FIRST COMMERCIAL PRODUCTION FACILITY GARRAF FIELD DEVELOPMENT PROJECT WEATHERFORD OIL TOOL MIDDLE EAST LTD.

. FOR PETRONAS CARIGALI IRAQ HOLDING BV

Document Title:

LP FLARE NETWORK CALCULATION

Document No.:

P10-1033-P-CA-0191 This document supersedes the LP Flare Calculation cited in P10-1033-P-RE-0006

Approved /Reviewed

Approved with Comment Resubmit for Approval E0 21-06-2013 Issued for Construction PKM SY AM

Resubmit for Review

Name Signature Title Date

REV

DATE

STATUS

PREPARED BY

CHECKED BY

APPROVED BY

CONTRACTOR

CLIENT

PROJECT DOCUMENTS ARE CONTROLLED DOCUMENTS. REVISIONS ARE DENOTED IN RIGHT HAND MARGIN
CLIENT: CLIENT REF:

PETRONAS CARIGALI IRAQ HOLDING BV

CONTRACTOR:

CHO/2010/DPP/067
CONTRACTOR REF:

WEATHERFORD OIL TOOL MIDDLE EAST LTD

P10-1033

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TABLE OF CONTENTS 1 2 Introduction ....................................................................................................... 3 Summary............................................................................................................ 3 2.1 Purpose ......................................................................................................... 3 2.2 Definition of Standard and Normal Conditions .............................................. 3 2.3 References .................................................................................................... 3 2.4 Assumptions.................................................................................................. 4 2.5 Calculation Basis........................................................................................... 4 2.6 Results and Conclusions ............................................................................... 5
2.6.1 2.6.2 2.6.3 Backpressure .................................................................................................................. 5 Mach No. & Rho V2 ........................................................................................................ 6 NOISE ............................................................................................................................... 6

LP Flare .............................................................................................................. 6 3.1 LP Flare Sources .......................................................................................... 6 3.2 LP Flare Network .......................................................................................... 7 3.3 LP Flare Relief Loads & Relief Gas Composition .......................................... 8
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 1 Stage Separator (V-1010 / 1020) ............................................................................... 8 ND 2 Stage Separator (V-1110 / 1120) .............................................................................. 8 Dehydrator (V-1510 / 1520) & Desalter (V-1610 / 1620) ................................................ 9 Produced Water Treatment Package (AQ-4210) ............................................................ 9 Fuel Gas Treatment Package (AQ-6020) ..................................................................... 10 Power Plant Fuel Gas Conditioning Package (AQ-7501) ............................................. 10
st

5 6 7

3.4 LP Flare Purge ............................................................................................ 10 3.5 LP Flare Knock Out Drum, V-6205.............................................................. 11 3.6 LP Flare Stack (Smokeless Flaring) ............................................................ 11 3.7 LP Flare Tip................................................................................................. 11 LP Flare Scenarios .......................................................................................... 11 4.1 Scenario 1 ................................................................................................... 12 4.2 Scenario 2 ................................................................................................... 12 4.3 Scenario 3 ................................................................................................... 13 4.4 Scenario 4 ................................................................................................... 13 4.5 Scenario 5 ................................................................................................... 14 4.6 Scenario 6 ................................................................................................... 14 4.7 Scenario 7 ................................................................................................... 15 4.8 Scenario 8 ................................................................................................... 15 4.9 Scenario 9 ................................................................................................... 16 4.10 Scenario 10 .............................................................................................. 16 4.11 Scenario 11 .............................................................................................. 17 Relief Load In Various Scenarios .................................................................. 17 Basis For Aspen Flare System Analyzer Study ............................................ 18 LP Flare Design Criteria ................................................................................. 18 7.1 Header and Tailpipe .................................................................................... 18 7.2 Noise Limitations ......................................................................................... 18 Recommendations .......................................................................................... 18

