FM Global
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CFD Modeling of Industrial Fire and Suppression Using HPC
Yi Wang, Ph.D.Group ManagerFire Dynamics GroupResearch Division, FM Global
2016 OLCF User Meeting, May 24-26, 2016
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FM Global – A Unique Company Largest commercial and industrial property insurer “The majority of loss is preventable” Engineering and Research 180 years of loss prevention & mitigation
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Industrial & Commercial Fire
Annual loss in US: $3 billion Across all industries: manufacturing and storage
– Chemical– Semi-conductor, data center– Pharmaceutical – Forrest product – Mining– etc.
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Fire Research Large scale tests Explosion Suppression Flammability Fire Modeling
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Fire Research
Testing and experimental– Largest fire testing lab
Modeling – 2000 core cluster
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Why CFD Modeling Large scale fire tests are:
– Expensive– Hard to quantify & generalize results– Limited by test facility & safety
Physical based fire model– Gain insight of fire test– Help design and interpret tests– Reduce number of large-scale fire tests
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Multi-Scales & Physics -- HPCFire Growth Suppression
Spray plume interaction
Water transport on fuel surfaces
Water interactions with fire
Buoyancy driven turbulence
Diffusion combustion
Convective & radiative heat transfer
Solid pyrolysis
FM Global
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OpenFOAM and FireFOAM Open source CFD toolboxes written
in C++– Unstructured mesh– Segregated solution– Pressure-based solver– 2nd order fully implicit scheme– Parallel computing: MPI – Object oriented programming
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FireFOAM
A buoyancy-driven diffusion flame LES solver With fire specific sub-models Open source ( fmglobal.com/modeling )
FireFOAM
Gas phasecombustion
Soot & Radiation Pyrolysis Spray Surface water
flow
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Gas Phase Eqns: LES0j
j
ut x
ρρ ∂∂ + =∂ ∂
shj
s
t
tth
jj
sjs
xq
xhD
xDtpD
xhu
th ωνρ
ρρ ′′′+∂
′′∂−
∂∂
+∂+=
∂∂
+∂
∂
~
Pr
~~~
kYj
k
t
tk
jj
kjk
xYD
xxYu
tY ωνρ
ρρ ′′′+
∂∂
+∂=
∂∂
+∂
∂
~
Pr
~~~
Momentum
Sensible Enthalpy
Mass
Specie Mass Frac
( ) ii
ijk
k
i
j
j
it
jj
jii gxp
xu
xu
xu
xxuu
tu ρδννρ
ρρ +∂∂−
∂∂−
∂∂
+∂∂+∂=
∂∂
+∂
∂ ~
32~~~~~
Eddy-viscosity model
EDC combustion models
FM Global
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Solid Phase: Pyrolysis
Heat transfer and chemical process
( )"r
s s pqTCp T k m H
t x x xρ ∂∂ ∂ ∂ ′′′= + + ∂ ∂ ∂ ∂
exp aEm ART
ρ − ′′′ = −
PyrolysisHeat transferChemical Kinetics
GasvCharvVirgin gc +→
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Coupling
Solid Liquid Gas
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Discrete Phase
Droplet transport: – Lagrangian Particle Tracking
Radiation: – Directional & spectral dependence
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Scale Up
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Projects in OLCF
Profiling Rack storage Roll paper Sprinkler atomization -- VOF IO improvement
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Profiling
Diagnostics12%
Spray2%
Film2%
U9%
Combustion1%Species
8%
Radiation23%
Energy4%
Pressure12%
Turbulence2%
User V5%
Pyrolysis15%
Others5%
FireFOAM
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Diagnostics Spray Film Gas Pyrolysis
Per
cent
age
48 CPU96 CPU192 CPU384 CPU
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Rack Storage
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0
10
20
30
40
50
60
70
0 50 100 150 200 250 300 350
Che
mic
al H
eat R
elea
se R
ate
[MW
]
Time [s]
7-tier, Wood-Pallet7-tier, No-Pallet
Scale Up
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Sprinkler Atomization -- VOF
Injection pattern– Velocity, droplet size, number, etc.– Laser diagnostics– Fire modeling inputs
Volume of Fluid (VOF) approach– First principle– Computational intensive
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IO Improvement
OpenFOAM I/O– Many small files– Not scalable
ADIOS– Adaptive I/O system– Minimizes input/output bottleneck
Norbert Podhorszki, Karl Meredith, Mark Olesen
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Paper Burns Well!
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Fire Hazard – Test Experience
>20MW, 1-5MW/s– Paper type: weight based– Storage Height– Storage configuration
Standard array Open array
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Protection Challenges
Storage height increase– 15-20 meters or more
Open array
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Calibration Validation Prediction 26-lb paper test matrix
– Intermediate-scale parallel roll • 2.13m (1-roll high)
– Open Array• 4.26 m (2-roll high)• 6.39 m (3-roll high)• 8.52 m (4-roll high)
– Standard Array• 6.39 m (3-roll high)
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Mesh
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0
10
20
30
40
50
60
0 20 40 60 80 100
Che
mic
al H
eat R
elea
se R
ate
[MW
]
Time [s]
Test, 2-rollTest, 3-rollTest, 4-rollModel, 2-rollModel, 3-rollModel, 4-roll
HRR Prediction for Different Heights
Peak Fire Growth Rate (MW/s)
5 seconds averageH Model Test
4.26 m 0.81 0.676.39 m 2.1 1.78.52 m 3.5 2.78
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HPC for Industrial CFD
I/O and in situ diagnostics GPU
– Pressure Poisson Solver– Lagrangian droplet– Thermal radiation
Broader industrial user base of OpenFOAM
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Acknowledgement OLCF Staff
– Suzy Tichenor– Jack Wells– Ramanan Sankaran – Norbert Podhorszki– Many others ……
Team at FM Global– Karl Meredith– Ning Ren– Prateep Chatterjee– Ankur Gupta– Sergey Dorofeev– Many others …...
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Thanks!
Questions?