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issue 2.01
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dynamics
Features
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BIGGER, BETTER
THERMOFLUIDS
PRO-S3
FLOW ASSURANCE
In Turbomachinery
Aerodynamic Analysis
Contents
03
04
05
06
09
11
13
14
15
19
21
23
27
29
32
33
35
37
40
41
43
45
47
49
51
53
54
Introduction
The Power of Integration
by Jean-Claude Ercolanelli
Breaking News
ING Renault F1 Team unveil new CD-adapco logo
Key Studies
Flow & thermal analysis of a turbine blade - Denis Yurchenko and Pavel Krukovsky
Partner News
New consulting services from DNV with fluid dynamics software from CD-adapco
Dassault Systmes Announces CAA Software Partnership with CD-adapco
Product news
STAR-CCM+ STAR-CD STAR-CAD Series
19
23
27
29
33
37
41
43
45
51
Surface Wrapping
Surface Wrapping Technology for Industrial CAE
Surface Wrapping Seminar
CD Giveaway
CFD
Business Benefits
A Business Benefits Argument for CFD
Turbomachinery
Thermofluids in Turbomachinery
Conjugate Heat Transfer; Dynamic thermal response
Automotive
STAR-CCM+
An Elegant Engineering Solution to Engine Conjugate Heat Transfer
Bigger, Better, Motor Sport CFD
In the world of simulation, bigger is usually better.
Motorcycle race aerodynamics
Aerodynamic Analysis of a Motorcycle and Rider on a high speed corner
Consumer Products
Dont Waste Hot Water:
Computer Simulation unlocks the secret of the Perfect Shower
Marine
Germanischer Lloyd & CD-adapco join forces
State-of-the-art simulation for the marine industry
Oil & Gas
Computational Flow Assurance
New Challenges Increase the Importance of 3-D CFD in the Oil and Gas Industry
Forever Blowing Bubbles
Revolutionary MBF Separator Design with CFD
DVD Giveaway
Flow, Thermal & Stress Simulation Technology from CD-adapco
Reducing Separation Anxiety
Powerful 3D Flow & Thermal Simulation
CPI
Slag-Cleaning
Building Services
Flow modeling
Belarusian National Academic Grand Theatre of Opera and Ballet
Parallel Computing
Gaining CAE Productivity with CD-adapco & Panasas
Regulars
Training
Dr Mesh
Winners
CAE Guru 2008
Upcoming Events
Printed on Nine Lives recycled paper using vegetable inks. Were doing our bit, are you?
Reduce your Carbon Footprint today http://www.carbonfootprint.com/
EDITORIAL
Dynamics welcomes editorial from all users of CD-adapco software or services.
To submit an article:
Email editorial@uk.cd-adapco.com Telephone: +44 (0)20 7471 6200
Editor
Sub-editors
Art Director
Advertising
Multimedia Director
Subscriptions
Dynamics is published approximately three times a year, and distributed internationally.
To subscribe or unsubscribe, please email info@uk.cd-adapco.com
Telephone +44 (0)207 471 6200
Bringing it all
together, the power
of integration
03
dynamics 2.01
Jean-Claude Ercolanelli
Vice President, Product Management
CD-adapco
L EMAIL jc.ercolanelli@fr.cd-adapco.com
L EMAIL info@uk.cd-adapco.com
dynamics 2.01
04
W Fig:01
External and internal heat transfer
coefficients (far left and middle) of
the turbine blade with resulting
temperatures shown on the right.
L MORE INFORMATION
05
http://www.ittf.kiev.ua
dynamics 2.01
Partner News
Dassault Systmes
DNV (Det Norske Veritas) has selected a software solution for computational
fluid dynamics (CFD) from CD-adapco to extend its leading-edge technical
consulting service line. The new software will be a valuable addition to the DNV
toolbox to provide accurate and reliable estimation of slamming and sloshing
loads, which are critical for the design and operation of both ships and offshore
structures.
Denis Yurchenko and Pavel Krukovsky - Institute of Engineering Thermophysics, Kyiv, Ukraine
S Fig:02
L MORE INFORMATION
info@uk.cd-adapco.com
http://www.dnv.com/
dynamics 2.01
06
W Fig:01
A transient, fluid structure interaction
simulation of a flexible baffle in an air
stream is enabled by coupling
ABAQUS finite element analysis
software with computational fluid
dynamic (CFD) results from STAR-CD.
This color contour plot of fluid
pressures in STAR-CD depicts a
specific instance in time, at which the
polyhedral CFD mesh from STAR-CD
has moved to accommodate the
structural deformation of the ABAQUS
baffle model.
Dassault Systmes
Announces CAA
Software Partnership
with CD-adapco
W Fig:02
This thermal-stress analysis of an engine
manifold is performed by coupling the
computational fluid analysis from STAR-CD
with the structural analysis in ABAQUS finite
element analysis. This color contour plot
from ABAQUS shows temperature
distribution on the manifold resulting from
the flow of hot exhaust gases.
07
dynamics 2.01
http://www.3ds.com/alliances/software-partnership/
S Fig:03
In this model of an engine manifold, a thermal-stress analysis is performed by coupling the computational fluid analysis results from STAR-CD with
the structural analysis in ABAQUS (Figure 2).
dynamics 2.01
08
..::PRODUCT NEWS
..::PRODUCT NEWS
STAR-CD
STAR-CAD Series
PRODUCT NEWS
Jean Claude Ercolanelli, VP of Product Management, CD-adapco
STAR-CCM+
The November release brought STAR-CCM+ version 2.10 and an
extensive list of new features, the most significant being the
addition of the Lagrangian multiphase capability to add to the
existing free surface models. From calculating the impact of rain
droplets on the windscreen of a car to predicting the erosive effect
of small particles of sand carried in an oil pipeline, the Lagrangian
models allow users to simulate the transport of solid particles,
liquid droplets or bubbles of gas by a background fluid.
STAR-CCM+
STAR-CD
STAR-CAD Series
During November 2007 CD-adapco announced three major product
releases, firstly STAR-CCM+ V2.10 and the STAR-CAD Series V4.14
were released, closely followed by STAR-CD Version 4.04.