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INTRODUCTION
The LP Flare Network is an important part of FCP as it ensures the safe disposal of st nd hydrocarbon releases from various pressurized sources. The 1 Stage and 2 Stage separators of both trains are continuously relieving to LP flare header to maintain separator pressure. The following equipment / packages are also connected to the LP flare system for relief gas disposal: desalters, dehydrators, crude heater packages, fuel gas package, power plant fuel gas conditioning and produced water treatment packages. The LP Flare source releases are estimated considering that each FCP Train is operating at the design production rate of 55000 bpd. Calculations produced in this document have been determined using Aspen Flare System Analyzer Version 7.3. Once the various operating and relief scenarios that could occur are defined and the relief rates, venting rates and fluid properties are input into the flare system model, Aspen Flare System Analyzer performs numerous iterative calculations to size the LP flare network. Piping information i.e. layout, pipe lengths and fittings data are taken from piping isometrics in order to build the model.

SUMMARY
2.1 Purpose

The purpose of this calculation is to identify relief scenarios and determine the relief loads directed to the LP flare system and to select the line sizes in the flare system.

2.2

Definition of Standard and Normal Conditions

The standard and normal conditions for volumetric measurement of gases and liquids are defined at pressure and temperature of: Standard = 1.013 Bara and 15.6C. Normal = 1.013 Bara and 0C.

2.3

References
Sr No 1 2 3 4 5 6 Documents Attachment Attachment-A Attachment-B Attachment-C Attachment-D Attachment-E Attachment-F No of Pages 4 2 2 2 4 2

Extract of PSV Datasheet sizing Doc No. : P101033-P-DS-0003 Rev D2 (For Process Trains) st 1 Stage Separator Total Flaring HYSYS stream summary st 1 Stage Separator Blocked outlet HYSYS stream summary st 1 Stage Separator Fire Case HYSYS stream summary st nd 1 Stage & 2 Stage Separator - Blowdown Results nd 2 Stage Separator Total Flaring HYSYS stream summary

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No of Pages 2

Attachment
st

8 9 10 11 12 13 14 15 16 17 18 19

2 Stage Separator gas flow during 1 Stage separator blocked outlet - HYSYS stream summary nd st 2 Stage Separator- Gas blowby from 1 Stage separator - HYSYS stream summary nd 2 Stage Separator Fire Case HYSYS stream summary Dehydrator Fire Case HYSYS stream summary Desalter Fire Case HYSYS stream summary PW Treatment Package- PSV Data Fuel Gas Package- PSV & BDV Data Power Plant Fuel Gas Conditioning PackagePSV & BDV Data Extract of Calculation for LP Flare KO Drum, Doc No.: P10-1033-P-CA-0146
Flare package data from Flare Industries

nd

Attachment-G

Attachment-H Attachment-I Attachment-J Attachment-K Attachment-L Attachment-M Attachment-N Attachment-O Attachment-P Attachment-Q Attachment-R Attachment-S

2 2 2 2 2 3 3 1 2 1 2 17

Purge gas calculation Fuel Gas Package H&M Balance

P&IDs Piping Isometrics Pressure/flow summary (Results for scenarios 1-11)

20 21

Attachment-T Attachment-U

81 11

2.4

Assumptions

1. Any operational contingency on one train will not affect the operation of other train. 2. Pipe lengths and fittings for the Fuel Gas Conditioning Package AQ-7501 and the Produced Water Treatment Package AQ-4210 are assumed. 3. Thermal relief from piping and pig receivers are not considered in this calculation as flow rates are insignificant for this relief contingency. 4. The relief case for the Produced Water Package AQ-4210 is control valve failure based on nitrogen flow. This flow data is currently not available. However, as this flow is limited by an RO and insignificant relative to the governing case for the LP flare, the available data for the thermal relief case given in attachment L is used in the calculations.

