PRESENTATION TOPICS. Company Overview; Problem Description; Goals; Methodology; Conclusion and next steps.

Transcription

1 COMPUTATIONAL FLUID DYNAMICS ANALYSIS OF A THREE PHASE SEPARATOR AND RE-ENGINEERING OF INTERNALS IN ORDER TO IMPROVE THE EFFICIENCY AND PERFOMANCE OF THE SEPARATOR VESSEL Ramirez-Jaimes. R., Gordillo-Celis. C. A., Macías-Macías. C., Montañez. U., Buitrago. J., Higuera-Niño. H., Rubio. H. M., Wolf-Maciel. M. R., Maciel-Filho. R.

2 PRESENTATION TOPICS Company Overview; Problem Description; Goals; Methodology; Conclusion and next steps.

3 HNA PROCESS AND EQUIPMENT SOLUTIONS: Oil & Gas Services HNA Solutions is a Colombian Company that provides computer based engineering services, mechanical expertise and internal professionals for retrofits including: Full process system reviews CFD simulations of separators and scrubbers Numerical analysis of separators and scrubbers Piping Flow Regime studies and assessment of performance implications. General CFD simulations Production development including conceptual design, research and development and testing

4 HNA PROCESS AND EQUIPMENT SOLUTIONS: Oil & Gas Background HNA professionals have a personal background with high profile clients and proven results in the following services: Mechanical Design and Production Computer Based Numerical Analysis Oil & Gas Separation Designs Process Simulation Thermal Treaters. Mansarovar Energy CO Process Research and Development

5 HNA PROCESS AND EQUIPMENT SOLUTIONS: Why HNA Solutions Independent: we don t tailor our results to fit standard or off the shelf hardware. We treat every single process as a new problem. Experience: we have experience in the whole scope of research and development. Our proven strength is in developing real world solutions. Responsive: we address the actual issues. Reliable: we have proven methods and proven techniques. Active: we are already working in the Oil and Gas industry with a number of high profile clients.

6 PROBLEM DESCRIPTION The characteristics of fluid flow and phase separation in an oil-water-solid gravity separator equipped with an H-type distributor and two fire tubes were numerically analyzed in order to improve the separation performance of the already existing inlet distribution system. Geometric Details of the Existing Distribution System

7 PROBLEM DESCRIPTION The existing distribution system shows low separation efficiency owing to the small mass transfer area created by the H-type distributor, wasting much of the available area in the separator. Besides, this configuration allows the solids to accumulate inside and outside the distributor tubes, at the separator walls and over the fire tube creating heat and mass transfer problems and pitting corrosion. Contours of water velocity 13cm under the H-type distributor slots. Oil Volume Fraction Isosurface Oil Volume Fraction Streamlines

8 GOALS The main objective of this project was to design a new distribution system for the oil-water-solid separator that improves the separation performance of the already existing distribution system. Also, to diagnose the separation performance of the Gunbarrel currently installed H-Type distributor.

9 METHODOLOGY First Stage: Performance diagnosis of the H-Type distribution system Problem Identification a. Problem Physics b. Objectives c. Domain CFD Pre-Processing a. Geometry b. Meshing c. Physical model setup (initial and boundary conditions) Alter operating conditions. Alter meshes. Processing Computational Solution Post-Processing a. Analyse the results b. Visualization

10 METHODOLOGY Second Stage: A. New distribution system design Gunbarrel frontal view Star type distribution system detail

11 METHODOLOGY SOLUTION Second Stage: B. Hydraulic analysis of the new distributor in order to ensure uniform distribution inside the tank. PRE-PROCESSING CFD + FACTORIAL DESIGN POST-PROCESSING NO SPECIFICATIONS OK? YES OPTIMAL DESIGN

12 METHODOLOGY Second Stage: B. Hydraulic analysis of the new distributor in order to ensure uniform distribution inside the tank: Optimization. Domain type: Fluid domain Materiales: Oil and Water Setup: Multiphase model: VOF Bouyancy model: Floating Bouyancy reference density: [lb ft^-3] Gravity direction: -Y Heat Transfer model: Isothermal Reference pressure:1 [atm] Turbulence model: k-epsilon Bouyancy model: density difference. Surface Tension: [Dyne cm^-1] Surface tension model: Continuum Surface Force. Primary Fluid: water PHYSICAL MODEL SETUP Boundary Conditions Intlet Normal to the boundary condition momentum: Normal speed 0,67 Inlet Velociity: 0.67 [m s^-1] Outlet Boundary type: Flux direction: Mass and Oil Fraction: 0,33 Water Fraction: Boundary Type:

13 CONCLUSIONS AND NEXT STEPS First Stage FLUTE 1 FLUTE 2 FLUTE 3 FLUTE 4 VELOCITY [msˆ-1] 1, , , ,0866 EFFICIENCY PER FLUTE 75 % 78 % 85 % 85 % TOTAL EFFICIENCY 90,98 % INFLUENCE AREA 21 %

14 CONCLUSIONS AND NEXT STEPS Second Stage: New distribution system «Star type» FLUTE 1 FLUTE 2 FLUTE 3 FLUTE 4 FLUTE 5 FLUTE 6 VELOCITY [msˆ-1] 0,38 0,45 0,35 0,37 0,34 0,33 TOTAL EFFINCIENCY 73 % INFLUENCE AREA 65 %

15 CONCLUSIONS AND NEXT STEPS Second Stage: Hydraulic study for different configurations of the proposed «Star Type» distributor Efficiency: 21,8% Efficiency: 1,5% Efficiency: 32,4% Efficiency: 44,13% Efficiency: 34,0% Efficiency 90,8%

16 CONCLUSIONS AND NEXT STEPS Second Stage: «Star» type distributor optimized. Includes a flow aligner device FLUTES (ARMS) QUANT. L [mm] DN Ubicación " Distribution angle 60 Inclination angle 6 FLUTE 1 FLUTE 2 FLUTE 3 FLUTE 4 FLUTE 5 FLUTE 6 TOTAL EFFICIENCY VELOCITY [msˆ-1] 0, , , , , , ,3% DISCHARGE [m^3 s^-1] 0, , , , , , ,3% MASS FLOW [Kg s^-1] 1, , , , , , ,5%

17 CONCLUSIONS AND NEXT STEPS Comparative analysis between the «H-Type», «Star-Type» and «Star-Type» optimized distributors: Influence in the Gunbarrel separation performance STREAMLINES H-TYPE distributor Star-TYPE distributor Star-TYPE optimized distributor

18 CONCLUSIONS AND NEXT STEPS Comparative analysis between the «H-Type», «Star-Type» and «Star-Type» optimized distributors: Influence in the Gunbarrel separation performance VELOCITY OF FLUID SUPERIOR VIEW D) H-TYPE distributor Star-TYPE distributor Star-TYPE optimized distributor

19 ACKNOWLEDGEMENTS