Case S Studies f from t m the he O Oil & l & Ga Gas Ind Industry: y: Do Down ho n hole le t to F Flo low A Assuranc nce & & Separation n Ale lex R Read
Ov Over ervi view w � CFD i D in O n Oil & l & Ga Gas Ind Industry Dr y Drivers � Appli lication & n & v vali lidation e n example les: f : from d m down ho n hole le t to f flo low a assuranc nce & & separation n � All a ll about me me: : – Degrees in Engineering, CFD and Business from University of Leeds, UK & Rice University, Houston, USA – 12+ years at CD-adapco – Engineer à Customer Support for Northern EU à Regional lead for Southern US/LATAM à O&G Industry Lead – Works closely with many of the world’s leading O&G companies
Ind Industry Dr y Drivers Change in economic Technology & simulation reserves to deep-water, à innovation and HPHT & unconventionals, understanding of new … challenges Technology & simulation à minimize & quantify Capital/risk intensive risks, maximize durability Simulating systems: Improvements in multi-physics, -fidelity, modeling capabilities, complex geometries, experience & confidence HPC
Appli lication A n Areas � Upstream m – Down hole tools – Completions – Subsea – Flow Assurance – Offshore – Separation – Gas dispersion/explosions � Midstream m – Flow conditioning/metering � Do Downs nstream m – Refining
Gr Gravel p l packi king ng: DE : DEM � Gr Gravel p l pack: c k: coarse gravel u l used t to f filt lter sand nd f from t m the he wells llstream � Cha halle lleng nge: : und nderstand nd t the he packi king ng p process & & distribution n
Slurry flow in pipe Unif iform rm so solid lid vo volu lume me fra ract ctio ion Measu Me sure reme ment pla lane g g 1m m (vf vf) ) and slu slurry rry ve velo locit city y (V) (V) V V D D L=1 =10m m d=2 =270 µ m , , vf =0 =0.2, d=4 =480 µ m , , vf =0 =0.203, d=9 =90 µ m , , vf =0 =0.19, D=5 =51.5mm mm V=5 V=5.4 D=5 =51.5mm mm V=3 V=3.41 D=1 =103mm, mm, V=3 V=3 m/ m/ m/s m/ s m/ m/s s s s d=1 =165 µ m , , vf =0 =0.189, d=1 =165 µ m , , vf =0 =0.0918 d=1 =165 µ m , , vf =0 =0.273, D=5 =51.5mm, mm, V=4 V=4.17 m/ m/ D=5 =51.5mm mm V=3 V=3.78 m/ m/s s D=4 =495mm mm V=3 V=3.46 s s m/ m/s s
Erosion n
Subsea: F : Flo low Ind Induced V Vibration n § Challe llenge: Production restricted due to fatigue concerns on subsea manifolds & jumpers § Solu So lutio ion: STAR-CCM+ was used to predict the fatigue life, allowing an increase in production rate. Different designs were evaluated producing a 2X increase in fatigue life and a 3X reduction in erosion. § Imp mpact ct: The increased production rate over the life of the well meant the ROI for the simulation was several hundred million dollars. 9
Flo low A Assuranc nce: M : Mult ltipha hase F Flo low i in P n Pipeli line ne
STAR-OLGA coupling (TMF, Cranfield) Mo Model l the lo long pip ipe usin sing OLGA A wit ith slu slug tra rackin cking Pressure and temperature Mass flux, velocity and Flow direction density of each Model Mo l pip ipe elb lbow usin sing ST STAR AR-C -CCM+ M+ phase
Slu lug f flo low p pass a an e n elb lbow ( (TMF, , Cranf nfield ld) Note the passin ssing of Note the in incre crease se in in pre ressu ssure re liq liquid id slu slug in in “b “blu lue”. ”. as s liq liquid id slu slug passe sses. s. Pressu Pre ssure re on the outer r part rt Gas s vo volu lume me fra ract ctio ion
Slu lug f flo low p pass a an e n elb lbow ( (TMF, , Cranf nfield ld) Coupling model Experiment Slug frequency (Hz) 0.5 0.5 slug front: 2.8 to 3.6 Slug velocity (m/s) 3.6 slug tail: 3.0 to 3.5 Peak force on bend (N) 44 to 54 40 to 60 Maximum force on bend (N) 54 60
Severe s slu lugging ng i in r n riser ( (TMF, , Cranf nfield ld) ) Experiment Star-CD-1 STAR-CCM+ 1 Star-CD-2 STAR-CCM+ 0.8 Riser DP, bar 0.6 0.4 Riser top 0.2 0 50 100 150 200 250 300 350 Flow time t, s 4 inch riser Riser DP = P base - P top 10.5 m 55 m pipeline Riser base
Flo low A Assuranc nce: P : Pigging ng Disp isperse rsed so solid lid-liq -liquid id flo low St Stra ratif ifie ied gas-liq s-liquid id flo low
Slu lug c catche her: S : STAR-C -CCM+/OLGA § Challe llenge: Assess performance of slug catcher using STAR-CCM+ § So Solu lutio ion: OLGA used to simulate upstream pipeline system to predict slugging event. OLGA coupled to STAR-CCM+ for detailed transient VOF simulation to predict slug catcher performance for 2 hour slug event § Imp mpact ct: Coupled solution provides ability to perform system-wide simulation ensuring high fidelity of inlet conditions at vessel and high- fidelity 3D simulation of slug catcher with STAR-CCM+
Separation n Eulerian-Eulerian results: Velocity magnitude through inlet diffuser Pa Page 17
Separation: V n: Vane ne p pack d k de-mi -misters
Au August st 2008
• Droplets trapped by vane pack (126 mmscfd, K=0.195) 150 microns 50 microns 5 microns
Efficiency of Vane Pack at 57 bar 100 80 % mass of droplets removed Design (K = 0.32) 60 126 MMSCFD (K = 0.195) 105 MMSCFD (K = 0.161) 40 94 MMSCFD (K = 0.146) 20 0 0 20 40 60 80 100 120 140 Droplet size (micron)
Separation: F n: Fla lare kno knock o k out d drum m § Challenge: Reduce liquid oil Before carried over to flare from drum Solution: Through STAR-CCM+ , § CD-adapco Consulting Services identified cause of carry-over, quantified and suggested options to improve design After § Impact: • Improved flare combustion • Avoided damage to flare tip • Reduced risk (of flaming rain) 22
Flo low C Cond nditioni ning ng r e t e M c i n o s a r t l U
Conc nclu lusions ns � Ind Industry c y cha hang nges i inc ncreased u use o of s simu mula lation n � Example les / / e experienc nce i in w n wide v variety a y appli lications ns � Simu mula lating ng S Sys ystems ms mu mult lti-p -phys ysics/fideli lity s y simu mula lations ns
Tha hank Y nk You! Questions ns?
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