Subsea Trends & Technology - offshorevast.se · Page 2 09.16.2016 Siemens PLM Software Overview ......

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Subsea Trends & Technology Alex Read, Director, Industries Group, CD-adapco September 15 th 2016

Transcript of Subsea Trends & Technology - offshorevast.se · Page 2 09.16.2016 Siemens PLM Software Overview ......

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Subsea Trends & TechnologyAlex Read, Director, Industries Group, CD-adapco

September 15th 2016

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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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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

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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

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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:

[email protected]

siemens.com