The release of major new versions of all three product lines is
testimony to the CD-adapcos Power of Integration, a common
theme running through all of our products: STAR-CCM+ offers a
single integrated process from 3D-CAD geometry to the CFD
solution; STAR-CD provides an integrated platform for flow, thermal
and stress analysis and the STAR-CAD Series integrates industrial
strength flow and thermal technology into CAD and PLM
environments.
The release of new versions of all our products required an
integrated effort across the whole of CD-adapco, and demonstrates
commitment at every level towards delivering the best-in-class CAE
technology for our users and partners.
The concerted rate of product development continues with the
arrival of STAR-CAD series and STAR-CCM+ V3.02 and the
impending release of STAR-CD 4.06.
L DOWNLOAD http://www.cd-adapco.com/products/index.html
09
dynamics 2.01
dynamics 2.01
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T Fig:01
Geometries of part of a complex
conceptual building design.
Images courtesy of Atelier Ten
T CAD
T Import
T Wrapped
Dealing with the consequences of dirty or complicated CAD data has long been the
biggest bottleneck in the CAE process and, until recently, was the single largest
obstacle preventing the routine implementation of numerical simulation early in the
industrial design process.
Although the route from CAD model to CAE solution
has been much improved in recent years, with the
introduction of better translators and CAD-embedded
CAE simulation technology, there still exists a
significant group of problems where CAD geometries are too big or
complex to be handled easily. These problems typically involve
large assemblies of complex CAD parts, many of which contain
more detail than is strictly necessary for the CAE calculation.
Estimates from the automotive industry suggest that as much as
80% of the simulation effort spent in a typical CAE project is
taken up in generating the computational model, the lions share
of which is surface preparation and repair.
11
dynamics 2.01
S Fig:02
What constitutes dirty CAD?
High fidelity wrapped surface of Atelier
The surface wrapper is useful for dealing with many different
Ten conceptual design
instances of dirty or overcomplicated CAD:
1. Any complex collection of CAD parts, such as an
automotive underhood that needs to be combined into a
single surface for meshing. Early in the design process,
before packaging issues have been resolved, individual
components often do not fit together perfectly, as they
would in the final configuration, meaning that their volumes
overlap or surfaces potentially interfere with each other.
2. A fully detailed CAD part that requires too much detail for
CAE analysis, and which needs to be de-featured prior to
constructing a computational mesh suitable for analysis.
dynamics 2.01
12
FREE
CD
13
dynamics 2.01
L TO RECEIVE YOUR FREE CD PLEASE E-MAIL info@uk.cd-adapco.com OR CONTACT YOUR LOCAL OFFICE.
dynamics 2.01
14
Benefit 1:
Improved Product Quality
Increasing product quality is a strategic objective of every company
involved in product design or manufacture. Despite the fact that
improvements in product quality are notoriously hard-won, increased
product quality is the most frequently achieved benefit of using CDadapcos CFD technology, according to the users that responded to our
survey. In their responses, 66% stated that they had managed to
achieve increased product quality as a direct result of applying CFD
simulation in their product design process. The average increase in
quality estimated by these users was 19%.
By most standard definitions, quality is the extent to which a product
meets or exceeds a customers expectations. American business quality
guru Joseph M. Duran defines quality as fitness for use, where fitness
is defined by the customer. What constitutes a high quality product is
hard to define because quality, like beauty, is in the eye of the beholder,
or more specifically, in the eye of a potential consumer. Although quality
is difficult to define, most people can instantly recognise a quality
product:
Better quality products are more desirable to the consumer, and
therefore more saleable. A product that is perceived (by the customer)
to be high in quality will also typically command a premium over a lower
quality alternative. Increasing the quality of an existing product will,
almost always, result in increased revenue for that product and,
provided that the improvements can be delivered at a reasonable cost,
will deliver an increased profit.
A Business Benefits
Argument for CFD
Stephen Ferguson, CD-adapco
15
dynamics 2.01
If making better quality products were easy then everyone would do it.
Any improvement in product quality is usually the result of significant
investment in design, engineering, manufacturing and marketing. In
CAE-mature industries, such as the automotive sector, utilizing CFD is
a competitive necessity since everyone sees benefits in using it. For
these industries, small increases in the quality of an already highly
engineered product (for example a 1% increase in fuel economy of an
automobile) are likely to command a significant premium in the
marketplace.
However, applying CFD simulation to the redesign of a product that has
not previously been the subject of CAE analysis can deliver immediate
and sizeable benefits. Within a few days of installing STAR-Works,
Benefit 2:
Reduction in the number of physical prototypes
Robert Pirsig
Zen and the Art of Motorcycle Maintenance (1974)
dynamics 2.01
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Accuracy
Flexibility
Expertise
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Benefit 3:
A Faster Time to Market
If two products, equal in quality and cost, are released to the market
six months apart, the revenue generated by the first product during
that time is incremental profit. Beyond this, being first to market
generally helps to increase both brand awareness and market share
while simultaneously maximising the potential lifetime of the product.
A faster-time-to-market is an obvious benefit of reducing the amount
of physical prototyping required to bring a product to fruition, but also
a direct benefit of the availability of simulation data early in the design
process. This allows designers to rapidly eliminate poor design
variants, allowing them to focus their efforts on a smaller number of
potentially more productive designs. In safety critical or politically
sensitive applications, simulation results can also help to demonstrate
compliance with legislative requirements, ultimately overcoming one of
the final barriers to product release.
In their responses, 39% of our users claimed that, by applying CFD
simulation to product design, they had managed to reduce time-tomarket, by on average 11%. Although the length of development
cycle varies by product and by industry, the development process for
most products is typically measured in years rather than months, for
which an 11% speed-up represents a significant competitive
advantage over a similar product that was not engineered using CFD.
Benefits 4 and 5:
Fewer Field Failures and Avoided Product Recalls
In the perception of most consumers, durability is a key factor in
determining product quality. Market research3 has conclusively
demonstrated that consumers are not only capable of accurately
estimating product durability, but that their perception of durability is
often linked to the price that they are willing to pay for a product.