2.5

Calculation Basis

1. Various relief loads to LP flare network is considering that both crude processing trains are operating at 55,000 bpd (Design Flow). 2. PSV rated flow is used as the relief load for all cases except fire. 3. For fire case, the required flow of relief valve is used as the relief load even if the governing case is the fire case as there are other mitigating devices in place to reduce the relief load e.g. blowdown and active fire protection. The fire case relief loads also do not govern the flare header sizing in this plant. 4. API Fire circle (of 232 m ) is considered to identify the number of equipment in fire zone.
2

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nd

5. LP flare relief load for fire case scenario of any of these three equipments (2 stage separator, desalter & dehydrator) is the same. As fire circle will cover all three nd equipments 2 stage separator, desalter & dehydrator of the particular train. 6. During operational contingency on one train, it is considered that the feed to the fuel gas package AQ-6020, will be at normal user flow rate demand (i.e., 2 Crude heaters + LP & ATM purge flows + Power Plant Fuel Gas Conditioning Package=2x1591+3x80+3x55+7964=11551 kg/h) from the other normal operating train. st Otherwise, the fuel gas package will be withdrawing equally from the 1 stage separators of trains 1 and 2 and the remaining gas is flared off. 7. During a fire scenario, the relief loads considered are for equipment located in the fire zone and the blowdown rates are from equipment outside the fire zone. 8. In the case of multiple working PSVs, the total relief load is distributed equally to the operating PSVs. 9. In normal operation, fuel gas is continuously purged at 3 locations into the flare header ends to prevent burn back in the flare tip. 10. For the determination of maximum backpressures for multiple PSVs, the farthest working PSVs from the flare stack are assumed to be relieving.

2.6

Results and Conclusions

Aspen Flare System Analyzer simulations are carried out for all scenarios & results are evaluated against the design criteria.

2.6.1

BACKPRESSURE

Maximum back pressure for all scenarios (See attachment-U) is tabulated below. PCV / Relief Scenarios Maximum Back Location Valve Pressure, barg
Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6 Scenario 7 Scenario 8 Scenario 9 Scenario 10 Scenario 11 0.24 Note 2 1.37 1.40 1.14 1.16 0.40 0.39 1.79 0.34 0.15 Train 1- 2 Stage Separator, V-1110 Note 2 nd Train 1- 2 Stage Separator, V-1110 nd Train 2- 2 Stage Separator, V-1110 Train 1- Dehydrator, V-1510 Train 2- Dehydrator, V-1520 st Train 1- 1 Stage Separator, V-1010 st Train 2- 1 Stage Separator, V-1020 Fuel Gas Package, AQ-6020 Power Plant Fuel Gas Conditioning Package, AQ-7501 AQ-4210, IGF
nd

PCV-1110 Note-2 PSV-1110C PSV-1120C PSV-1510 PSV-1520 PSV-1010 C PSV-1020 C PSV-6000 A/B PSV-6027/28 PSV-4220/4221

Notes: 1- Maximum back pressure is observed at downstream of PSV-6000 A/B. 2- In scenario 2 (Total Blowdown), all BDVs will be operating and BDVs operation is independent of back pressure. 3- In scenarios 3 and 4, the maximum back pressures slightly exceed the allowable 30% nd back pressure, set in the simulation. However, as balanced bellows PSVs are used on 2 stage separators and the rated flow is 30% higher than the required flow, there is no concern.

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2.6.2

MACH NO. & RHO V2

In all scenarios, Mach No is significantly lower than 0.6 in all flare headers and sub-headers as well as Mach No. is lower than 0.5 downstream of all control valves (See Attachment U). In all scenarios, Rho V is significantly lower than 200000 kg/m/s , therefore is no concern (See Attachment-U).
2 2

2.6.3

NOISE

In all scenarios noise is significantly lower than 85 dB (A) thus there are no noise issues (See Attachment-U).

