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Subsea Trends & TechnologyAlex Read, Director, Industries Group, CD-adapco
September 15th 2016
Restricted © Siemens AG 2016
09.16.2016Page 2 Siemens PLM Software
Overview
• Subsea market conditions (short & long term trends)
• Industry response
• Simcenter introduction & role
• Examples
• Lazy wave riser design (WGK)
• Subsea choke (FMC Technologies)
• TLP orientation (Atkins)
• Flow induced vibration
• Vortex induced motion (Chevron, Technip)
Summary
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09.16.2016Page 3 Siemens PLM Software
Subsea Market Conditions
Lower-for-longer market environment caused by GCC
countries pursuing market share (vs price)
Increase in production from Saudi & Iran raised
output by 1mbpd
Weaker demand growth (energy efficiency, Chinese
economic transformation, …)
Sustained “low” oil price
US$380bn total project CAPEX deferred, with
deepwater projects hit hardest [source
WoodMackenzie]
Sustained price needed for Deepwater $60+?
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Long term view (trends only)
Economic growth fuels energy
consumption
Energy intensity reduced
Significant growth in Renewables,
but from small base
Gas wins share, “cleaner” HC &
increased supply (fracking) & trade
(LNG)
Global demand for O&G increasing
Source: BP, Energy Outlook – www.bp.com/energyoutlook
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So what now?
• Understand what it takes to succeed in the low cost environment.
• Innovation. Standardization. Reduce costs & overdesign, without
compromising safety.
• “Digital Twin”, including Simulation & Design Space Exploration enable
innovation & cost reduction (see auto industry)
• Prepare – develop core capabilities & ability to scale
• Challenges & Opportunities differ: Onshore (tight) vs Offshore; greenfield vs
brownfield; …
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STAR-CCM+
Simcenter™ Portfolio for Predictive Engineering Analytics
STAR-CCM+
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Simcenter™ Portfolio for Predictive Engineering Analytics
STAR-CCM+
Fluid Dynamics
Solid Mechanics
Fluid-structure
Interaction
Heat Transfer
Particle Flows
Reacting Flows
Multiphase
Electrochemistry
Electromagnetics
Acoustics
Rheology
Multiphysics
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Simcenter™ Portfolio for Predictive Engineering Analytics
HEEDS – Multidisciplinary design exploration
HEEDS
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SubsurfaceProcess & Separation
Technical Safety
Refining & PetroChem
Application Areas
Marine & Offshore
Subsea & Flow Assurance
Restricted © Siemens AG 2016
09.16.2016Page 10 Siemens PLM Software
Simulation & Design Space Exploration Innovate to Reduce Cost
Lazy Wave Riser
Challenge:
• Design Lazy Wave Riser within constraints to
provide best design for competitive tender (short
turnaround)
Objectives:
• Minimize tension at vessel
Analysis tool:
• Orcaflex
Variables:
• Suspended length; Sag; Hog; Length on seabed;
Touchdown
10 10 | Lazy Wave Riser
Suspended Length
Hog
Sag
Touchdown
Length on Seabed
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Design Exploration
HEEDS & Orcaflex
11 | Design Exploration
OrcaFlex Analysis
SHERPA
Response
Change design variables
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Design Exploration
12 | Design Exploration
OrcaFlex Analysis
SHERPA
Response
Change design variables
Optimal
Design
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Optimized Design
The optimal design found by HEEDS was the 110th
design evaluated
• 33% reduction in line tension at vessel under load
case 1
• 35% reduction in line tension at vessel under load
case 2
• 34% reduction in line tension at vessel under load
case 3
• 33% reduction in line tension at vessel under load
case 4
• 33% reduction in line tension at vessel under load
case 5
• 33% reduction in line tension at vessel under load
case 6
13 | Optimized Solutions
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Wood Group Kenny, Riser Design
Challenge:
• Improve the design of a steep wave riser:
• Minimize cost (buoyant cost + flexible cost)
• Minimize line tension at vessel
Result:
• Optimized designs have the following ranges