While all products have a finite lifetime, the failure of a product in
service can have serious consequences, particularly in the case of safety
critical applications, in which unforeseen failure can result in injury or
Benefit 6:
Increased Satisfaction of External Customers
Customer satisfaction is the bigger picture. While the benefits listed above
might help to increase margins and satisfy internal customers, the biggest
benefit of any process improvement occurs when it makes a tangible
difference to the end user of the product. More satisfied customers are
also more loyal, generally more likely to offer you repeat business or to
forgive any temporary lapse in service. According to the survey, 44% of
users managed to increase the degree of satisfaction experienced by their
external customers.
Multiple Benefits
Realised individually, any of the six benefits described above is likely to
yield significant bottom-line benefits for an organization that successfully
adopts CFD or CAE technology. However, the real benefit of CFD
simulation is that even if you are seeking to realise a single specific
benefit, the ancillary benefits of increased engineering insight will inevitably
lead to a better overall product. In our survey, 76% of respondents realized
two or more of the benefits, 11% four or more, and 4% all six.
REFERENCES
www.cd-adapco.com
L MORE INFORMATION
info@uk.cd-adapco.com
[1] STAR-Works helps VIASYS Healthcare to Breathe More Easily, SW Ferguson, CD-adapco, Dynamics #27
[2] Walter Bauer, Daimler AG in an address to the 2006 STAR Conference
[3] Physical quality, price, and perceptions of product quality: Implications for retailers, JJ Wheatley, JS Chiu, A
Goldman - Journal of Retailing, 1981
dynamics 2.01
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S Fig:04
Full CHT analysis of a turbocharger including
compressor, turbine and lubricating channels
Thermofluids
in Turbomachinery
The recent advances brought to you in STAR-CCM+ are changing the standard
in Thermal analysis for turbomachines. Those pains, particularly caused by
limitations in complex geometry handling and fluid-solid contiguous meshing,
are set to become just a memory.
CD-adapcos geometry and automated meshing
technologies have been successfully applied to the
combined fluid and thermodynamics in a wide range of
turbomachinery flows. In this article, we expound two
key areas; turbine-blade cooling and turbocharger turbines. From
geometry to solution, full conjugate-heat-transfer analyses reduce
from weeks to days.
S Fig:03
19
Turbine-blade Cooling:
Making the analysis process more efficient
The high-temperature of operation in aero and industrial gas
turbines, require active cooling to prolong turbine blade life, with
cooler air bled from the compressor to flow paths cut inside the
blade to provide direct cooling of the metal. The analysis of these
geometries presents a significant challenge, including extreme
physical conditions and highly complex geometries with many
small features relative to the overall size of the domain, stretching
computational and software resources to the limit.
The traditional way of modeling turbine blade cooling is to split the
system into separate functions, external flow, internal cooling and
solid thermal analysis, all coupled together through common
boundary conditions (Figure 1). The flow analysis is completed
first, using a guessed surface temperature or heat flux
dynamics 2.01
BLADE METAL
THERMAL & STRESS
S Fig:01
The traditional process in blade cooling analysis the external flow, internal flow
and metal thermal analyses are performed separately.
dynamics 2.01
20
W Fig:04
Section of Computational Mesh showing
Cylinder Head, Block, Gasket and Coolant Flow
Passages with close up below.
(Image Courtesy GM)
STAR-CCM+
An Elegant Engineering Solution to Engine
Conjugate Heat Transfer
Richard Johns, Automotive Director CD-adapco
21
dynamics 2.01
W
W
W Fig:01
Coolant flow streamlines through a four
cylinder engine.
(Image Courtesy GM)
Apply BCs
Asses Design
Asses Design
S Fig:02
S Fig:03
simultaneously whist the fluid flow is only considered in those for which
it is relevant. In addition to the traditional convective flow boundary
conditions the heat transfer between the solid and the fluid
incorporates a model for sub-cooled nucleate boiling which, in turn,
depends upon the local pressure, fluid and structural temperatures
and fluid properties. In addition to enhancing the rate of heat transfer
under boiling conditions, vapor is also generated and a transport
equation for vapor fraction is also solved.
There are a number of advantages to this approach compared to the
multi-code solution methodology described earlier:
Faster:
It is a one pass, single code methodology see figure 3, in which
there is no iteration between codes
More Accurate:
A simultaneous solution to the coupled fluid-structural flow and heat
transfer is obtained. Furthermore, it is the only way in which boiling
can be incorporated properly.
Integrates into Existing Processes:
The way in which gas-side boundary conditions are applied is identical
to existing methods instead of mapping to an FE surface the data is
mapped to a STAR-CCM+ mesh.
Validation of the model has been carried out with reference to
experimental rig data and good agreement was found for the heat flux
for flow, pressure and surface temperature conditions typical of those
found in engines. Figures 1 show some typical results from the same
multi-cylinder engine shown in figure 4. Run time for this calculation
was 5 hours on 10 cpus but overall process time was significantly
reduced compare to the original multi-code approach.
Many OEMs are now assessing the STAR-CCM+ solution described
above and anticipate both process efficiency and accuracy
improvements through adopting this technology. Clearly, this is but one
application in one industry and this methodology has potential benefits
across a wide range of analogous problems elsewhere.
dynamics 2.01
22
In the world of simulation, bigger is usually better, nowhere more so than in the
world of motorsport CFD, where leading teams regularly run simulations using
computational meshes that are counted in hundreds of millions of cells. A long
time staple of the Formula 1 world, CFD is now finding increased use in NASCAR
(for aerodynamics, underhood thermal management and engine simulations).
This article describes how STAR-CCM+ is enabling teams in both F1 and NASCAR
set-up, simulate, and analyze bigger, and hopefully better simulations.
Bigger, Better,
Motor Sport CFD
Alex Read, CD-adapco
Why so big?
Race teams use Computational Fluid Dynamics (or CFD) as an aid and
extension to physical testing. It is used to reduce the dependence on
expensive wind tunnel testing by rapidly identifying the best designs,
and subjecting only those to testing, and to provide information would be difficult
to obtain through testing alone. For NASCAR underhood thermal management,
this can be detailed visualization of the flow and thermal field in the engine
compartment. For external aerodynamics, it may be the cars front and rear
down force balance when drafting.