LP FLARE
3.1 LP Flare Sources

LP Flare sources are tabulated below

Source V-1010 V-1110 V-1510 V-1610 AQ-1111 V-1020 V-1120 V-1520 V-1620 AQ-1112 AQ-6020 AQ-7501 AQ-4210 Name Train 1, 1 Stage Separator Train 1, 2
nd st

PCV / BDV / Relief Valve PCV-1011, BDV-1010, PSV-1010 A/B/C PCV-1110, BDV-1110, PSV-1110 A/B/C PSV-1510 PSV-1610 TSV-11101 PCV-1020, BDV-1020, PSV-1020 A/B PCV-1120, BDV-1120, PSV-1120 A/B PSV-1520 PSV-1620 TSV-11201 PSV-6000 A/B, BDV-6001, BDV-6010 PSV-6027/28, BDV-6001, BDV-6002 PSV-4210/4211, PSV-4220/4221 Stage Separator

Train 1, Dehydrator Train 1, Desalter Train 1, Crude Heater (Note 1) Train 2, 1 Stage Separator Train 2, 2
nd st

Stage Separator

Train 2, Dehydrator Train 2, Desalter Train 2, Crude Heater (Note 1) Fuel Gas Package (Note 2) Power Plant Fuel Gas Conditioning Package (Note 2) Produced Water Treatment Package

Note 1: Source modeled in Flare-Net but as this is a thermal relief case it is ignored in the simulations. Note 2: Only the governing and blowdown sources that are modeled in Flare-Net are given here.

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3.2

LP Flare Network

The LP flare network model schematic is shown below.

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3.3

LP Flare Relief Loads & Relief Gas Composition

The LP flare sources have different relief loads in accordance with the overall relief scenario. The relief gas composition is dependent on the relieving scenario.

3.3.1

1ST STAGE SEPARATOR (V-1010 / 1020)

PCV-1011 /1021 Total Flaring Attachment-B PSV-1010 A/B/C / 1020 A/B/C Blocked outlet Attachment-A PSV-1010 A/B/C / 1020 A / B /C Fire Attachment-A BDV-1010 / 1020 Adiabatic Blowdown Attachment-E

PCV / BDV / Relief Valve

Scenario Reference Relief load, kg/h Pressure, barg Temperature, C M.W. Composition
o

36668.7 9.9 65.8 24.2

Attachment-B

30713* 19.8 66.0 22.8

Attachment-C

10637 21.8 174.3 34.8

Attachment-D

4559 10.3 66 24.2

Attachment-B

For adiabatic blowdown, composition is considered similar to total flaring case. *Required flow given, the rated flow of 33654 kg/h for two operating PSVs is used in calculations.

3.3.2

2ND STAGE SEPARATOR (V-1110 / 1120)

PCV-1011 /1021 Total Flaring Attachment-F 10545.9 PCV-1011 /1021
st

PCV / BDV / Relief Valve

PSV-1110 A/B/C / 1120 A/B/C Gas Blowby Attachment-A 55556

Scenario Reference Relief load, kg/h Pressure, barg Temperature, C M.W. Composition
o

During 1 Stage Blocked outlet Attachment-G 12921

PSV-1010 A/B/C / 1020 A / B /C Fire Attachment-A 8813

2.4 104.1 38.3

Attachment-F

2.4 104.6 42.6

Attachment-G

4.9 105.0 25.6

Attachment-H

5.6 141.7 37.8

Attachment-I

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Stage Separator (V-1110 / 1120) During Blowdown BDV-1110 / 1120 Adiabatic Blowdown Attachment-E 4354 BDV-1110 / 1120 Fire Case Blowdown Attachment-E 6207

PCV / BDV / Relief Valve

Scenario Reference Relief load, kg/h Pressure, barg Temperature, C M.W. Composition
o

2.8 105 38.3

4.5 105 38.3

Attachment-F Attachment-F For adiabatic & fire blowdown, composition is considered similar to total flaring case.

3.3.3

DEHYDRATOR (V-1510 / 1520) & DESALTER (V-1610 / 1620)

PSV-1510 / 1520 Fire Attachment-A PSV-1610 / 1620 Fire Attachment-A

PCV / BDV / Relief Valve

Scenario Reference Relief load, kg/h Pressure, barg o Temperature, C M.W. Composition

15993 20.5 199.3 34.7

Attachment-J

15991 20.5 199.3 34.7

Attachment-K

3.3.4

PRODUCED WATER TREATMENT PACKAGE (AQ-4210)

PSV-4210 / 4211 Thermal Relief* PSV-4220 / 4221 Thermal Relief*

PCV / BDV / Relief Valve

Scenario

Reference Attachment-L Attachment-L Relief load, kg/h 650* 650* Pressure, barg 9.6 9.6 o Temperature, C 70 70 M.W. 24.2 24.2 Composition Attachment-R Attachment-R *Thermal relief load used in calculations in the absence of actual data for control valve failure case. See section 2.4.

