Kameleon FireEx An Advanced Computational System for Calculation of Fire Structure Interaction

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1 Kameleon FireEx An Advanced Computational System for Calculation of Fire Structure Interaction Abstract During the last years new technology has been developed and introduced to the industry, allowing a rigid analyzing of the interaction between fire and structure and thus improved fire design. The most important factor for achieving cost reducing design and safer systems for personnel is detailed knowledge of the development and behaviour of real fires in combination with advanced structural response simulations. Such advanced methods are tracing the accidental events from the actual hydrocarbon leak, ignition and combustion, heating of structural components up to material softening/weakening. The Kameleon FireEx system comprises the CFD simulator Kameleon FireEx (KFX) for detailed fire simulation, automatically linked to the FEM code Fahts/Usfos for detailed non linear structural response analysis. This article focuses on the methodology being used by ComputIT for fire analysis and fire design, a methodology that has been applied for a large number of industrial analyses with good results. Simulation results are presented as examples, and achievements in projects are given. Introduction Fire is a continuous threat for most offshore oil and gas installations. It is required that the structure resists fires with a given probability long enough to evacuate the platform. The platform integrity is also crucial with respect to the economic consequences of fire accidents. In the past, design of structures for fires is mainly based on prescriptive standards for the size of fire heat loads. Typically, a conventional fire design procedure might be: 1) Find a standard heat flux, for example 200 kw/m 2, 2) Let the entire structure be exposed to this heating, 3) If the steel temperature exceeds 400 C, insulate the steel surface with passive fire protection (PFP). The total surface of the structural components of a platform, representing the potential exposed to fire, is typically m 2 (for comparison the area of a football ground is approximately m 2 ). If all surfaces should be protected, the total weight of the PFP would be ton with corresponding costs of magnitude 5-20 mill. A question that may be raised is: Do we need to protect all surfaces? The experience of ComputIT is that for many installations the answer is no. This article focuses on the methodology ComputIT is using for fire analysis and fire design, a methodology that has been applied for a large number of industrial analyses with good results.

2 The KFX Integrated fire analysis During the last years new technology has been developed and introduced to the industry, allowing for a much more rigid analyzing of the interaction between fire and structure and thus improved fire design. It has become quite common to use Finite Element Method (FEM) which is a rigid and accurate method for calculation of the structural response to fires. However, in combination with this it is also quite common to use very simplified methods for calculating the fires loads, which might be insufficient in combination with rigid FEM analysis. Typically a pool fire is taken as a heat load of 150 kw/m 2 and a jet fire as 250 kw/m 2. This is a strong simplification of real fire behaviour, and the consequences will often be very conservative design with respect to structural protection and insufficient design with respect to personnel safety, evacuation etc. A fire will in general vary by time, both in intensity and location, and all surfaces will not be heated by the same load during a fire, nor will one specific surface be heated by the same load during the whole fire. Often might also 400 C be accepted if the integrity is maintained due to redistribution of forces. The most important factor for achieving cost reducing design and safer systems for personnel is detailed knowledge of the development and behaviour of real fires in combination with advanced structural response simulations. Such advanced methods are tracing the accidental events from the actual hydrocarbon leak, ignition and combustion, heating of structural components up to material softening/weakening. The ComputIT methodology is in principle given by: The fire simulations (transient and 3D) including temperature calculation in solid materials, are carried out by the CFD fire simulator Kameleon FireEx (KFX). The KFX simulations account for the actual release of hydrocarbons, which in many cases are limited due to process segmentation and shut down systems, and is in detail calculating the heat loads, radiation, smoke production, smoke distribution etc in real process environments. Detailed structural analyses are carried out by the Finite Element (FEM) codes Fahts and Usfos to check the structure s load bearing capacity. The temperatures are intermediate results only. Identify weak parts and reinforce/insulate these components. The coupling between the fire simulations and the structural simulations are done automatically as a part of the KFX system The results of the fire and the structural response simulations may be visualized by video technique for a realistic impression of the fire and its consequences. The following analysis procedure for structure integrity is used: Apply mechanical loads (operational loads and wind) to 100 % Apply temperature history Increase mechanical loads by 10 %, (at least) An alternative procedure is to apply step 1 and 2 in once, i.e. to check the stability of the structure at different stages during the fire. Based on the temperature situation, parts of the structure are assigned the degraded material properties. If the temperatures exceed f ex 1000 C, the parts are completely removed from the finite element model (become non structural). For the cases with high temperature, the alternative procedure is preferred because it is more robust numerically for elements with zero stiffness and capacity.