Race teams other requirements are accurate results and rapid and robust
model turn around. This presents a particular challenge in areas like external
aerodynamics where components have a strong interdependence. For example,
the performance of the rear wing of an F1 car will vary depending on the set-up
of the components in front of it: and vice-versa. F1 teams opt for running
detailed models of the full car to ensure accurate aerodynamic resolution for all
parts of the car. Similarly in NASCAR the interaction between cars is a key part
of racing. As a lot of the time the cars are bumper to bumper and door handle
to door handle, understanding the effect on front and rear down force and
airflow to the engine compartment when in close proximity to other cars, can be
the difference between success and failure.
Historically, this has presented problems: is my computer big enough to store and
solve at each of my hundreds of millions of cells? If it is, is my CFD tool
sufficiently adept at utilizing this enormous computing resource, with hundreds of
processors operating in parallel, to enable me to create, set-up, run and postprocess my case within a reasonable timeframe?
CD-adapco has a proud history of solving these problems for race teams:
supplying CFD tools to, among others, the double World Championship winning
ING-Renault F1 team since its inception in 2001. Our latest offering, STARCCM+, has been specifically designed for motor sport CFD, with regular
evaluation and specification being carried out by top motor sport teams during
its development.
Around five years ago we starting to develop STAR-CCM+ from a blank sheet of
paper, explains Dr Richard Johns, CD-adapcos Director for the Automotive
industry, which allowed us to use everything wed learnt in the previous twenty
years of developing and using CFD, as well as the latest computing technology.
In addition, at CD-adapco, we see our users as partners and not just clients.
As well as using our own know-how, our motor sport partners were integral in
defining STAR-CCM+s specification and reviewing its progress. The result is a
code thats revolutionizing motor sport CFD, allowing teams to run ever more
detailed models, with ever more computational cells, while shortening case
turnaround times.
23
dynamics 2.01
W Fig:01
STAR-CCM+ simulation of single NASCAR
The Technology
Much of the focus on CFD codes has been the time it takes for them
to solve the Navier-Stokes equations for a large number of
computational cells. Of equal importance is the time required to
create, set-up and post-process the case, which can take days or
even weeks. A key technology in STAR-CCM+ is the process by which
it does this for very large cases. First, all the steps of the simulation
process are integrated into one tool: from CAD geometry to postprocessing. This saves a considerable amount of time as there is no
requirement to export and import large data sets and there is no
requirement to re-specify parameters in different tools or when
running iterative design studies.
The starting point for the calculation was creating a mesh around a
single car, providing the baseline drag, lift and yaw force values. A
second car was then introduced and analyses were performed with
the cars directly in-line, and with an offset as if at beginning an
overtaking maneuver. The drivers goal when in the drafting formation
is to reduce the drag on both cars, making them collectively faster. If
the second car is in the correct position, it has the effect of increasing
the pressure at the rear of the lead car, reducing its overall drag.
dynamics 2.01
24
Computational Flow
Assurance
Risk Mitigation &
Performance Improvement
T Fig:02
Billion cell STAR-CCM+ simulation of entire NASCAR grid.
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STAR-CCM+ simulation of
offset drafting between two
NASCARs
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dynamics 2.01
STAR-CD
For more information on Flow, Thermal & Stress Simulation, please visit: www.cd-adapco.com
Or contact: info@us.cd-adapco.com
Staying ahead
In motor sport CFD from F1 to NASCAR bigger, is better. As teams
continue to push the envelope of CFD so the tools they use need
to adapt to their requirements. By adopting state-of-the-art
technology, in combination with years of know-how from us and our
partners, STAR-CCM+ is helping race teams run bigger models,
faster and ultimately to stay at the front of the grid.
www.cd-adapco.com
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W Fig:02
Different configurations or both bike and
ride angle were studied automatically
using the mesh replace feature and the
surface wrapper
Aerodynamic Analysis
of a Motorcycle and Rider
on a high speed corner
W Fig:01
Slice view of final polyhedral mesh with
volume source visible around the bike.
27
dynamics 2.01
dynamics 2.01
28
the quantity of water used in showers in the UK will rise from about, 650
Ml/d in 2000 to over 1200 Ml/d by 2020. As a result the use of water for
showering is likely to become a major component of the water by domestic
customers consumption (potentially rising to over 15% of total household
water consumption by 2020). Unchecked this could have serious
implications for both the environment and the UK economy.
Climate change
The average domestic water usage in the UK is around 150 litres per
person per day5, over two times the recommended target of 70 litres per
day for new dwellings6. In America, this average increases to a staggering
360 litres per day while in parts of the developing world, for example India,
people survive with a daily usage of 25 litres or less7.
Water is a precious resource. Water used for showering has been steadily increasing
year on year. DEFRAs Market Transformation Programme (MTP) recently
commissioned Arup to undertake research to help understand ways of designing a
more efficient shower head. The adoption of more efficient shower heads, will lead to
a reduction in water AND energy use leading to a reduction in our carbon footprint.
Parameters such as flow rate, water temperature, skin
pressure and orifice size all contribute to the sensation of
a comfortable shower. Martin Shouler, leader of
environmental services engineering in Arup, brought
together a specialist team for the research using Computational Fluid
Dynamics (CFD).
Shower Power
Showering has always been about more than simply keeping clean.
Although its uncertain as to exactly how long humans have been
showering, ancient Greek and Egyptian murals suggest that weve
been doing it for at least a few thousand years. Indeed, washing by
pouring water over ones head probably dates back to primeval times.
Showering now occupies a special place in popular culture; while
bathing is usually associated with luxury, tranquillity and relaxation,
showering is typically credited with stimulation and invigoration, both
mental and physical. While our ancestors might have been content to
shower under a waterfall (or even using one of those strange rubber
contraptions that fitted over the bathroom taps), modern consumers
have developed a much more sophisticated taste in showering
equipment.
Modern showers are expected to provide multiple spray settings,
which provide a body and scalp massage while covering the occupant
in a plentiful supply of temperature controlled warm water. Power
showers include mains pressure showers and pumped showers.