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3.3.5

FUEL GAS TREATMENT PACKAGE (AQ-6020)

Fuel Gas Treatment Package (AQ-6020) relief load is 63000 Kg/hr for the governing case. The PSV rated flow is limited to this required flow by the upstream train 1 and 2 control valve Cvs and system hydraulics.
Equipment PCV / BDV / Relief Valve

V-6000 PSV-6000A/B Control Valve Failure Attachment-M

V-6000 BDV-6000 Adiabatic Blowdown Attachment-M

S-6000 A/B BDV-6010 Adiabatic Blowdown Attachment-M

Scenario Reference Relief load, kg/h Pressure, barg Temperature, C M.W. Composition
o

63000 15.1 60 24.2

Attachment-M&R

331.5 8.6 60 24.2

Attachment-M&R

932.6 8.0 75 24.2

Attachment-M&R

3.3.6

POWER PLANT FUEL GAS CONDITIONING PACKAGE (AQ-7501)

Power Plant Fuel Gas Conditioning Package (AQ-7501) relief load is 8381 kg/hr for the governing case. Equipment E-6006 V-6005 E-6001
PCV / BDV / Relief Valve

Scenario Reference Relief load, kg/h Pressure, barg Temperature, C M.W. Composition
o

PSV-6027 / 6028 Tube Rupture Attachment-N

BDV-6002 Adiabatic Blowdown Attachment-N

BDV-6001 Adiabatic Blowdown Attachment-N

8381* 8.3 32.2 24.0

Attachment-N

705 21.6 10.0 24.0

Attachment-N

1596 20.5 10.0 24.0

Attachment-N

*Required flow is used as the relief rate is limited by the supply of gas to this package.

3.4

LP Flare Purge

LP flare network is purged continuously with fuel gas through three locations (Train1 flare header, Train 2 flare header and fuel gas package, AQ-6020). Fuel gas purging requirement (for burnback prevention) is based on Flare Industries values and velocity criteria are adjusted to match the flow requirement. Purge gas flow rates are estimated based on a velocity of 0.092 m/s at flare tip.

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During loss of fuel gas supply or during startup/shutdown, LP flare network is continuously purged with nitrogen through two locations (Train 1 Flare header, Train 2 Flare header). N2 purging requirement (for air-ingress prevention) is based on API velocity criteria (0.006-0.012 m/sec). Velocity of 0.012 m/sec is used for calculation and this is in close agreement with Flare Industries values. Refer to Attachment-Q for purge gas calculation.

3.5

LP Flare Knock Out Drum, V-6205

Calculated pressure drop across the LP flare KOD is approximately 10 mbar at the rated flow of 94400 kg/h. However, the actual pressure drop across the drum is likely to be higher because of the inlet device and sump pump obstruction to flow path. (Refer to Attachment-O, Calculation for LP Flare KO Drum P10-1033-P-CA-0146).

3.6

LP Flare Stack (Smokeless Flaring)

The LP flare stack assembly consists of a 36 inch inner flare gas riser and a 78 inch outer pipe. The dilution air is blown through the annulus between the riser and the outer pipe. The stack height is 45.7 m from ground level (see Attachment-P, LP Flare Package data from Flare Industries).

3.7

LP Flare Tip

The Flare Tip contains a dynamic seal. Its pressure drop is 25.77 mbar at the design flow (see Attachment-P, LP Flare package data from Flare Industries).

LP FLARE SCENARIOS
The following 11 scenarios are identified for the LP flare calculations. An individual scenario is selected to have maximum relief load in different parts of LP flare system or simultaneous maximum load in different area.

