Você está na página 1de 44

Capability Samples

The Company

• Formed in 1999
• Independent status
• Engineering solutions to fluid flow,
heat transfer, mass transfer and
chemical problems
• Focussed on CFD services
• Software development
Please address questions to ivar.iversen@prospect-fs.co.uk
Clients (O&G)

• Kvaerner Process (Norway)


• Optimus
• Halliburton
• Texaco
• Phoenix Petroleum Services
• Amerada Hess
• PGS Atlantic Power
• Naremco Technology
• AMEC Process and Energy
Some solutions delivered

HEATED BUNDLE AND SPACER


FIRED HEATER DIAGNOSIS
HEAT TRANSFER OPTIMISATION

BAFFLE DESIGN

SEPARATOR OPTIMISATION
Case studies

• A sample of case studies is included


to illustrate breadth of issues tackled
• In some cases confidentiality
prevents full details and pictures to
be disclosed
• Please contact
ivar.iversen@prospect-fs.co.uk
for specific information
Case 1

Design of a Downhole Tool

Using CFD to Develop


a Virtual Prototype
Virtual prototyping

COURTESY OF

INITIAL CONCEPT DEVELOPED CONCEPT


Virtual prototyping process

• Start with existing design


• Analyse and diagnose
• Iterate for improvement
• Report optimal design
• Build physical prototype
• Test
Y-tool bottom line
V1 = 100%
200%

180% • Time to prototype


160% reduced by months
140%
• Physical prototype met
.

120%
target performance
Relative Moment

100%

80%
• 60%+ increase in
60%
moment
40% • 50% increase in
20% potential market
0%
V1 V3 V2 V4 • Analysis costs repaid
Case
by sale of a single unit
Case 2

Simulating Separators in Floating


Production
to
Enhance Separation Performance
Extend Up-time
and
Improve Integrity
Pro-Motion 1.1

• Developed by Prospect Flow Solutions


• Extension to Fluent 5 CFD software
• Enables multiphase sloshing
phenomena to be simulated under
general conditions of motion
• Proven track record for FPSO motion
• Validated against tests at Heriot-Watt
Test rig

CL

PROBE 1 PROBE 2
AIR
590 590

178
WATER

300
AXIS OF ROTATION
890

DIMENSIONS IN
mm
The CFD Model

REPORTING SURFACES
The simulations

ANIMATED
Depth trace at RH probe
Comparison with Period Correction
First 30 Seconds
0.350
CFD
HW
0.300

0.250
.
Depth (m)

0.200

0.150

0.100

0.050

0.000
0 5 10 15 20 25 30

Time (s)
HP Motion Response

ANIMATED
Baffle Characterisation

L:R Perforation model, flow path lines coloured by pressure (Pa)


HP Motion Response

ANIMATED
HP Separator Loads

HP Separator Longitudinal Analysis


Weir Forces
50000 from

40000

30000

Fx
20000
Force (N)

Fy

10000

0
0 5 10 15 20 25 30 35
-10000

-20000

Time (s)
Bottom line

• Accurate free surface tracking


• Interface break-up diagnosed
• Resonance diagnosed
• Internals may be optimised to
maintain interface and avoid
resonance
• Paid for by first process-trip avoided
Case 3

Diagnosis of Separator Performance


and
Design of Optimal Configuration
Summary

• Excessive oil in water from


production separator
• Existing configuration simulated
with CFD
• Advised lowering oil-water
interface to match residence time
for oil and water
Liquid-Liquid Separator

RTD - NC1750_1320_40 RTD - NC1750_950_40


0.012 0.012

0.010 0.010

Water RTD
Vo 0.008 Oil RTD
0.008
lu Water RTD

Volume Fraction
m Oil RTD
e 0.006
0.006
Fr
ac
tio
n 0.004 0.004

0.002 0.002

0.000 0.000
0 200 400 600 800 1000 1200 1400 1600 1800 2000 0 200 400 600 800 1000 1200 1400 1600 1800 2000
Time/Secs Time/Secs

EXISTING CONDITION RTD OPTIMISED CONDITION RTD


Bottom line

• Problem diagnosed early


• Advice backed up by simulations
and sensitivity studies
• New internals avoided
• Shutdown extension avoided
• Oil in water better than target
Case 4

Low Erosion Choke Valve

Design for Target Cv Curve


Summary

• Choke valve downhole with tight


space restrictions
• Cv curve specified for varying
stroke
• Erosion to be minimised
• Pressure drop must take place in
annulus
Target Cv

• Cv = 0.5 at 10% stroke


• Cv = 95 or better at 100% stroke
• Available stroke = 8.325”
Staggered hole model

HOLE DIAMETER 0.281”


Pressures

L TO R: STROKE 10%, 40%, 80%,


100%
Achieved profile
Cvfor WholeValve

120

100 Target
Local model prediction
80 Global model prediction

60
Cv

40

20

0
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Stroke
Results summary

• Cv for water (100% stroke) = 90


• Dp at 300 US gal per min = 9 psi
• Helical hole pattern will smooth
valve operation
• Holes may be aligned rather than
staggered at large stroke to
increase Cv
Bottom line

• Used flow turns to get pressure drop


without large velocity increases
• Tuned valve for target Cv
• Reduced time to prototype by
months
• Hole pattern selected based on
minimum erosion prediction
Case 5

Flow Assurance

Geometry Rationalisation
and
Material Selection
in Heated Bundle
Summary

• Skene tie-in to Beryl A via 15km


heated bundle
• Operating conditions over field life to
be simulated
• Shutdown and start up events to be
characterised
• Optimise materials and configuration
• Predict losses
Sample design comparison

VARIANT 2 VARIANT 3
Leakage from spacers A
and B

L>R TEMPERATURE DISTRIBUTION °C ON ROCKWOOL IN SPACER A AND


B
HM-Return line

Heat Flux Distribution on HM-Return Line

350

300

250

200
Flux (W/m²) .

150
Case 2
100
Case 4
50 Case 6
Case 7
0
0 30 60 90 120 150 180 210 240 270 300 330 360
-50

-100
Azimuth
Bottom line

• CFD enabled conjugate heat transfer to


be quantified by conduction, convection
and radiation
• Complex interaction of material and
geometry was characterised
• CFD used in parallel with process/bundle
software (e.g. OLGA)
Case 6

Fluid Loading

Accounting for shape,


clustering and shielding
in load derivation on structures
Summary

• Conventional methods for deriving


environmental loads become
increasingly conservative for complex
shapes and structures
• Example application to a typical subsea
towhead
• Conventional methods predicted 76
tonnes
• CFD to be used to remove conservatism
CFD domain
Towhead and carrier
Bottom line

• Transient CFD simulation predicted 50


tonnes
• Calibrated against published data
• Substantial savings due to reduced
foundations
Other projects

• Rotating separators
• Cyclonic devices
• Ship hulls and moonpools
• External flows – gas build-up, ventilation and
dispersion
• Fluid loading of external and internal
structures
• Slug disruption of vessels
• Fired heater simulation

Please address questions to ivar.iversen@prospect-fs.co.uk