29
dynamics 2.01
Arups CFD model tracks the progress of the water droplets as they leave
the individual nozzles of the shower head until they hit the body of the
occupant or, upon missing entirely, gather in the shower tray. Whilst in free-
S Fig:01
Droplet trajectories and temperature
contours around the shower occupant.
dynamics 2.01
30
W Fig:01
W Fig:02
Shower head spray distributions were measured
experimentally for comparison.
The project also demonstrated that some popular shower designs are
more energy inefficient than others. From an energy point of view,
atomiser sprays were shown to be particularly inefficient, observes
Irene Pau, the Arup engineer responsible for performing the
simulations. The smaller droplet sizes result in a much larger
temperature drop en route to the body requiring the user to increase
the shower temperature in order to keep as warm.
REFERENCES
[1] United Utilities and Liverpool John Moore University Report Water efficient showers:
Project report, May 2007.
[2] MTP Briefing Note BNDWBATHS: Actions to improve bath design and efficiency,
31
www.mtprog.com
dynamics 2.01
March 2007.
L MORE INFORMATION
Germanischer Lloyd
& CD-adapco join forces
[3] Environment Agency Report Conserving water in buildings: Shower and baths.
[4] MTP Briefing Note UK water consumption of showers, 2007.
[5] MTP Report Product Overview: Water.
[6] GLA Report Water matters: The Mayors draft water strategy, March 2007.
[7] Waterwise web site Per capita consumption and metering level by country summary,
May 2006.
www.arup.com
www.cd-adapco.com
L MORE INFORMATION
info@uk.cd-adapco.com
http://www.gl-group.com
dynamics 2.01
32
State-of-the-art simulation
for the marine industry
Stephen Ferguson, CD-adapco
S Fig:01
Free surface simulation of the
Earthrace boat.
33
dynamics 2.01
and rudders, often causing surface pitting and fatigueinducing vibration. CD-adapcos simulation technology
accurately predicts the onset of cavitation and the
unsteady phenomena associated with the build up and
break up of large cavitation regions. Detailed analysis of
both steady and unsteady cavitation has been performed
with considerable success across the industry.
For a given design, this technology allows designers to
identify under which operating conditions the worst
cavitation problems are likely to occur, or alternatively
which design is least prone to cavitation under a given
operating condition.
S Fig:02
The Earthrace Boat (www.earthrace.net).
Designed to pierce through waves instead
of riding over them.
T Fig:04
Cavitation Analysis.
X Fig:03
L MORE INFORMATION
info@uk.cd-adapco.com
http://www.gl-group.com/
dynamics 2.01
34
X Fig:01
Gas bubble distribution through a subsea Christmas tree and
insulated pipeline configuration.
W Fig:03
Computational
Flow Assurance
Flow Assurance is
the ability to
identify and prevent
potential fluid
related problems
from impacting oil &
gas production
throughout the
asset life.
The rapid rise in the price of crude oil and natural gas, and the
general belief that prices will continue to rise as global energy
demand outstrips resources and production, is causing many
Dennis
Nagy, CD-adapco
business
changes in the oil and gas industry.
X Fig:02
35
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36
Douglas Lee
Forever Blowing
Bubbles
Revolutionary MBF Separator Design
with CFD
Stephen Ferguson in conversation with GLR Solutions Ltd. CEO Douglas Lee
Faced with increased water-cuts from maturing wells and a combination of environmental
legislation and operational demands, Oil and Gas operators are being forced to review their
separation processes. Not only must separation trains now handle a larger throughput of
well fluids (due to the increased water content), but the water that they deliver for disposal
or re-injection must also be cleaner than ever before.
In this article, we explore how Canadian company GLR
Solutions has applied advanced Computational Fluid Dynamic
simulation in the design and implementation of their Micro
Bubble Flotation technology which has become recognized in
the industry as one of the highest performance methods for treatment of
produced water.
At the heart of most Oil and Gas separation processes is the API Skim
Tank. Slow and reliable, the skim tank depends on the difference in
specific gravity between oil and water, lighter oil eventually floating to the
top of the denser water content, where it can easily be skimmed off.
Although ubiquitous, the standard skim tank suffers from the long
retention times required to perform effective separation, which can be
useful when buffering out the effects of upstream spikes in production,
but ultimately is inefficient when separating small amounts of oil from
large amounts of produced water. API gravity tanks are also relatively
inefficient when dealing with heavy oils or emulsions.
To counter these shortcomings, many modifications to the traditional API
vessel have been attempted, aimed at increasing the separation
efficiency of the API vessels (wherever possible using existing separation
equipment), often resulting in the introduction of internal structures or
distribution nozzles, which are intended to encourage the coalescence of
oil droplets within the tank. A more novel, and generally more effective
approach, involves flooding the separation vessel with bubbles of gas,
which adhere to similarly sized oil particles and float them to the surface
of the tank. This approach, known as Induced Gas Flotation, or IGF,
usually requires the partitioning of the vessel into various chambers so
37
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38
FREE
DVD
S Fig01
The silly Jabberwocky auctioned off one lampstand, although Tokyo
cleverly towed five bureaux, howeve
39
dynamics 2.01
Operational Results
Modifications of the existing tank 30-T-04 began in mid February of
2005. After cleaning and preparing the tank, nozzles were added and
internals were welded as designed by GLR Solutions. The microbubble
system was started up in May 2005, and favourable results for water
quality were observed within days of start-up.
During normal operations over the spring/summer of 2005, the skim
tank (30-T-04) receives approximately 15,000 bpd of produced water at
oil concentrations ranging from 100-600 ppm. The quality of the clean
water exiting the tank is consistently within 2-21 ppm during normal
operations. Periodically high inlet oil concentrations would occur in
which concentrations of oil would spike to 1,000-2,000 ppm and in rare
cases much higher. During these upsets it was found that oil removal
efficiencies would remain above 90% with outlet oil in water concentrations less than 40 ppm.
CFD modeling has proven to be a continuously useful tool in the design
of tanks and vessels and a critical tool to our R&D of new produced
water treatment technologies , says Douglas Lee. Many on-going
projects are being designed through the use of CFD modeling by GLR
Solutions and in the future solids will be tracked through CFD models
and a design will be determined in order to better handle produced
water with high solids concentrations.