Various Scenarios are listed below: Scenario 1 Total gas flaring Train 1 & 2 Scenario 2 Total Facility Blowdown nd Scenario 3 2 Stage Separator gas blowby, Train 1 nd Scenario 4 2 Stage Separator gas blowby, Train 2 Scenario 5 Fire Case Train-1 Scenario 6 Fire Case Train-2 st Scenario 7 Blocked outlet 1 Stage separator, Train-1 st Scenario 8 Blocked outlet 1 Stage separator, Train-2 Scenario 9 FG Package control valve failure Scenario 10 Power Plant Fuel Gas Conditioning Package Scenario 11 PWT Package control valve failure

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4.1

Scenario 1

Scenario 1 is maximum flaring of associated gas from both trains and each train is operating at design flowrate of 55000 bopd. Relief Loads from various sources are tabulated below.
Source V-1010 V-1110 V-1020 V-1120 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator PCV / BDV / Relief Valve PCV-1011 PCV-1110 PCV-1021 PCV-1120 Mass Relief Rate (Gas), kg/h 36668.7 10545.9 36668.7 10545.9 94429.3 Relief Scenario Total Flaring Total Flaring Total Flaring Total Flaring

Total LP Flare Load

4.2

Scenario 2

Scenario 2 is considering the total facility Blowdown e.g. during ESD. Relief Loads from various sources are tabulated below.
Source V-1010 V-1110 V-1020 V-1120 AQ-6020 AQ-6020 AQ-7501 AQ-7501 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator PCV / BDV / Relief Valve BDV-1010 BDV-1110 BDV-1020 BDV-1120 BDV-6000 BDV-6010 BDV-6001 BDV-6002 Mass Relief Rate (Gas), kg/h 4559 4354 4559 4354 331.5 932.6 1596 705 21391.1 Relief Scenario Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown

Fuel Gas Package Fuel Gas Package Power Plant Fuel Gas Conditioning Package Power Plant Fuel Gas Conditioning Package

Total LP Flare Load

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4.3

Scenario 3
nd

Scenario 3 is considering the Gas blowby from train 1, 2 Stage Separator and gas from train 2 is under normal flaring. Relief Loads from various sources is tabulated below.
Source V-1110 V-1110 V-1020 V-1120 Name Train-1, 2nd Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Purge Gas Flow Total LP Flare Load PCV / BDV / Relief Valve PSV-1110 B PSV-1110 C PCV-1021 PCV-1120 Mass Relief Rate (Gas), kg/h 27778.0 27778.0 25117.7 10545.9 240.0 91459.6 Relief Scenario Gas Blowby Gas Blowby Total Flaring less Fuel Gas Consumption of 11551 kg/h Total Flaring

4.4

Scenario 4
nd

Scenario 4 is considering the Gas blowby from train 2, 2 Stage Separator and gas from train 1 is under normal flaring. Relief Loads from various sources is tabulated below.
Source V-1010 V-1110 V-1120 V-1120 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 2nd Stage Separator Train-2, 2nd Stage Separator Purge Gas Flow Total LP Flare Load PCV / BDV / Relief Valve PCV-1011 PCV-1110 PSV-1120 B PSV-1120 C Mass Relief Rate (Gas), kg/h 25117.7 10545.9 27778.0 27778.0 240.0 91459.6 Relief Scenario Total Flaring less Fuel Gas Consumption of 11551 kg/h Total Flaring Gas Blowby Gas Blowby

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4.5

Scenario 5
nd

Scenario 5 is considering Train 1, 2 stage separator is under fire and depressurized. Fire st circle is spreading over desalter and dehydrator.1 stage separator is depressurized adiabatically. Train 2, Fuel gas Package & Power Plant Fuel Gas Conditioning Package is under adiabatic blowdown. Relief Loads from various sources is tabulated below.
Source V-1010 V-1110 V-1510 V-1610 V-1020 V-1120 AQ-6020 AQ-6020 AQ-7501 AQ-7501 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-1, Dehydrator Train-1, Desalter Train-2, 1st Stage Separator Train-2, 2nd Stage Separator PCV / BDV / Relief Valve BDV-1010 BDV-1110 PSV-1510 PSV-1610 BDV-1020 BDV-1120 BDV-6000 BDV-6010 BDV-6001 BDV-6002 Mass Relief Rate (Gas), kg/h 4559 6207 15993 15991 4559 4354 331.5 932.6 1596 705 55228.1 Relief Scenario Adiabatic Blowdown Fire Case Blowdown Fire Case Fire Case Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown

