Webinar with Inprocess Group: Flare Network

Revalidation Reduces CAPEX

Dr. Miquel Angel Als
Inprocess Technology & Consulting Group

Mr. Saifuddin Sheikh

Aspen Technology

April 15th, 2015

aspenONE Engineering for Safety Analysis

Utilize Aspen HYSYS & Aspen Plus for all the steps of your process
engineering design

Conceptual Basic
Engineering Engineering

Process Safety
Safety
Development Analysis
Analysis
Aspen HYSYS
& Aspen Plus

Equipment
Operations Safety Analysis is the
Design
& Planning
Support
focus of todays webinar
Economic
presentation
Evaluation

2 2015 Aspen Technology, Inc. All rights reserved.

aspenONE Process Safety Tools

PSV (Safety Analysis Environment)

Safety Solution
Breakdown
Depressuring

Dynamic Simulation

Aspen Flare System Analyzer

Focus products of todays webinar presentation

3 2015 Aspen Technology, Inc. All rights reserved.
Completing Pressure Relief Analysis Projects

PSV Sizing in
Simulator

Use AspenTech
Safety Tools to
complete pressure
relief analysis work
accurately and
efficiently with no
manual data transfer
between
programs

Dynamic Aspen Flare

Simulation System
Analyzer

4 2015 Aspen Technology, Inc. All rights reserved.

 Learn More About AspenTechs Process Safety Tools

Revisit Past Webinars

Dynamic Analysis PSV Specific Flare Network

Visit the AspenTech

View Short Tutorial Videos
Webpages

From the AspenTech Flare webpage view:
Introduction to Aspen Flare System Analyzer
Importing PSV results from Aspen HYSYS
and Aspen Plus into Aspen Flare System
Analyzer
5 2015 Aspen Technology, Inc. All rights reserved.
On the AspenTech Engineering Webpage:
Safety & Compliance Webpage Products:
Aspen Flare System Analyzer
Relief Sizing in Aspen Plus and Aspen
HYSYS
Dynamics in Aspen Plus and Aspen
HYSYS
Upcoming Event: OPTIMIZE 2015

6 2015 Aspen Technology, Inc. All rights reserved.

 PSV AND FLARE
NETWORK REVALIDATION
BY USING PROCESS SIMULATION

Miquel A. Alos
Inprocess Services Manager
 INTRODUCTION
Previous experience of Inprocess on
PSV&Flare Network Revalidation
Dynamic Flare load Study. CEPSA Huelva Refinery. Spain. 2015
Dynamic Flare load Study. CNRL Horizon Refinery. Canada. 2014
PSV Revalidation. BP Castellon. Spain 2014
Dynamic Flare load Study. CEPSA Gibraltra Refinery. Spain. 2013
Dynamic Flare load Study, Repsol Puertollano. Refinery. Spain. 2013
PSV and Flare Network Revalidation, Repsol Puertollano Refinery. 2013
Dynamic Flare load Study. Cidade de Ilhabela FPSO. SBM Brasil. 2012
Jakhira Gas Plant. Wintershall. Libia. 2011
Dynamic Flare load Study Mahogany Platform. BP. Trinidad. 2011
Dynamic Flare load Study Compressor Unit. PGNiG. Poland. 2011
Dynamic Flare load study for RD and KDC units. BP Lingen Refinery. Germany.
2011
PSV sizing. Wintershall. Lybia. 2010
Dynamic Flare load analysis of CDU. BP Gelsenkirchen. Germany. 2010
Dynamic Flare load study of a CDU. BP LIngen. Germany. 2010
Refinery Distillation Columns during Power Failure, Foster Wheeler. Italy. 2009
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 INTRODUCTION

Is the current
equipment size
appropriate for plant
safe operation?

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 INTRODUCTION

If Not, How
much is the
CAPEX?

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 INTRODUCTION

Lets think about the first question

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 INTRODUCTION

Lets think about the first question Capacity

SIZE BP

CAPACITY
PSV SIZE
RO SIZE
BACK PRESSURE

12
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 INTRODUCTION

Lets think about the first question Sub-headers

SIZE BP

P, T, u, FLOW

SUB-HEADERS
MACH NUMBER
MOMENTUM
FLUID TEMPERATURE
(HYDRATES)
METAL TEMPERATURE
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 INTRODUCTION

Lets think about the first question Common Reliefs

BP P, T, u, FLOW P, T, u, FLOW

SIZE BP

P, T, u, FLOW

FLARE LOAD
BACK PRESSURE
PRESSURE PROFILE
TEMPERATURE PROFILE
LIQUID KO DRUMPS
TOTAL RADIATION
14
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 INTRODUCTION

Lets think about the first question

15
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 INPROCESS
REFINERY METHODOLOGY
CASE STUDY

PSV Revalidation
Data Reduction

Relief Scenarios API 521

Relief Calculation - Simulation

PSV Sizing API 520
Aspen HYSYS Safety Analysis Utility

Documentation

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 REFINERY CASE STUDY

PSV Revalidation

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 REFINERY CASE STUDY

PSV Revalidation
87 PSV were revalidated
5 PSV shown an inappropriate area and must
be substituted
10 PSV shown hydraulic issues at the sub-
headers: a larger diameter is required for the
piping

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 INPROCESS
REFINERY METHODOLOGY
CASE STUDY

Flare Network Revalidation

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 INPROCESS
REFINERY METHODOLOGY
CASE STUDY

Flare Network Revalidation

Aspen Flare Analyser
Aspen Flare Analyser Model according
to Plant Layout
Common Relief Scenarios
General Power Failure
Partial Power Failure
Fire
Cooling Water Failure