GLR Solutions is also exploring further is the modifications to the
physical models of the CFD software itself, to allow them to include
explicitly the effects of model bubble and oil coalescence, as this is an
obvious occurrence within the system.
L TO RECEIVE YOUR FREE COPY OF OUR DVD PLEASE EMAIL oilandgas@cd-adapco.com OR CONTACT YOUR LOCAL OFFICE.
dynamics 2.01
40
Reducing
Separation
Anxiety with
powerful 3D Flow &
Thermal Simulation
S Fig:01
The largest single product
of the global oil and gas
industry is neither oil nor
gas, but water: produced at
a rate of approximately 3
barrels to every barrel of
oil, in 1999 the oil and gas
industry was responsible
for extracting 77 billion
barrels of water.
Separating reservoir fluids into streams of oil, water and gas is a major concern
to the global oil and gas industry, and has been almost since its inception.
Historically, the major driver for effective separation was economics extracting
the maximum amount of usable hydrocarbon from the reservoir fluids.
However, environmental concerns now mean that oil and gas producers are also
increasingly bound by legislation that strictly controls the levels of pollution in
discharged produced water this combination is the growing separation anxiety.
Designing separators to meet these demands remains a significant
engineering challenge. Critically, separators do not come in a onesize-fits-all specification. They must be carefully chosen to not only
account for the unique composition of fluids produced from a given
reservoir, but also for the likely changes in composition that will occur over the
lifetime of the well. Separator technology that is effective in early production
might become less effective, or even fail, as the well matures or because of
some temporary and unexpected change in the reservoir fluids. The increasing
cost of platform real estate also means that there is also constant demand
either to reduce the size of offshore separators or else to move them off the
platform altogether, turning to newly developed subsea separation technologies.
S Fig:02
41
dynamics 2.01
65m
35m
S Fig:04
5m
S Fig:05
CFD simulation of FWKO drum disturbed by a passing wave while aboard FPSO.
S Fig:03
CFD simulation of three-phase separator, showing path of various particle sizes.
CFD has been applied at every stage of the oil, gas and petrochemical
production process and can provide insight into any problem involving
fluid flow (whether liquid or gas or a mixture of both) or structural
components that are influenced by flow, and thus is particularly suitable
for separator analysis. CFD simulation can help both in the design of
new separator technology and in determining the range of operating
conditions under which existing technology might be successfully
deployed.
Data from CFD calculations can also be used to assist other types of
analysis, for example, the forces acting on the separator internals can
be calculated, either directly within the CFD code or via an external
stress-analysis software package. In extreme cases, where fluid forces
cause large deflections of components, the CFD simulation can be
coupled directly with the stress simulation tool and both stress and fluid
simulations can be performed simultaneously, each simulation feeding
new boundary conditions to the other.
Case study 1
Sloshing in a free water knockout drum
The free water knockout (FWKO) drum is perhaps the crudest form of
separator. FWKO drums work on a gravitational principle, relying on the
fact that oil has a lower specific gravity than water and, if allowed to
settle, will float to the top, forming a layer than can easily be skimmed
off and extracted. Water is extracted through a valve at the bottom of
the tank, while in the example shown in Figure 4, the oil trickles over a
weir plate at the left hand side of the drum into the oil stream outflow.
Under normal operating conditions, this system provides a very effective
means of preliminary. However, when deployed aboard an FPSO
(floating production, storage and offloading vessel), there is a risk of the
tank being disturbed by the motion of a passing wave, causing sloshing
within the tank and leading to significant amounts of water passing over
the weir plate or oil-emulsion contaminating the water outtake and
possibly damaging downstream separation equipment.
Figure 5 shows a large sloshing motion that has developed in the vessel
due the disturbing motion of a passing wave (as predicted by the CFD
calculation). The simulation predicts that, under these conditions, a
significant amount of water will slosh over the weir plate into the oil
outflow.
Case study 2
Redesign of a gas phase separator
The aim of a gas phase separator is to remove small particles of
hydrocarbon condensate (and other well-fluids) from a stream of natural
gas. To be effective, the separator needs to be able to remove the wide
variety of droplet sizes transported in a typical gas stream, from large
visible droplets of hydrocarbon, to individual mist particles measuring
just a few microns in diameter.
Exactly which fate each particle eventually meets depends largely on its
size, but for the separator to work effectively, all but the smallest
particles should be caught by one of the first three mechanisms. The
vane pack demister acts as the final line of defence, removing a fine
mist of droplets with diameters of around 10 mm or less. For effective
operation, it is critical that the demister is not blocked by much larger
oil particles, which, given enough time, should fall onto the surface of
the liquid layer due to the influence of gravity. The separator therefore
needs to be long enough, upstream of the demister, to ensure that the
gas flow has sufficient residence time to allow these larger particles to
fall into the liquid layer of hydrocarbon at the bottom of the tank.
The simulation results reported in Figure 3 show that the majority of 65
mm and 35 mm particles hit either the vessel wall or the liquid surface
a short distance after entering the separator. By contrast, many of the
small 5 mm particles are carried with the gas flow until it passes through
the vane pack, at which stage they are removed. The simulation
predicted an overall trapping efficiency of 90%, with almost a 100% of
particles of diameter 40 mm or higher removed by the separator. The
separator manufacturers were able to significantly reduce the length of
the separator, after establishing with the aid of further simulation, that
since larger particles were hitting the walls of the liquid surface soon
after entering the separator, much of the length upstream of the
demister was unnecessary.
dynamics 2.01
42
S Fig:02
Fig 2: Solid CAD model of the hearth, hot face refractory
lining, CFM panel and water-cooling passages
S Fig:03
S Fig:04
Symmetry plane volume-fraction-of-slag contour distribution
in the slag tap hole insert region (t = 456 seconds)
Slag-Cleaning
Bateman Minerals & Metals Investigates the
Possibility to Improve the Life Expectancy of a Slag
Tap Hole Insert Design in a Slag-Cleaning Furnace
Dr. B.J. Henning, Bateman Minerals & Metals, South Africa
Bateman Project Holding Limiteds Minerals & Metals Division are providers of comprehensive
project services, applying process technology and expert knowledge to the recovery of minerals
and metals. Long time users of CD-adapco software, Bateman recently employed STAR-CCM+ to
predict heat transfer in a slag tap hole insert for Slag-Cleaning Furnace applications.