(relative to baseline design):
• Cost reduction: € 0.59 million (24%) - € 0.38
million (15%)
• Line Tension at Vessel: 42.94 kN increase (57%)
- 45.49 kN decrease (60%)
Lower
Catenary
Section
Upper Catenary
Section
Flexcom Analysis
Ch
ange
des
ign
var
iab
les Evalu
ate respo
nses
Static and Dynamic Flexcom Analyses
Buoyant Section
“”HEEDS automates tedious, repetitive riser design and delivers cost-effective solutions”
FeasibleDesignsInfeasibleDesigns
30%$
50%$
70%$
90%$
110%$
130%$
150%$
Cost$ Tension$
Rela%ve'to'Baseline'Design'
FeasibleDesignsInfeasibleDesigns
30%$
50%$
70%$
90%$
110%$
130%$
150%$
Cost$ Tension$
Rela%ve'to'Baseline'Design'
FeasibleDesignsInfeasibleDesigns
30%$
50%$
70%$
90%$
110%$
130%$
150%$
Cost$ Tension$
Rela%ve'to'Baseline'Design'
Pareto front of
Optimal
Designs
Min
Be
nd
Rad
ius
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FMC Technologies, Reducing Choke Erosion
Challenge:
• Design pipe choke to reduce downstream
pressure and minimize erosion
• By varying 12 geometry parameters
• Results:
• Old process: 3 iterations in 9 days
• New process: 300 designs in 5 days
Process Automation
NX CAD
Generation
STAR-CCM+
CFD Simulation
Geometry Mesh Analysis
Objective Histories
Pressure Drop Erosion Rate
Pressure UC/DC 2700/2500[psia]
Working fluid (Gas+Water) 99.76/ 0.24%
Production Flow Rate 200 MMSCFD
Inner Diameters 7" XT/ 5" Choke
Particle Size 50[μm]
Sand Concentration, ppm 2
Sand Mass Rate, kg/s 9.7E-05
FeasibleInfeasible
Best Design Found (Iteration #253) dp = 535 psi Overall erosion rate = 0.164 g/hr
a002=0.68”
a008=0.63” a010=0.23”
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Atkins: Offshore Platform Optimization
Challenge:
• Choose best orientation for offshore Tension Leg
Platform (TLP) to:
• Maximize ventilation (smaller leakage gas clouds)
• Minimize helideck Impairment from exhaust
• Under wind from 8 directions at 2 speeds
• Vary platform orientation
Annual Wind Distribution
Combined
Calculate helideck impairment from exhaust.
Plan View Elevation View
Helideck Operational Zone
Helideck Operational Zone
“”Optimate helped us to easily explore our design
options.”— Gerard Reynolds, Atkins
Calculate helideck impairment from exhaust
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Reducing Overdesign: Flow Induced Vibration
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Case Study: Flow Induced Vibration (FIV)
Challenge:
Screening methods for FIV overly conservative,
leading to uncertainty in design
Solution:
wave6 and STAR-CCM+ predict acoustic and
structural modes, multiphase flow and fatigue life.
Validated through JIP.
Impact:
Avoid field failures, reduced production rates,
intervention, overdesign
Mode 1
17 Hz
Mode 2
39 Hz
Structural modes, free response
Mode 2
28 Hz
Mode 3
41 Hz
Acoustic modes – free response
17
Hz
37
Hz
1 MPa
RMS
0.85 MPa
RMS
0.77 MPa
RMS
0.45 MPa
RMS
Flow Direction
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Chevron Presentation at
DOT 2013
Solid lines are from
model test
Dots are from field
measurements during loop-
current events
Technip: Full-Scale VIM
• Field data of a Semi VIM motion showed poor
correlation with model test data
• Chevron ETC & Technip initiated CFD study
• Scale effect (Reynolds number)
• Mooring / Riser damping
• Achievements
• Validation in both model and full scale
• Identified main source of VIM response difference
• High-Reynolds number (12 million) wind-tunnel test
for full-scale benchmark
Model Scale Full Scale
(Re ~ 105) (Re ~ 107)
DOT2014: VORTEX-INDUCED MOTIONS OF A COLUMN-STABILIZED FLOATER
PART II: CFD BENCHMARK AND PREDICTION, G. Wu et al.
Full-scale CFD
(45 deg, Hull Only)
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Summary
• Challenging market in the short term
• Focus – be ready for recovery
• Cost reduction & innovation key – simulation & design space exploration role
• Specific examples provided
• Riser design
• Choke erosion
• Platform orientation
• Flow induced vibration
• Flow induced motion
Restricted © Siemens AG 2016
09.16.2016Page 21 Siemens PLM Software
Alex Read
Global Director, Industries Group (CD-adapco)
Business Development
11000 Richmond Ave, Suite 110
Houston, TX, 77042
Phone: +1 281 795 7437
E-mail:
siemens.com