Simulat ulatio ion n from subsea ea to separat ator or Matt Straw Norton on Straw w Consult ltant ants
Introduct oduction ion Matt Straw – PhD University of Nottingham, CFD in wind engineering (natural ventilation) – 15 years oil and gas engineering consultancy including • Subsea & flow assurance • Process & separation • Safety • Marine operations Norton on Straw Consult ltant ants – Oil & Gas engineering, focussed on simulation-based services – Technical management & business development Our wo work with CD-adap apco – Sector management for oil and gas (upstream) – Help to understand industry needs for current and future simulation – Industry and application experience
Presen enta tati tion on Indus ustry challe leng nges es & breadth h of simulat lation ion Overvie iew of how ow STAR-CCM+ is used in the industry Focus on a selection ion of applicat ations ions and – Provide some of examples of Norton Straw Consultants current projects – Look beyond current simulation methods – CD-adapco development – Trying to avoid duplicating topics from other talks in the session
Upstr tream am oil and gas UPSTREAM – EXPLORATION ION & PRODUCTION ION Engineer ineering ing challe leng nges es – Safety – Challenging environments – Costly and complex intervention – Complex fluids including solids – Long design life (25 years +) – Many uncertainties – Large structures Wide e range e of simulat lation ion required uired – Multiphase flow – Solids production & transport – Conjugate heat transfer – Complex chemistry – Complex rheology – Fluid-structure interaction
Upstr tream am oil & gas areas of applicat ation ion UPSTREAM – EXPLORATION ION & PRODUCTION ION Sub-surface ce – Reservoir – Drilling – Downhole Subsea ea – Production systems – Pipelines – Riser & umbilical systems – Flow assurance Offshore ore structures ctures & facili lities ies – Safety – Process & separation systems – Structural & marine Marine ine operation ons – Vessels operations – Deployment
Sub-sur urfac ace Relat Re ativ ively ly new ew area for detaile iled simulat lation ion Re Reservoir oir – Multiphase – Complex fluids, phase change – Wide scale disparity from reservoir down to pore-scale – Interaction with wellbore Drilling ing & dow ownhole ole – Complex fluid structure interaction issues (6 DOF) – Complex rheology – Solids Wide range of physics applicable le – DEM, Eulerian & Lagrangian gives us multiphase, solids and emulsions – Phase change, real gases (steam injection) – Chemical reactions and behaviour for Enhanced Oil Recovery
Subsea ea & flow ow assuranc ance Flow ow assur uranc ance e – guarant nteeing eing the flow ow – Multiphase flow & solids – Hydrate & thermal management Integ egrit ity – Corrosion – Solids management/ erosion (later talk) Vortex-ind induc uced ed vibratio ion n Flow ow-ind induced ed vibration ion (later talk) On On-bottom om stabilit ility
Co-simu Co imulat lation ion Co-sim Co imul ulat ation on will contin inue ue to develop as we we take on more physics STAR-CCM CCM+ / OLGA coupling ng – Large-scale disparity – 1D simulation advantageous for system-wide – 3D brings accuracy and physics – STAR-CCM+ - OLGA coupling can be used to 2 approaches together STAR-CCM CCM+ / Abaqus - Applications ions coupling ng fluid and structur ure – Riser fatigue, subsea jumper and pipeline flow-induced vibration – Interesting talk at the conference to follow Pressu sure and tempera ratu ture re OLGA with slug tracki king STAR-CCM+ M+
Offshor ore fa facilit lities ies Safety ety (present ntat ation ion later & tomorrow) Process & separat atio ion – Separator performance – Sloshing – Heat exchangers – System integrity Structural l & design – Wave loading – Green water
Oil & gas marine ne operati tions ons Pipeline ne and structur ure installat llatio ion Vessel el costs are signific ficant nt (~$20k to ~100k/day) Need to understan and limitin ing sea-stat ate Drag, added-mas ass & slam load required Simulat lation ion can reduce e conser ervat atis ism
Case e studies es
