/wax particles melt?
• Gas/oil/water flow: co-simulation withOLGA for upstream pipeline input
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 32/38
SLUG CATCHER (Upstream Olga Model)
(24 Km)
(200m)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 33/38
SLUG CATCHER: Oil Surface
Olga Oil Flow Rate Bluegraph below
(BC to CFD Model)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 34/38
Jumper Experimental Setup
(U. of Tulsa Hydrates JIP: scale)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 35/38
Talk to Us About Next Steps…
• More detailed technical presentations on specifictopics/examples of interest (live or via Webex)
• STAR-CCM+ demonstration (live or Webex)
• Trial licenses, Training, Mentoring
• Benchmarks/pilot project(s)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 36/38
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 37/38
Come to CD-adapco’s 2nd Annual
STAR Global Forum 2 1 : Simulation for Energy Engineering
Professor Philip J. Smith, Director Institute for Clean and Secure Energy (ICSE)
University of Utah
A. Michael Schaal, DirectorOil and Gas Division
Office of Integrated Analysis and ForecastingEnergy Information Administration (DOE)
8/12/2019 Up Front Flow Assurance(Looping)OTC2010
http://slidepdf.com/reader/full/up-front-flow-assuranceloopingotc2010 38/38
top related