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 Drum

• Case Study – Surge Sphere

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

Companies Helped By CD-adapco

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

• 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

Typical tie-back infrastructure

Project Work Areas

Project Work Areas

Typical tie-back infrastructure

• Vessels / FPSOs • Wave impact analysis

• Sloshing in tanks / separators

• Vessel Integrity

Project Work Areas

• Safety – Flare radiation

– Gas dispersion / Re-ingestion

– Free Falling Life Boats

Typical tie-back infrastructure

Outline

• Introduction to Engineering Services

• Process Equipment: An Overview

• Case Study – Flare Knock Out Drum

• Case Study – Stabilizer Feed Drum

• Case Study – Surge Sphere

Areas Of Interest

• Design Verification - Separation performance

– Liquid carry over

– Liquid carry under

– Sloshing – Effectiveness of baffles

– Vessel Integrity

Areas Of Interest

• Design Verification - Separation performance

– Liquid carry over

– Liquid carry under

– Sloshing vessels

• Resolving Current Issues

– Under performance

– Operational Issues

Outline

• Introduction to Engineering Services

• Process Equipment: An Overview

• Case Study – Flare Knock Out Drum

• Case Study – Stabilizer Feed Drum

• Case Study – Surge Sphere

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.

Operations Data

Flare event:

Increase in gas flow

Decrease in liquid

level

Flare Knock Out Drum

Gas Outlet Pipe

Liquid Outlet Pipe:

Wall (closed)

Gas Inlet Pipe:

Fixed mass inlet

Baffle Plate

Original Design

Inlet gas flow is directed

downwards onto the liquid surface

where it creates a large standing

wave.

Design Variations

Flat plate perpendicular to the inlet ducting

Flat plate angled towards the upper surface of the vessel

Design Variations

Saucer perpendicular to the inlet ducting

Vertical half pipe

Design Variations

Horizontal half pipe

Convex plate

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

Carry Over Comparison

Outline

• Introduction to Engineering Services

• Process Equipment: An Overview

• Case Study – Flare Knock Out Drum

• Case Study – Stabilizer Feed Drum

• Case Study – Surge Sphere

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

Flow Field Overview

Liquid hydrocarbons present

in the boot section

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

Original Configuration

Modified Configuration

Distributor Plate

Modified Weir Plate:

Glycol / Condensate

Interface raised 50mm

Alternative Internals Arrangement

Original Configuration

Modified Configuration

Flow Field Comparison

Original Configuration

Modified Configuration

Reduced

recirculation

zones

Improved flow through

the vane unit

Flow Field Comparison

Volume Fraction

of Oil

Original Configuration Modified Configuration

Carry-over Quantification:

Droplet Diameter 0.1mm