3 The structure is accepted if: Global stability is preserved at all stages of the temperature history Component strain level limited to 15%, (ref NORSOK) The additional weight is applied to get an idea of the residual strength at the end of the fire history, but does not represent any requirement as such. In general, member yielding and buckling causing load shedding is allowed. Kameleon FireEx Kameleon FireEx (KFX) is a field model for gas dispersion and fire simulation, developed at ComputIT/NTNU/SINTEF. The KFX development is a continuous activity at ComputIT, at present supported by Total, Statoil, the ENI-group, ConocoPhillips and Hydro. Kameleon FireEx is capable of calculating heavy and light gas dispersion as well as hydrocarbon liquid pool fires, spray fires, and gas jet fires, in enclosures and in open air. In addition fire suppression using monitors, deluge, sprinkler, and water mist systems can be included in fire simulations and interact with the flow and energy field in the gas phase. KFX includes CAD import capabilities, and is widely used internationally for safety analysis in the oil and gas industry. Advanced rendering technique gives, by creation of realistic pictures and animations of fire developments, a unique opportunity to interpret the results of the transient calculations and to increase the understanding of the complicated flame physics that is very important in fire safety design. Kameleon FireEx is based on a Cartesian finite volume technique to solve the averaged basic transport equations from fluid dynamics. The SIMPLEC algorithm [6] is used for calculating the pressure terms in the momentum equations based on the pressure correction which must be imposed in order to obtain mass conservation. The turbulent transport effects are modeled as gradient diffusion with turbulent viscosity calculated from the k-ε model of turbulence. The averaged reaction rates for the species mass fractions are modeled according to the Eddy Dissipation Concept (EDC) for combustion by Bjørn F. Magnussen [1]. The thermodynamic properties are calculated by the CHEMKIN [4] package and tabulated. The source terms for soot are modeled according to the Eddy Dissipation Soot model by Magnussen [1]. It includes a transport equation for the soot nucleus that is the starting point for the soot particle growth. The soot mass fraction is used to find the correct radiative absorption coefficient of the control volumes. The absorption coefficient is used in the Discrete Transfer Model by Lockwood and Shah [2] to calculate realistic radiative transfer in flame and between the flame and its surroundings. Fire mitigation by water systems is treated by a two phase spray model. A Lagrangian description is selected for the behavior of the droplets [13], [14]. The cloud of droplets is represented by a number of discrete numerical droplets each representing a group/class of real droplets [14]. The number of physical droplets represented by each numerical droplet, i.e. the total number of numerical droplets to be used, depends on the computational capacity available. When calculating the effect of for instance deluge on fire evolution it is assumed a certain particle size or particle size distribution. Based on the prescribed or assumed release rate the number of droplet parcels are calculated and then released in the prescribed direction from the nozzles.