Data
Design load, P, T and composition
Challenge: A single set of components
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 REFINERY CASE STUDY

Flare Network Revalidation

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 REFINERY CASE STUDY

Flare Network Revalidation

Model includes 120 PSV
General Power Failure
Partial Power Failure
Fire at each single fire area (diameter 25 m)
Cooling Water Failure

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 REFINERY CASE STUDY

Flare Network Revalidation

Model includes 120 PSV
General Power Failure
Partial Power Failure
Fire at each single fire area (diameter 25 m)
Cooling Water Failure
Results
Flare load
Mach Number
Temperature out of range
KO T or P out of range
PSV Backpressure

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 REFINERY CASE STUDY

Flare Network Revalidation

120 PSV and their sub-headers and headers have been
revalidated
From PSV Revalidation
5 PSV shown an inappropriate area and must be
substituted
Under GPF
16 PSV must be substituted due to a back pressure
issue
Under Fire
12 PSV must be substituted due to a back pressure
issue
Diameter should be increased for 369 meters of piping

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 REFINERY CASE STUDY

Flare Network Revalidation

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 REFINERY CASE STUDY

Flare Network Revalidation

About 6.5 M$

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 INTRODUCTION

Is there a possibility
to reduce CAPEX by
estimating the flare
network behaviour in
a more accurate way?

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 INTRODUCTION

Is there a possibility
to reduce CAPEX by
estimating the flare
network behaviour in
a more accurate way?

How about
Dynamic Process
Simulation
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 INTRODUCTION

FLARE LOAD ESTIMATION IN INDUSTRY : HOW API WORKS

The API 521 standard provides general guidelines on

estimating relief loads but it leaves the calculation details to
the process engineers judgment
Most flare are evaluated considering a steady-state case and the
calculation of the flare load is made without considering
superimposed and non-linear phenomena.
Flare networks designed with conventional methods might be
oversized and therefore they could be capable of accommodating
new loads

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 INTRODUCTION

FLARE LOAD ESTIMATION IN INDUSTRY : HOW API WORKS

API 521 01/2007 (Chapter 5.22)*:

Dynamic simulation can be used in pressure-relief
system design to calculate transient pressure increases
as indicated in 5.19 or to calculate required relief rates
from individual pressure-relief devices. Conventional
methods for calculating relief loads are generally
conservative and can lead to overly sized relief- and
flare system designs. Dynamic simulation provides an
alternative method to better define the relief load and
improves the understanding of what happens during
relief.

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 INTRODUCTION

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 INTRODUCTION

Dynamic Analysis Aspen HYSYS

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 INTRODUCTION

Dynamic Analysis
By combining these 3 components, dynamic
simulation provides a rigorous alternative to
conventional calculation methods:

it is possible to create a detailed

model of the process unit and the
dynamic phenomena that occur
during the relief event.
It is possible to develop a realistic
understanding of the overall relief
behaviour of the process unit.

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 INTRODUCTION

Dynamic Analysis
Non Simultaneity:

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 INPROCESS METHODOLOGY

Unit Selection
Dynamic Analysis
Large load to flare
Small Current size
Back Pressure

Unit Dynamic Modeling

Dynamic Flare Network Model

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 REFINERY CASE STUDY

Dynamic Analysis
Model
ModelScope
Scope
Large
Largeload
load to flare
to flare
Unit
Unit7272(De-asphalting
(De-asphalting Unit):Unit):
(8(8PSV) GPF(30
PSV) GPF (30t/h)
t/h)Fire
Fire(38(38
t/h)t/h)
Unit
Unit6060(CDU):
(CDU): 101-1 GPF(55
101-1 GPF (55 t/h)
t/h)
Unit
Unit6262(Catalytic Reformer):
(Catalytic Reformer): 120-4
120-4 GPFGPF
(86 (86
t/h) t/h)
Small
SmallCurrent size
Current size
Unit
Unit62:
62:120-2
120-2and 120-3Fire
and 120-3 Fire(30
(30 t/h)
t/h)
Unit
Unit62:
62:120-5
120-5Fire (24t/h)
Fire (24 t/h)
Unit
Unit61:
61:110-2
110-2Fire (15t/h)
Fire (15 t/h)
Unit
Unit69:
69:199-3
199-3Fire (6t/h)
Fire (6 t/h)

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 REFINERY CASE STUDY

Dynamic Analysis

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 REFINERY CASE STUDY

Dynamic Analysis

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 REFINERY CASE STUDY

Dynamic Analysis
GPF

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 REFINERY CASE STUDY

Dynamic Analysis
FIRE

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 REFINERY CASE STUDY

Dynamic Analysis
15 PSV and their sub-headers and headers have been
revalidated. For the other PSV, the loads from PSV
revalidation have been used
2 PSV shown an inappropriate area and needed to be
substituted
21 PSV must be substituted due to a back pressure issue
Diameter should be increased for 294 meters of piping

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 REFINERY CASE STUDY

Flare Network Revalidation

About 4.5 M$

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 RESULTS & CONCLUSIONS

Application of Dynamic Simulation to

the Flare Network revalidation did
supposed a reduction in CAPEX of
around 2M$

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 Question & Answer

44 2015 Aspen Technology, Inc. All rights reserved.

45 2015 Aspen Technology, Inc. All rights reserved.