Flow ow assuranc ance e - Hydrat ate e managem emen ent Hydrat ate e – Ice – like solid formed between hydrocarbon gas and water – Avoidance is a major design and operational consideration – Can block a production system; complex and expensive to remedy Current nt design n strat ategy egy – Methanol injection during production (expensive to inject and reclaim) – Avoid temperatures below which hydrates form – A challenge during a shutdown for more complex structures (rather than pipelines) – Usually requires insulation
Hydrat rate e managem emen ent-curre urrent nt method hod Start with production on condit itio ion Turn off production ion and allow ow to cool – Monitor minimum fluid temperature – Fails when reaches hydrate appearance temperature Typicall ally build in conser ervat atis ism e.g. – Assumed to be in extreme current – Worst-case insulation properties – Starting production fluid temperature Minimum fluid temperature Hydrate appearance temperature
Hydrat rate e managem emen ent t - develop opmen ent Thermal al analysis is can produce e conser ervat ative e designs ns Hydrat ate e risk is often ex extremely ely low ow when productio ion n fluid reaches es hydrat ate formation ion temperat ature Volum ume of fluid at hydrat ate e format ation on temper erat atur ure e is typically lly negligib ible le for a few ew hours after minimum um fluid temperat atur ure e reaches es hydrat ate e appearan ance Impacts design n & instal allat lation ion signifi fican antly ly – Insulation application time and costs – Structural design (avoiding cold spots) – Dry weight for installation (vessel costs high) How ow do we we reduce e conser ervat atis ism? – Understand the risk better – Model hydrate formation?
Hydrat rate e managem emen ent t - develop opmen ent Oil-dom omina inated ed 3 phase e flow ow (more prev evalen ent in gas syste tems ms) Eulerian erian multiph phase e flow ow model: – Phase 1: Oil – continuous fluid – Phase 2: Gas – dispersed bubbles – Phase 3: Water/hydrate – dispersed droplets (fH=0) turn into hydrate particles (fH=1) Oil region modelled Flow ow directi tion on Hydrate + wate ter Hydrate Oil Wate ter Gas 1. 1. Methane (CH 4 ) gas bubbles dissolv olved ed into the oil 2. 2. Water er dro roplet lets contact dissolv olved ed CH 4 , turn into to hydrate e particles icles when the below ow hydra rate e nucleatio eation n tempera rature ure 3. 3. Dissolv olved ed gas is consumed ed in the hydrate e formation ion pro rocess
Hydrat rate e managem emen ent t - develop opmen ent Tempera ratu ture re of oil (Note areas cooler than hydrate Hydrate fraction on in nucleation temperature of water ter 15.6°C) (Hydrate starts to form when temperature drops below 15.6°C) This can easily be implemented ted in ST STAR-CCM+
Corros osion ion predicti tion n develop opmen ent t in STAR-CC CCM+ Flows ows with low ow wa water cut – Gas with water cut is complex to model – Empirical models not suitable so – Follow the water - Use liquid films to identify risk Solids deposit ition ion – Sediment deposition can lead to accumulation of sulphide-reducing bacteria – Follow the solids – use DEM, Eulerian or Lagrangian
Corros osion ion & electr troc ochem hemic ical al develop opmen ent An area where, , in oil and gas, we we have not ot seen CD CD-adap apco o electroc ochem emic ical l develop opment ent wo workin ing in collab abor orat ation ion with Prof. John Harb, BY BYU Activel ely develop opin ing case studies ies, inp nput valued if data availab able le E-coating Pitting Galvanic 3D Flow + CP Crevice Corrosion
Closing ing remarks rks Simulat lation ion use in upstream eam continu inues es to grow ow and develop STAR-CCM CCM+ gives us wide range of physics Speed of meshing ing and set-up up is key ey to spending ng more time e solving ng the engine neer ering ng problem Continued inued developm pment ent in STAR-CCM CM+ continu inues es to improv ove simulat lation ion and subsequent uent enginee eerin ing Co Co-sim imul ulat ation on opportun unit ities es widens our applications ions
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