4 FEM tools Fahts/Usfos An important feature of the KFX system is the link to the finite element code Usfos. The response program consists of two parts; one for temperature response, Fahts, and one part for mechanical response, Usfos. The KFX results give the heat flux at the individual structural component surfaces. The structural model is automatically transferred to surface shell elements in order to receive the correct heat flux and to capture thermal gradients over the cross section, caused by uneven fire exposure and/or partly protected members. The heat exposure, (radiation heat flux and convective heat flux), is then varying from point to point on the structure depending on the actual point s coordinates and surface orientation (f ex if the surface is facing against or away from the fire, etc.). Different surfaces receive individual heat flux, and for instance for column elements only the outer side will experience the fire. Internally, radiation between the inner surfaces will transfer heat from the most exposed side to colder parts. Some keywords about the temperature module (Fahts) : Model file compatibility with Sesam, Sacs, Staad and more Fully integrated with the Kameleon FireEx database Efficient non linear time domain solver Unprotected and insulated members Fully or partly insulated cross sections Internal radiation inside hollow members Automatic re-meshing of beams to shells (surface) Shielding Temperature dependent material properties Usfos includes non-linear geometry effects, material yielding and thermal effects, (expansion, yield stress and E-modulus degradation) and calculates instability of individual components as well as system collapse. Some keywords about the mechanical response module Usfos: Model file compatibility with Sesam, Sacs, Staad and more Non Linear material and geometrical effects Detects Local buckling and Global instability Beams and shells Static and Dynamic analysis Efficient solver General Accidental Limit State simulation Case example of integrated fire analysis A case where a floater is exposed to severe accidental fire scenarios is briefly discussed below as an example of the integrated fire structure analysis. The scope has been evaluation of mechanical consequences of accidental fires that could heat the columns which are unprotected. It is required that the structural integrity is maintained for a certain time during an accidental fire. This study is carried out with use of realistic fire simulations and realistic heat loads, realistic temperature distribution in structures, and realistic load bearing. The study and its results as such are not discussed in this article, only a few results are shown as illustration.

5 Due to an initial risk analysis the leakage is modeled as a horizontal gas jet directed normal to one of the platform legs. In cases where there is leakage of both oil and gas, the oil leakage is assumed to settle on the sea as an oil pool which evaporates and burns around the column. For some cases the effect of water cooling of the column has also been included in the structural analysis. A number of different fire scenarios are defined in accordance with the risk analysis, and below are shown two examples of the fire simulations. Figure 1: KFX simulation of oil and gas fire close to a platform column The structural system is a 3D frame structure (deck) supported on 4 columns. The columns are stiffened with both ring stiffeners and vertical stiffeners. Inside the column, another stiffened cylinder with 5 m smaller diameter exists. Simulations are carried out for non-protected and partly protected (PFP columns and stools), also in combination with water cooling of some of the equipment. Below are shown response examples for the worst case and with all protection means activated. Parts of the outer skin of the column will be heated rapidly due to the intense heating, but it will take time before the inner structures will respond similarly. If a rescue vessel is able to start the cooling of the outer skin of the column after 30 min using fire monitors, the outer skin will cool rapidly and the material recovers, and also the heating of the inner structures stops and gradually reverses due to loss of energy towards the cold surface.

6 Figure 2 below describes the temperature field (outer and inner structures) after 30 and 60 minutes for the most severe fire case corresponding to fire situation number two in Figure 1. The colour images show the extent of the cooling zone. Figure 2 Temperature field after 30 and 60 min. Cooling after 30 min. The structural integrity is checked for the different platform conditions, from the completely unprotected situation assuming no cooling from a rescue vessel to several modified systems. A substantial number of numerical simulations have been performed for various fire scenarios and different mitigating actions. With no protection the column will fail for the worst situations. Figure 3 below shows the mechanical response for the most severe case when water cooling and PFP in a limited area is utilized. To the left, the situation after ½ hour just before the cooling takes place, is presented, and after 1 hour (image to the right). The plots clearly state the effect from the cooling, where the contacting plus recovery of the steel reduce the mechanical utilisation of the southern part of the column.

