The oil & gas industry continues to face a sustained period of low prices. To succeed we need innovative designs to lower costs while making no compromise in safety and performance.
Engineering design has traditionally been developed using simplified or empirical analysis (1D tools), physical testing, and experience-based learning in the field. While these methods are important, they can limit the ability to innovate (it’s costly to try something new), lead to excessive engineering time and costs and result in overdesign.
Siemens’ software enables engineers to explore designs digitally through detailed, accurate computational fluid dynamics (CFD) simulation and design space exploration. Through simulation you can explore designs virtually with a high-degree of fidelity, improving confidence and performance while reducing uncertainty, risk, cost and time. These benefits can apply to a wide range of examples:
Design of downhole tools & drilling equipment
Drillbits need to be designed to balance drill cuttings transport and removal to increase Rate Of Penetration (ROP), without reducing durability through erosion. The response of downhole tools to the harsh operating conditions they will face is critical in successful and reliable operation. STAR-CCM+ enables engineers to explore design space to find better, more reliable drillbit designs, faster.
Flow Assurance & Subsea
Hydrate plugs forming during a shut-in, excessive erosion and pipe vibration can risk tens of millions of dollars in lost production revenue and remediation costs. STAR-CCM+ allows subsea and flow assurance engineers to design effective insulation systems to maximize the no-touch time, minimize field-life erosion and avoid the risks of vibration to maximize production reliability while minimizing the cost of design, materials and installation.
Marine & Offshore
Accurate Vortex Induced Motion (VIM) prediction can make or break the viability of a floating production facility. Traditional scale model testing methods have been shown to significantly overestimate the magnitude and frequency of VIM, adding millions to project costs. STAR-CCM+ provides engineers with an accurate, full-scale Numerical Wave Basin, reducing uncertainty from scale effects and riser and mooring line damping.
Process & Separation
Under-performing separators significantly impact production rates and revenue. Simplified vessel sizing calculation, empirical analysis and experience alone do not guarantee performance; especially in floating production, where sloshing needs to be controlled for process performance and structural integrity.
STAR-CCM+ enables technology and equipment developers to accurately simulate the full range of multiphase flows to identify optimum designs and demonstrate full-scale performance at real operating conditions.
Design and position of helidecks is critical to ensure weather conditions don’t limit helicopter operations and threaten offshore safety and evacuation. CFD offers the only means of predicting wind conditions at full-scale in a virtual environment and is specified in the Civil Aviation Authority standards for helicopter landing areas. STAR-CCM+ enables engineers to quickly create 3-dimensional models of a production facility and accurately simulate the full range of wind conditions to position and design helidecks that maximize availability and safety.
Efficient transport and processing of natural resources is critical to a viable midstream or downstream business. Effective burner design in a fired heater requires efficient combustion and thermal management while emissions need to be minimized to reduce environmental impact. Empirical calculations cannot reproduce the complexities of such systems and testing can be time-consuming, expensive and limit innovation. STAR-CCM+ has the capability of simulating all of the complex processes from flow distribution and mixing to combustion and clean-up of exhaust gases and waste products. The design-space exploration and optimization capability of HEEDS further enables engineers to increase their understanding and improve their system performance in less time at lower cost.