The purpose of the investigation was to determine whether
the slag draining process causes erosion of the castable
refractory lining, which operates under arduous, high
temperature conditions in close proximity to the pyrometallurgical process. Estimating the refractory lining wear mechanisms is
critical to ensure satisfactory extended service life. STAR-CCM+ was
used to simulate the free-surface fluid flow and conjugate heat
transfer characteristics of the current slag tap hole insert design.
The furnace consists of a liquid copper blister, slag and a gaseous air
freeboard. Monel tubing water-cooling passages are cast into a
Composite Furnace Module (CFM) to enable cooling water to be
circulated through the CFM and slag tap hole insert respectively.
The free-surface fluid flow model was initialized at two different blister
bath levels, while maintaining a constant slag level. The conjugate
heat transfer model was simulated in a steady-state condition with
fixed wall temperatures and forced free convection conditions. The
combined free-surface and conjugate heat transfer model was
simulated in a transient mode for a fixed time period with a
combination of boundary conditions. The first model simulated a 180degree section of the furnace inventory and the last two models a
wedge section of the refractory lining regions initially and then the
furnace inventory added lastly.
In the case of the conjugate heat transfer and combined mechanisms
models, an inlet velocity was specified at the inlet ports of the watercooling passages and a pressure boundary specified at the outlets to
enable the pressure drop characteristics of the water-cooling
passages to be predicted.
43
dynamics 2.01
S Fig:01
Solid CAD model of the two inventory levels and gaseous air freeboard inside the furnace
S Fig:05
Surface temperature contour distribution for
the CFM copper panel & slag tap hole insert
S Fig:06
S Fig:09
Surface temperature contour distribution for the
castable refractory lining (t = 316 seconds)
S Fig:10
The predicted steady state solution results for the surface temperature
contour distributions for the CFM panel and water-cooling passages are
shown in figures 5 and 6.
The predicted transient results for the surface temperature distributions
in the melt; castable refractory, CFM panel and water-cooling passages
are shown in figures 7 and 9 to 11. The predicted transient result for
the surface volume fraction distribution in the melt is shown in figure
8. The predicted transient result for the velocity vector distribution on
the symmetry planes in the melt is shown in figure 12.
For modeling purposes, STAR-CCM+ has provided a cost effective
method of determining possible operating procedure changes to
enhance the slag tap hole insert life expectancy. Data will also be
L MORE INFORMATION
S Fig:07
Surface temperature contour distribution for the melt
in the slag tap hole insert region (t = 316 seconds)
S Fig:08
Surface volume-fraction-of-slag contour distribution
for the liquid melt (blister, slag & gaseous air)
S Fig:11
Surface temperature contour distribution for
the water-cooling passages (t = 316 seconds)
S Fig:12
Symmetry plane velocity vector distributions for
the liquid melt (blister, slag & gaseous air)
http://www.batemanengineering.com/
dynamics 2.01
44
X Fig 01:
S Fig 03:
S Fig 02:
W Fig 05:
To ensure that the proposed ventilation scheme would be effective in ensuring the comfort of the audience,
orchestra, actors and lighting, simulations were performed using STAR-CD. A worst case scenario study was carried
out imposing the conditions that are likely to be encountered during a performance, with a full auditorium, orchestra
and stage at full capacity, stage lights on and house lights off.
The large amounts of heat generated by the lights (generating up to 900 kW of power) actually lead to overheating
of the stage area. This in turn leads to air spilling into the main auditorium and out through the ceiling exhaust
S Fig 04:
45
Zone
Parterre
Dress circle
Balcony
Stage plane
Orchestra Pit
L, m3/h
80 400
27 370
13820
43 420
10 700
t, seconds
22
22
18
22
20
dynamics 2.01
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46
ActiveStor Feature
STAR-CD Benefit
DirectFLOW Protocol
Maximizes Performance: Parallel I/O enables faster CFD solutions from STAR-CD.
Maximizes Productivity: Drives STAR-CD efficiency for single job scalability and
multiple job throughput, and simplifies the coupling of STAR-CD with FEA software.
47
dynamics 2.01
S Fig:02
Panasas ActiveStor feature saves up to 43% over traditional
disk file systems.
S Fig:03
dynamics 2.01
48
..::REGULARS Training
Training at CD-adapco
We regularly hold CD-adapco product training sessions at our offices in:
London, Detroit, Seattle, Nrnberg, Paris and Turin.
Other courses as listed on our website can be scheduled to suit your requirements
and information can be requested from our training administrators (see below).
To register for a course:
Use the online form, or request a faxable form from your training administrator:
USA:
UK:
Germany:
France:
Italy:
training@us.cd-adapco.com
info@uk.cd-adapco.com
traning@de.cd-adapco.com
info@fr.cd-adapco.com
info@it.cd-adapco.com
STAR-CD Basic
STAR-CCM+
pro-STAR advanced meshing
STAR-Design
Advanced STAR-CCM+
Advanced STAR-CD
Advanced Meshing
Moving Mesh
Advanced Modeling
User Subroutines
Spray & Combustion
E2P
Training:
Introduction to CFD
Course Duration: 1 Day
Course Schedule: Please check regional training centers for upcoming dates.
Cost: Please contact your local office see www.cd-adapco.com
Course Details
With the advent of upfront simulation, CFD has become accessible
to a broad spectrum of engineers working in a wide range of industries
and disciplines, many of who have little formal fluid mechanics
training. Understanding the fundamental principles that underlie
commercial CFD solvers can help the user to effectively harness the
power of modern CFD and innovate successful processes within their
organization. As an added bonus, the bargaining power is placed back
with the CFD buyer once they are equipped with the correct evaluation
skills and information about current hot topics and advances.
CD-adapco are pleased to announce a brand-new one day training
course, that is aimed at introducing new users, or non-users who
encounter CFD, to these fundamentals. Industry development and
the impact of external factors, such as hardware advances, will also
be discussed.