7 Figure 3 Plastic Utilization field after 30 and 60 min. Some examples of the results from this analysis are : The fire simulations of the unprotected structure in this particular study show temperatures up to ~1300 C on the outer skin and ~1000 C on the inner (shielded) structures. The simulations have shown that the floater could collapse due to the heating from fire on sea accidents within ½ to 1 hour. The most critical detail seems to be the load transfer from the deck to the entire column cross section, the four stools. The stools and parts of the ring beam could be heated to relatively high temperatures, and are likely to fail. If the load transfer structures (stools/ring beam) were intact during fire i.e. cooled or passive fire protected, and with cooling of a sector of the column, the floater is likely to survive all fire scenarios. For the case with protected stools/ring beam, the system is likely to survive all fire cases if cooling from a rescue vessel starts within 30 minutes. Some Projects and Achievements ComputIT has carried out a lot of studies of this kind during the last 10 years, and below some main achievements in projects are given. Year Installation Achievement/result 1995 Platform Minimum PFP thickness, little or no coat back 1998 Floater m 2 outer surfaces recommended without PFP 1999 Topside module PFP at only 15% of heat exposed surface (400/2.500 m 2 ) 2002 Barge module No coat back, Access to all welds of interest (gap accepted) 2002 Floater All outer surfaces recommended without PFP (ca m 2 ) 1998 Whole deck area recommended unprotected, (exposed to jet-fire) 2002 Utility shaft No PFP on all steel structure surfaces of Utility shaft of concrete platform 1996 Topside module Little and simple protection of topside module. No coat back 2001 Flare boom Unprotected Flare boom, at process level, (aluminum coating) 2004 Floater Effect of water cooling from rescue vessel. Extended response time

8 Conclusions The interaction between fire and structure can easily and realistic be analyzed in detail by the Kameleon FireEx system It is possible to reduce costs significantly and still maintain safety by use of detailed simulation tools The methodology has been used in a large number of industrial studies with good results Results from detailed analysis have shown to differ significantly from results based on simpler methods Further Information For further details, please contact: Trond Evanger ComputIT PO Box 1260 Pirsenteret N-7462 Trondheim Norway Tel: Fax: trond.evanger@computit.no Tore Holmås AkerKværner Offshore Partner AS Postboks 1, Sandsli N-5861 Bergen Norway Tel: Fax tore.holmas@akerkvaerner.com

9 References 1 Magnussen, B.F., and Hjertager, B.H., Olsen, J.G. and Bhaduri, D. The Seventeenth Symposium (International) on Combustion, The Combustion Institute, p. 1383, (1979) 2 Magnussen B.F., "The Eddy Dissipation Concept", XI Task Leaders Meeting, Energy Conservation in Combustion IEA (1989). 3 Magnussen, B.F. "Modeling of Reaction Processes in Turbulent Flames with Special Emphasis on soot formation and combustion", Particulate Carbon Formation During Combustion, Plenum Publishing Corporation, Magnussen, B.F. "Heat transfer in Gas Turbine Combustors. A Discussion of Combustion, Heat and Mass Transfer in Gas Turbine Combustors", Conference Proceedings no. 390, AGARD - Advisory Group for Aerospace Research & Development, Launder, B.E. and Spalding D.B Computer Methods in Applied Mechanics and Engineering, No. 3, pp , Tesner, P. A., Snegiriova, T. D., and Knorre, V. G. Combustion and Flame, 17, 253 (1971). 7 Patankar, S.V. and Spalding, D.B. Int. J. Heat Mass Transfer, Vol. 15, pp , Shah, N.G. "The Computation of Radiation Heat Transfer", Ph.D. Thesis, University of London, Faculty of Engineering, Lakså, B. and Vembe, B.E.: "KAMELEON II. A general purpose program system for simulation of fluid flow, heat and mass transfer". Sintef report STF15 F91048, Vembe, B. E. et.al: Kameleon FireEx A simulator for gas dispersion and fires IGRC 12 Ultimate strength testing of Structural Members with Passive Fire Protection. SINTEF report STF22 F99840, Trondheim Ultimate strength testing of Structural Members with Attachments. SINTEF report STF22 F00836, Trondheim USFOS: Ultimate Strength Analysis. User s and Theory manuals. SINTEF reports. Trondheim FAHTS: Fire And Heat Transfer Simulations. Theory and User s Manual. SINTEF report, Trondheim Fire and Flaring Impacts Temperature and Mechanical Response Analysis of the Kristin Platform, ComputIT report: R0109, Trondheim 2001.

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