Fuel Gas Package Fuel Gas Package Power Plant Fuel Gas Conditioning Package Power Plant Fuel Gas Conditioning Package

Total LP Flare Load

4.6

Scenario 6
nd

Scenario 6 is considering Train 2, 2 stage separator is under fire and depressurized. Fire st circle is spreading over desalter and dehydrator.1 stage separator is depressurized adiabatically. Train 1, Fuel gas Package & Power Plant Fuel Gas Conditioning Package is under adiabatic blowdown. Relief Loads from various sources is tabulated below.
Source V-1010 V-1110 V-1020 V-1120 V-1520 V-1620 AQ-6020 AQ-6020 AQ-7501 AQ-7501 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Train-2, Dehydrator Train-2, Desalter PCV / BDV / Relief Valve BDV-1010 BDV-1110 BDV-1020 BDV-1120 PSV-1510 PSV-1610 BDV-6000 BDV-6010 BDV-6001 BDV-6002 Mass Relief Rate (Gas), kg/h 4559 4354 4559 6207 15993 15991 331.5 932.6 1596 705 55228.1 Relief Scenario Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Fire Case Blowdown Fire Case Fire Case Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown Adiabatic Blowdown

Fuel Gas Package Fuel Gas Package Power Plant Fuel Gas Conditioning Package Power Plant Fuel Gas Conditioning Package

Total LP Flare Load

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4.7

Scenario 7
st

Scenario 7 is considering that Train 1, 1 stage separator is under relieving under blocked outlet condition and Train 2 is normal flaring. Relief Loads from various sources is tabulated below.
Source V-1010 V-1010 V-1110 V-1020 V-1120 Name Train-1, 1st Stage Separator Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Purge Gas Flow Total LP Flare Load PCV / BDV / Relief Valve PSV-1010 C PSV-1010 B PCV-1110 PCV-1021 PCV-1120 Mass Relief Rate (Gas), kg/h 16827 16827 12921 25118 10545.9 240.0 82478.9 Relief Scenario Blocked Outlet Blocked Outlet Blocked Outlet of 1st Stage separator Total Flaring less Fuel Gas Consumption of 11551 kg/h Total Flaring

4.8

Scenario 8
st

Scenario 8 is considering that Train 2, 1 stage separator is relieving under blocked outlet condition and Train 1 is total flaring. Relief Loads from various sources is tabulated below.
Source V-1010 V-1110 V-1020 V-1020 V-1120 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Purge Gas Flow Total LP Flare Load PCV / BDV / Relief Valve PCV-1011 PCV-1110 PSV-1020 C PSV-1020 B PCV-1120 Mass Relief Rate (Gas), kg/h 25118 10545.9 16827 16827 12921 240 82478.9 Relief Scenario Total Flaring less Fuel Gas Consumption of 11551 kg/h Total Flaring Blocked Outlet Blocked Outlet Blocked Outlet of 1st stage separator

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4.9

Scenario 9
st

In this scenario, the 1 Stage Separator fuel gas PCVs of both trains are wide open and the maximum flow through each PCV, assuming a hydraulically balanced system, is 63000 kg/h st divided by 2 i.e. 31500 kg/h. Thus, the flare PCV flow from each 1 stage separator is equal nd to the total flaring load of 36668.7 kg/h less 31500 which equals 5168.7 kg/h. The 2 stage separator flare PCV is maintaining its position and relieving 10545.9 kg/h. Relief loads for this scenario are given below.
Source V-1010 V-1110 V-1020 V-1120 AQ-6020 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Fuel Gas Package PCV / BDV / Relief Valve PCV-1011 PCV-1110 PCV-1021 PCV-1120 PSV-6000 A/B Mass Relief Rate (Gas), Kg/Hr 5168.7 10545.9 5168.7 10545.9 63000 94429.3 Relief Scenario 1st Stage Separator fuel gas PCVs Total Flaring 1st Stage Separator fuel gas PCVs Total Flaring Control Valve Failure

