What You Need to Know The importance of Up-Front and Multi-Fidelity - - PowerPoint PPT Presentation

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Flow Assurance By Design

Multi-Fidelity Simulation for Improved Design, Development, and Validation

• f Subsea Pipelines and Equipment

What You Need to Know…

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The importance of “Up-Front” and “Multi-Fidelity” simulation The Company Behind the Solutions: CD-adapco Examples and Benefits of 3-D Flow and Thermal Simulation The Software Behind the Benefits: ST STAR-CCM+ AR-CCM+

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Ocean Temperature Ocean Pressure Well Fluid Temp/pressure Slugging/Hydrates Inhibitors Accessibility for Repair/Replacement

The Importance of 3D Simulation in Engineering Design

• “The deeper you go, the less you know”

– Engineers need to know if proposed equipment and system

designs will function properly under increasingly harsh

• perating 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

3D Simulation is rapidly moving from a troubleshooting tool into a leading position as a design tool: “Up-Front 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

– 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.

– 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:

– 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, data

acquisition

• 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-- It’s cheaper to be wrong in the virtual world-- Failure in the real world is not an option! Failure in the real world is not an option!

Example Areas for Use of 3D Flow and Thermal Simulation in Deep Offshore Engineering

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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

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

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 (component loads)
• Equipment optimization (weight

reduction)

• Erosion
• Heavy oils
• Inhibitors, top-line wetting
• Sulfur transport/melting

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

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

• 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

Temperature Temperature Viscosity Viscosity Density Density

Pressure drop along pipe

With cooling With cooling Isothermal Isothermal

Multiphase Flow in Pipe Bends

Large bubbles Large bubbles Medium Medium bubbles bubbles Small bubbles Small bubbles Liquid Liquid

4-phase model for 4-phase model for more accuracy more accuracy

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Example: Riser Section

• 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 section Orange – riser (unheated)

• 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 (2)

Example: Thermal Study (3)

Examples: Solid Transport / Erosion

Examples: Solid Transport / Erosion

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“These applications demonstrate that CFD offers the potential for huge “These applications demonstrate that CFD offers the potential for huge advancements in drilling, especially under more challenging conditions. CFD advancements in drilling, especially under more challenging conditions. CFD gives design engineers the ability to easily and accurately analyze fluid flow, gives design engineers the ability to easily and accurately analyze fluid flow, making it possible to rapidly evaluate alternatives and also provides making it possible to rapidly evaluate alternatives and also provides comprehensive diagnostic information. The result is that design engineers comprehensive diagnostic information. The result is that design engineers can optimize the drilling bit from a fluid flow perspective during the design can optimize the drilling bit from a fluid flow perspective during the design phase.” phase.”

• -Dr. Michael Wells, Director of Research and Development,
• Dr. Michael Wells, Director of Research and Development,

Hughes Christensen Division of Baker Hughes 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 Testimonial to the Benefits of 3D CFD

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The Software Behind the Benefits:

ST STAR-CCM+ AR-CCM+

The Integrated Flow, Thermal and Stress Process

Geometry Import & CAD –Embedded Front End Accelerated Pre-Processing with Surface Wrapping Automated Volume Meshing Advanced Physics Solutions

Your CAE Partner for Success 26

Pipe Junction: flow regime disruption

2 m

Some Further Examples of Some Further Examples of 3D Flow/Thermal Simulation Solutions… 3D Flow/Thermal Simulation Solutions…

Slug Catcher Slug Catcher Christmas Tree: Christmas Tree: Bubble Simulation Bubble Simulation Pig Insertion Pig Insertion Top-side Separator Top-side Separator

• 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

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CD-adapco: The Company Behind the Solutions

A Selection of our Oil and Gas Clients

• 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 The Concept

OLGA <-> STAR: OLGA <-> STAR: Flow rates/pressure Flow rates/pressure STAR <-> OLGA: STAR <-> OLGA: Flow rates/pressure Flow rates/pressure

Study 3D effects of in-line equipment: valves, junctions, elbows, risers, obstacles, jumpers, Study 3D effects of in-line equipment: valves, junctions, elbows, risers, obstacles, jumpers, separators, slug catchers, compressors, ... separators, slug catchers, compressors, ... One-way or two-way, one end or multiple ends of 3D in-line equipment

One-way or two-way, one end or multiple ends of 3D in-line equipment

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 with

OLGA for upstream pipeline input

SLUG CATCHER (Upstream Olga Model)

(24 Km) (24 Km) (200m) (200m)

SLUG CATCHER: Oil Surface

Olga Oil Flow Rate Blue graph below (BC to CFD Model)

Jumper Experimental Setup Jumper Experimental Setup (U. of Tulsa Hydrates JIP: (U. of Tulsa Hydrates JIP: ¼ scale) scale)

Talk to Us About Next Steps…

• 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

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:

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Continental Breakfast 9:00 am – 10:30 am

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Lunch (by invitation only—contact SPT directly) 12:15 am – 1:45 pm – SPT’s CEO Tom Even Mortensen will speak during lunch

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Networking Happy Hour 5:00 pm – 8:00 pm

• Partner Showcase Demonstration Area: STAR-OLGA Link

STAR-OLGA Link

Come to CD-adapco’s 2nd Annual STAR STAR Global Global Forum 2010: Simulation for Energy Engineering 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)