New Course
A new foundation level Introduction to CFD course is now being offered at CD-adapco for those with little or no training in Fluid
Mechanics. The course is aimed at introducing new users, or non-users who encounter CFD, to the fundamentals of the subject.
Please contact your local office for more information.
Courses outline:
Note:
In most situations it will be possible to register trainees on the course of their choice. However, if requests for places on courses are
received too close to the course date, this may not be possible. Availability of places can be obtained by contacting your local office.
Please see below for our upcoming schedule of training courses. See our website for most up to date schedules.
1:
2:
3:
4:
5:
Introduction
Basic Equations
Boundary Conditions
Meshes for CFD
Turbulence
6:
7:
8:
9:
Post-processing
Quality of results
Hardware for CFD
Final tests
To register:
For more details please contact your local Training centre.
49
dynamics 2.01
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50
..::REGULARS Dr Mesh
..::REGULARS Dr Mesh
Turn it on!
The first step to fixing your surface is to right click on the surface
representation you want to repair and hit repair you can then
choose which regions you want to check and which errors you
want to flag. In the case of face quality and proximity you will also
be asked for a threshold value to fill in too.
Shrink n Grow
When you browse to a surface problem a few triangles around the
fault will be displayed, before you fix the problem you may need
to shrink or grow what is displayed and what is selected. The
display control (at the bottom of the panel) is used to control
what is displayed on screen and then grow and shrink displayed
faces can be used to increase and decrease the area displayed
and there are also buttons for show and hide all and show and
hide selected.
Once you have what you want on screen you need to select some
objects, what you can select is controlled by the three boxes
faces, edges and vertices, unchecking any of these will stop that
object being selectable. As with the display control you can also
change the selection by growing and shrinking, selecting zones
and finally selecting vertices or edges connected to a triangle.
W Fig03:
The selection and display control panels,
buttons with a white triangle in the
corner mean other options are available
by right clicking
Fix it up!
S Fig01
Dr Mesh Gets
You Out Of a Fix
(By Getting You Into Another One)
Start up the repair tool and choose what you want to look for
Dr. Mesh
Dr Mesh (Ph.D. CFD)
S Fig04:
S Fig05:
S Fig06:
The top of the tool will tell you how many problems you have
51
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52
01
Upcoming Events
02
03
04
05
06
01 January
Giorgio Pagliara
Pro S3
Motorsport Aerodynamics
02 February
American Dynamics Flight Systems
Unmanned Systems
03 March
Julien Champigny
Areva
Nuclear
04 April - WINNER
Per Adamsen
Danfoss
Industrial Applications
05 May
Dr. Peter Nefischer
BMW
Engine Thermal Management
06 June
Chris Connor
Jacobs
Motorsport Aerodynamics
07 July
Joel Davison
CD-adapco
Re-entry Vehicles
08 August
Christof Hinterberger
EMCON Technology
Emissions Technology
09 September
Vincenzo Gagliardi
IMAL
Mixing
11 November
Dr. Allan Thomson
Wood Group
Turbomachinery
10 October
Edson Luiz Zaparoli
ITA Brazil
Electronic Cooling
12 December
Ivn Platas
Epsilon Euskadi & METCA
Motorsport Aerodynamics
08
09
10
11
dynamics 2.01
Coal-Gen 2008
13 - 14 August 2008
Kentucky International Convention Center, Louisville, KY
http://cg08.events.pennnet.com/fl//index.cfm
OTC
5 - 8 May 2008
Reliant Center, Houston, TX
http://www.otcnet.org/2008/index.html
Electric Power
6 - 8 May 2008
Baltimore Convention Center, Baltimore, MD
www.spe.org/atce/2007
ICONE 16
12 - 14 May 2008
Disney's Contemporary Resort, Orlando, FL
http://www.asme.org
Power-Gen 2008
2 - 4 December 2008
Orange County Convention Center, Orlando, FL
www.power-gen.com
12
CRAY's IMEM
13 April 2008
The Detroit Downtown Courtyard by Marriott,
Detroit, MI
http://www.cray.com/kiva/
53
North America
2008 HP CAE Symposium
8 April 2008
Long Beach Marriott, Long Beach, CA
http://www.hp.com
07
CD-adapco regularly participates in many global trade shows. To get the chance to talk in person
with our experienced and friendly representatives, please make a note of our appearances at the
confirmed shows below. For more information please contact our events staff:
North America: Tara Firenze tara.firenze@us.cd-adapco.com
Europe: Maeve OBrien maeve.obrien@de.cd-adapco.com
Europe
STAR European Conference 2008
17 - 18 March 2008
Novotel, Hammersmith, London
http://www.cd-adapco.com/euconf2008
RINA Marine CFD
26 - 27 March 2008
Southampton, UK
http://www.rina.org.uk
Hannover Messe
21 - 25 April 2008 - Messegelnde
30521 Hannover, Germany
www.hannovermesse.de
29. Vienna Motor Symposium
24 - 25 April 2008
Kongresszentrum Hofburg Wien, Vienna, Austria
http://www.vk.at/index_de.htm
Engine Expo
6 - 8 May 2008
Stuttgart Messe, Stuttgart, Germany
http://www.engine-expo.com/
ETMM7
4 - 6 June 2008
The Amathus Beach Hotel, Limassol, Cyprus
http://www.ercoftac.org/index.php?id=931
Neue Entwicklungen in der Giesimulation
26 - 28 May 2008
Gieerei-Institut, RWTH Aachen, Germany
www.dgm.de
Power Gen Europe 2008
3 - 5 June 2008
Fiera Milano, Milan, Italy
http://pge07.events.pennnet.com/fl/index.cfm
ASME Turbo Expo 2008
10 - 12June 2008
Estrel Berlin Hotel & Convention Centre in Berlin, Germany
http://igti.asme.org/
ONS 2008
26 - 29 June 2008
Stavanger Forum, Stavanger, Norway
http://www.ons.no/
SMM 2008
23 - 26 June 2008
Hamburg Messe, Hamburg, Germany
www.smm2008.com
Nafems UK
10 June 2008
Scottish Enterprise Technology Park, Glasgow
http://www.nafems.org/events/nafems/2006/Page5/
dynamics 2.01
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