www.cd-adapco.com Flow Assurance By Design Multi-Fidelity Simulation for Improved Design, Development, and Validation of Subsea Pipelines and Equipment
What You Need to Know… The importance of “Up-Front” and “Multi-Fidelity” simulation Examples and Benefits of 3-D Flow and Thermal Simulation The Software Behind the Benefits: ST STAR-CCM+ AR-CCM+ The Company Behind the Solutions: CD-adapco 2
Ocean Temperature Slugging/Hydrates Ocean Pressure Inhibitors Well Fluid Temp/pressure Accessibility for Repair/Replacement 3
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 operating 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 3D CFD with STAR-CCM+ / coupled 1D-3D: • – Higher fidelity physics/geometry – Detailed simulation – More computing resource required (but getting cheaper) Test: • – Includes all physics – Costly, time-consuming, lack of facility availability, scaling, data acquisition 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 Subsea and topside: Separators/Slugcatchers/FWKO Jumpers/errosion Advanced thermal /flow modeling VIV of risers/umbilicals Split nodes Subsea processing Pumps Sand transport Coldspots Component Errosion Drill Bits/Sand Control ICV/Valves 7
Further Relevant Topside 3D Flow and Thermal Simulation Application Areas Flare Combustion/Radiation Tankers/LNG Ships: Seakeeping, Sloshing, Propulsion VIM of Spars Offshore Platforms: Wave Slamming, Wind Loading 8
Subsea Applications (partial list) Gas lift VIV • • Equipment sizing Heat transfer coefficinets • • Operating procedures In-pipe heating • • Cool-down times/ Installation ( component loads) • • insulation Equipment optimization (weight • Solid transport reduction) • Displacement problems Erosion • • Hydrate remediation Heavy oils • • Testing of assumptions Inhibitors, top-line wetting • • (e.g. wax during pigging) 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 Viscosity Viscosity Density Density Temperature Temperature
Pressure drop along pipe Isothermal Isothermal With cooling With cooling
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 16
Example: Riser Section
Example: Thermal Study (1) • 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. Blue – unprotected pipeline section Red – heated pipeline section Orange – riser (unheated)
Example: Thermal Study (2) • 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 25 o C. (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 (3)
Examples: Solid Transport / Erosion
Examples: Solid Transport / Erosion 2222
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 “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) 23
The Software Behind the Benefits: ST STAR-CCM+ AR-CCM+
The Integrated Flow, Thermal and Stress Process Advanced Physics Automated Solutions Volume Meshing Accelerated Pre-Processing with Surface Wrapping Geometry Import & CAD –Embedded Front End
Some Further Examples of Some Further Examples of 3D Flow/Thermal Simulation Solutions… 3D Flow/Thermal Simulation Solutions… Pig Insertion Pig Insertion Slug Catcher Slug Catcher Top-side Separator Top-side Separator 2 m Christmas Tree: Christmas Tree: Pipe Junction: flow regime disruption Bubble Simulation Bubble Simulation Your CAE Partner for Success 26
CD-adapco : The Company Behind the Solutions 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
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