SLIDE 1
Outline
- Introduction to Engineering Services
- Process Equipment: An Overview
- Case Study – Flare Knock Out Drum
- Case Study – Stabilizer Feed Drum
- Case Study – Surge Sphere
STAR-CCM+ In The Process Industry Mark Farrall, Director, - - PowerPoint PPT Presentation
STAR-CCM+ In The Process Industry Mark Farrall, Director, - - PowerPoint PPT Presentation
STAR-CCM+ In The Process Industry Mark Farrall, Director, Engineering Services Europe Outline Introduction to Engineering Services Process Equipment: An Overview Case Study Flare Knock Out Drum Case Study Stabilizer Feed
SLIDE 2
SLIDE 3
Engineering Services: The Customer-Flexible Role
We concentrate on the underlying need: what do “You” need to know or find out Jump Start In-house Analysis Capabilities Further advance In-house Analysis Capabilities
- Where CD-adapco already knows how to do it
- Where no one knows how to do it
Validate/Evaluate the Software in “Your” Application Understand How a Current Product Works Support New Product Development Overcome Short Term Resource Needs Overcome Near Term Schedule Needs Team with CD-adapco in a Proposal to Make “Your” Services More Comprehensive to “Your” customers Fulfill a Contractual or Legal Requirement
SLIDE 4
Companies Helped By CD-adapco
SLIDE 5
Outline
- Introduction to Engineering Services
- Projects Work Areas
- Process Equipment: An Overview
- Case Study – Flare Knock Out Drum
- Case Study – Stabilizer Feed Drum
- Case Study – Surge Sphere
SLIDE 6
- Onshore / Offshore Pipelines
– Slugging – Chemical injection management – Investigation of the effects of Gas lift – Thermal Insulation (Start-up and Shut-down) – STAR-Olga coupled analyses
Typic pical al tie ie-ba back ck in infras astru tructure ture
Project Work Areas
SLIDE 7
Project Work Areas
Typic pical al tie ie-ba back ck in infras astru tructure ture
- Vessels / FPSOs
- Wave impact analysis
- Sloshing in tanks / separators
- Vessel Integrity
SLIDE 8
Project Work Areas
- Safety
– Flare radiation – Gas dispersion / Re-ingestion – Free Falling Life Boats
Typic pical al tie ie-ba back ck in infras astru tructure ture
SLIDE 9
Outline
- Introduction to Engineering Services
- Process Equipment: An Overview
- Case Study – Flare Knock Out Drum
- Case Study – Stabilizer Feed Drum
- Case Study – Surge Sphere
SLIDE 10
Areas Of Interest
- Design Verification - Separation performance
– Liquid carry over – Liquid carry under – Sloshing – Effectiveness of baffles – Vessel Integrity
SLIDE 11
Areas Of Interest
- Design Verification - Separation performance
– Liquid carry over – Liquid carry under – Sloshing vessels
- Resolving Current Issues
– Under performance – Operational Issues
SLIDE 12
Outline
- Introduction to Engineering Services
- Process Equipment: An Overview
- Case Study – Flare Knock Out Drum
- Case Study – Stabilizer Feed Drum
- Case Study – Surge Sphere
SLIDE 13
Flare Knock Out Drum
- Motivation: Oil carry-over from the Knock-Out Flare Drum during
- flaring. The liquid level inside the vessel was observed to drop during
flaring events. Further indicators of this came from a temperature increase in the vessel. Heavier hydro-carbons can produce a diesel “sheen” on the surrounding sea after flaring. Lighter hydro-carbons can sometimes produce a “burning rain” from partially burnt oil.
- Solution: Multiphase model of the Knock-Out Flare Drum to identify
cause of carry-over; Identify potential design solutions.
- Business Benefit: Oil carry-over can lead to poor combustion and
resultant damage to the flare tip. Liquid level dropping can trip the level alarm which shuts down production.
SLIDE 14
Operations Data
Flare event: Increase in gas flow Decrease in liquid level
SLIDE 15
Flare Knock Out Drum
Gas Outlet Pipe Liquid Outlet Pipe: Wall (closed) Gas Inlet Pipe: Fixed mass inlet Baffle Plate
SLIDE 16
Original Design
Inlet gas flow is directed downwards onto the liquid surface where it creates a large standing wave.
SLIDE 17
Design Variations
Flat plate perpendicular to the inlet ducting Flat plate angled towards the upper surface of the vessel
SLIDE 18
Design Variations
Saucer perpendicular to the inlet ducting Vertical half pipe
SLIDE 19
Design Variations
Horizontal half pipe Convex plate
SLIDE 20
Final Design
The new concave plate design directs the flow to the sides of the drum and then downwards. When the inlet gas stream reaches the liquid surface it has lower velocity and is directed more horizontally than the original design. Only small waves are generated
SLIDE 21
Carry Over Comparison
SLIDE 22
Outline
- Introduction to Engineering Services
- Process Equipment: An Overview
- Case Study – Flare Knock Out Drum
- Case Study – Stabilizer Feed Drum
- Case Study – Surge Sphere
SLIDE 23
Inlet Pipe Inlet Pipe Diffuser Vane Unit Weir Plate Boot Vortex Breaker Condensate Outlet Gas Outlet Vane Pack Glycol Outlet
Stabilizer Feed Drum
- Motivation: Condensate carry-under from the Stabilizer Feed Drum
- Solution: Multiphase model of the Stabilizer Feed Drum to identify
cause of carry-under; Identify potential design solutions; Qualitative flow field comparisons; Quantitative carry-over comparisons
- Business Benefit: Vessel out of use
SLIDE 24
Flow Field Overview
Liquid hydrocarbons present in the boot section
SLIDE 25
Flow Field Overview
Gas Recirculation Zone
- The gas exiting the inlet device impacts the liquid surface and moves
around the upstream part of the vessel.
- As the vane pack covers only have the vessel height the gas flows over the
top and down, generating a large recirculation zone in the main part of the vessel.
- Chance for surface entrainment leading to liquid carry over
SLIDE 26
Original Configuration Modified Configuration
Distributor Plate Modified Weir Plate: Glycol / Condensate Interface raised 50mm
Alternative Internals Arrangement
SLIDE 27
Original Configuration Modified Configuration
Flow Field Comparison
SLIDE 28
Original Configuration Modified Configuration Reduced recirculation zones Improved flow through the vane unit
Flow Field Comparison
SLIDE 29
Volume Fraction
- f Oil