Case S Studies f from t m the he O Oil & l & Ga Gas - - PowerPoint PPT Presentation

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

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

Ov Over ervi view w

Change in economic reserves to deep-water, HPHT & unconventionals, … Technology & simulation à innovation and understanding of new challenges

Ind Industry Dr y Drivers

Improvements in modeling capabilities, experience & confidence Simulating systems: multi-physics, -fidelity, complex geometries, HPC Capital/risk intensive Technology & simulation à minimize & quantify risks, maximize durability

Upstream m

– Down hole tools – Completions – Subsea – Flow Assurance – Offshore – Separation – Gas dispersion/explosions

Midstream m

– Flow conditioning/metering

Do Downs nstream m

– Refining

Appli lication A n Areas

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

Gr Gravel p l packi king ng: DE : DEM

Slurry flow in pipe

d=9 =90 µm, , vf=0 =0.19, D=1 =103mm, mm, V=3 V=3 m/ m/ s s d=1 =165 µm, , vf=0 =0.189, D=5 =51.5mm, mm, V=4 V=4.17 m/ m/ s s

Unif iform rm so solid lid vo volu lume me fra ract ctio ion (vf vf) ) and slu slurry rry ve velo locit city y (V) (V) g g L=1 =10m m V V 1m m D D Me Measu sure reme ment pla lane

d=2 =270 µm, , vf=0 =0.2, D=5 =51.5mm mm V=5 V=5.4 m/ m/s s d=1 =165 µm, , vf=0 =0.0918 D=5 =51.5mm mm V=3 V=3.78 m/ m/s s d=4 =480 µm, , vf=0 =0.203, D=5 =51.5mm mm V=3 V=3.41 m/ m/s s d=1 =165 µm, , vf=0 =0.273, D=4 =495mm mm V=3 V=3.46 m/ m/s s

Erosion n

Subsea: F : Flo low Ind Induced V Vibration n

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§ Challe llenge: Production restricted due to fatigue concerns on subsea manifolds & jumpers § So Solu 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.

Flo low A Assuranc nce: M : Mult ltipha hase F Flo low i in P n Pipeli line ne

STAR-OLGA coupling (TMF, Cranfield)

Mass flux, velocity and density of each phase Pressure and temperature Flow direction Mo Model l the lo long pip ipe usin sing OLGA A wit ith slu slug tra rackin cking Mo Model l pip ipe elb lbow usin sing ST STAR AR-C

• CCM+

M+

Slu lug f flo low p pass a an e n elb lbow ( (TMF, , Cranf nfield ld)

Gas s vo volu lume me fra ract ctio ion Pre Pressu ssure re on the outer r part rt Note the passin ssing of liq liquid id slu slug in in “b “blu lue”. ”. Note the in incre crease se in in pre ressu ssure re as s liq liquid id slu slug passe sses. s.

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 velocity (m/s) slug front: 2.8 to 3.6 slug tail: 3.0 to 3.5 3.6 Peak force on bend (N) 44 to 54 40 to 60 Maximum force on bend (N) 54 60

4 inch riser 55 m pipeline 10.5 m Riser top Riser base Riser DP = Pbase - Ptop

Severe s slu lugging ng i in r n riser ( (TMF, , Cranf nfield ld) )

50 100 150 200 250 300 350 0.2 0.4 0.6 0.8 1 Flow time t, s Riser DP, bar Experiment Star-CD-1 Star-CD-2

STAR-CCM+ STAR-CCM+

Flo low A Assuranc nce: P : Pigging ng St Stra ratif ifie ied gas-liq s-liquid id flo low Disp isperse rsed so solid lid-liq

• 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+

Pa Page 17

Eulerian-Eulerian results:

Velocity magnitude through inlet diffuser

Separation n

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

20 40 60 80 100 20 40 60 80 100 120 140 % mass of droplets removed Droplet size (micron)

Efficiency of Vane Pack at 57 bar

Design (K = 0.32) 126 MMSCFD (K = 0.195) 105 MMSCFD (K = 0.161) 94 MMSCFD (K = 0.146)

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Separation: F n: Fla lare kno knock o k out d drum m

§ Impact:

• Improved flare combustion
• Avoided damage to flare tip
• Reduced risk (of flaming rain)

§ Solution: Through STAR-CCM+, CD-adapco Consulting Services identified cause of carry-over, quantified and suggested options to improve design § Challenge: Reduce liquid oil carried over to flare from drum

Before After

Flo low C Cond nditioni ning ng

U l t r a s

• n

i c M e t e r

Ind Industry c y cha hang nges  i inc ncreased u use o

• f 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

Conc nclu lusions ns

Questions ns?

Tha hank Y nk You!