Client
Star Energy.
Challenge
Wall thickness thinning occurred noticeably faster in one separator unit than in its sister units, and the reason was not identifiable from inspection data alone.
Approach
CFD modeling and simulation of the two-phase flow separator were conducted, with corrosion rate and wall shear stress as the variables of interest, based on the as-built geometry of the vessel.
Result
The simulation localised the high wall shear stress zones inside the vessel and correlated them with the areas showing the fastest measured thinning.
Client outcome
The client obtained a physics-based root cause for the accelerated thinning to guide inspection intervals and remedial action.