Total LP Flare Load

4.10 Scenario 10
Scenario 10 is considering normal train operation with tube rupture occurring in the chiller exchanger in the Power Plant Fuel Gas Conditioning Package. Relief loads for this scenario are given below.
Source V-1010 V-1110 V-1020 V-1120 AQ-7501 Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator Power Plant Fuel Gas Conditioning Package Purge Gas Flow Total LP Flare Load PCV / BDV / Relief Valve PCV-1011 PCV-1110 PCV-1021 PCV-1120 PSV-6027/28 Mass Relief Rate (Gas), kg/h 30893 10545.9 30893 10545.9 8381 240 91498.8 Relief Scenario Total Flaring less half of 11551 kg/h Total Flaring Total Flaring less half of 11551 kg/h Total Flaring Tube Rupture

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4.11 Scenario 11
Scenario 11 is considering normal train operation with the PWT Package fuel gas padding valve failing open. Relief loads for this scenario are given below.

Source V-1010 V-1110 V-1020 V-1120 AQ-4210

Name Train-1, 1st Stage Separator Train-1, 2nd Stage Separator Train-2, 1st Stage Separator Train-2, 2nd Stage Separator PW Treatment Package Purge Gas Flow

PCV / BDV / Relief Valve PCV-1011 PCV-1110 PSV-1010 A BDV-1120 PSV-4210/11 or PSV4220/21

Mass Relief Rate (Gas), kg/h 30893 10545.9 30893 10545.9 650 240 83768.3

Relief Scenario Total Flaring less half of 11551 kg/h Total Flaring Total Flaring less half of 11551 kg/h Total Flaring Control Valve Failure

Total LP Flare Load

RELIEF LOAD IN VARIOUS SCENARIOS

LP flare relief load for various scenarios is tabulated below Scenarios Scenario 1 Scenario 2 Scenario 3 Scenario 4 Scenario 5 Scenario 6 Scenario 7 Scenario 8 Scenario 9 Scenario 10 Scenario 11 Relief Load , kg/h Relief Load, MMscfd

94429.3 21391.1 91459.7 91459.7 55228.1 55228.1 82478.7 82478.7 94429.3 91498.8 83768.3

71.87 15.07 70.04 70.04 34.79 34.79 62.97 62.97 71.87 69.64 63.02

Scenario 1 and 9 are the governing relief load for LP flare system.

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BASIS FOR ASPEN FLARE SYSTEM ANALYZER STUDY

1. Calculation is carried out in the Rating Mode. 2. Pipe roughness used is 0.050 mm. 3. Calculation options assumed are as follows: VLE Method = Peng Robinson; Enthalpy Method = Lee Kessler; Pressure Drop Method = Beggs and Brill (Homogenous) Friction Factor Method = Chen

LP FLARE DESIGN CRITERIA

7.1 Header and Tailpipe
Parameter Mach No. Criteria <0.6 Reference Process Design Philosophy, P10-1033-P-RE-0003

Pipe Work Main Header / Sub header

7.2

Noise Limitations

A. For emergency conditions the noise level not to exceed 115 dB(A). B. For normal operation noise levels not to exceed 85 dB(A).

RECOMMENDATIONS
The Power Plant Fuel Gas Conditioning Package (AQ-7501) PSV`s are currently conventional types. From the Flarenet simulations it is recommended to select balance bellow PSV`s to handle higher back pressures. It is also recommended for Petronas to revise the Flarenet model with final PSV relief loads and back pressures once the Power Plant Fuel Gas Conditioning Package vendor has finalized the design.

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