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Dynamic modelling and simulation of

Flare Systems
Flow Assurance and Dynamic Simulations Seminar, Stavanger 29.10.2013
Jrgen Osenbroch | Process Specialist Engineer, Aker Solutions MMO
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Introduction

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Typical flare system

Typical relief sources
Pressure Safety Valves (PSVs)
Blowdown valves (BDVs)
Pressure Control Valves (PVs)

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Typical simulation of flare systems

Traditional flare system design and capacity evaluations:
Steady State simulations traditionally performed
Hysys Depr.Utility and Flarenet
Continuous peak flow
Flare system volume not accounted for
No accumulation in system
Conservative design

Advantage using Dynamic Simulations

Includes packing effect in the flare system network
Peak flow and pressure staggered and delayed
Requires modelling of flare system

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Typical flare simulation tools used by Aker Solutions

Hysys Depr. Utility (dynamic)
Flarenet (steady state)
OLGA (dynamic)
Hysys Dynamics (dynamic)

Selection criteria

Gas or multiphase flow

Number of sources
Composition
Customer preference

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The Project
Accomplice:
- Henriette Raddum
- Musab Ilahi

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Project Background
Background:
Modification project on existing platform
Tie-in of new fields new equipment increased blowdown volumes
Increased inlet separator pressure higher initial blowdown rate
Static simulations Flare KO drum peak pressure close to max

pressure allowed by design code (design pressure + 10%)

Sequential depressurisation introduced

Is there a more realistic and accurate approach ?

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Hmm

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Ahaaaa..

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Dynamic Simulation Model for Blowdown & Flare System

Develop
Dynamic simulation tool for blow down segments and Flare Systems

Why
Analyse packing effect and transient flow and pressure development

Benefit
Minimise Project Execution cost (less modifications necessary)
Minimise sequential blowdown

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Project Scope and Deliverables

Scope of Work
Base case: Total platform depressurisation (maximum gas to flare)
Sensitivities related to
Failure of sequential blow down
Blowdown of liquid segments

Deliverables
Tool for estimating BD segment volumes, weight and gas/liquid fraction
Framework for modelling individual BD segments in Hysys Dynamics
Framework for modelling entire flare system in Hysys Dynamics

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Development of Dynamic Flare Simulator

Tool: Hysys Dynamics (v7.3)
Challenge: Never done before in this scale (as far as we know)
Key to success: Good engineers, close collaboration with Company

and AspenTech focal point of contact

Approach
All BD segments and entire Flare System modelled from isometrics
Headers and lines downstream BD valves modelled in detail using pipe

segments
Pipes without BD valves simplified (e.g. PV/PSV tailpipes)
Pipes less than 4 not included unless connected to BD valve
Blowdown segments/volumes modelled as vessels
Compared to Hysys Depressurizing Utility
Sequential blowdown included

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A typical BD system
Output from
segment to
full model

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HP Flare system - zoomed

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HP Flare system
Flare tip
KO Drum

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Simulation results

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Dynamic Flare Model - Results

Adiabatic blowdown simulated
Failure of one BD valve with time delay
Remaining BD valve time delays included

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Dynamic Flare Model Results (Massflow)

1400000

1200000

Massflow [kg/h]

1000000

800000
Accumulated System Massflow
600000

Flare Tip 43-FC01

400000

200000

0
0

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200

400

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600

800
1000
Time [s]

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1200

1400

1600

1800

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Dynamic Flare Model Results (Massflow)

Zoomed
1400000

1200000

Massflow [kg/h]

1000000

800000
Accumulated System Massflow
600000

Flare Tip 43-FC01

400000

200000

0
0

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50

100

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150
200
Time [s]

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250

300

350

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Dynamic Flare Model Results (Massflow)

1400000

1200000

Massflow [kg/h]

1000000

800000
Accumulated System Massflow
Flare Tip 43-FC01
600000

Accumulated System Massflow

Flare Tip 43-FC01

400000

200000

0
0

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50

100

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150
200
Time [s]

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250

300

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Dynamic Flare Model - Results

Up-stream
metering
station

KO Drum

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XX Flare
Manifold

Upstream
flare tip

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Dynamic Flare Model Results (Pressure)

9

Pressure [bara]

5
KO Drum 43-VD01
Upstream Flare Metering station
4

Upstream Flare Tip 43-FC01

XX Flare Manifold

0
0

200

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400

600

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800

1000
Time [s]

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1200

1400

1600

1800

2000

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Dynamic Flare Model Results (Pressure)

Zoomed
9

Pressure [bara]

5
KO Drum 43-VD01
Upstream Flare Metering station
4

Upstream Flare Tip 43-FC01

XX Flare Manifold

0
0

50

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100

150

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200

250
Time [s]

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350

400

450

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Dynamic Flare Model Results (Pressure)

12

10

Pressure [bara]

KO Drum 43-VD01
Upstream Flare Metering station
Upstream Flare Tip 43-FC01

XX Flare Manifold
KO Drum 43-VD01
Upstream Flare Metering station

Upstream Flare Tip 43-FC01

XX Flare Manifold

0
0

200

400

600

800

1000

Time [s]

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Dynamic Flare Model - Results

Dynamic
Simulation

Steady State
Simulation

Peak pressure [bara]

KO Drum

8,34

10,86

XX Manifold

6,14

7,94

Upstream Flare
Tip

3,65

4,77

Peak mass flowrate [kg/h]

KO Drum

815 054

1 040 430

XX Manifold

149 527

159 190

Upstream Flare
Tip

932 052

1 199 620

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Simulation model tested against

field measurements

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Dynamic Flare Model Platform ESD blowdown

ESD 2.0 blowdown
Field data provided by Company
Simulated in HYSYS Dynamic Flare Model
Simulation results compared against field measurements

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Dynamic Flare Model ESD blowdown

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 Well & Condensate segments - Pressure

Sleipner Dynamic Flare Model Sleipner ESD blowdown

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 Gas segments - Pressure

Sleipner Dynamic Flare Model Sleipner ESD blowdown

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Summary

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Dynamic Flare Model Project Summary

The following has been developed:
Framework for calculating BD segments volume, weight, gas/liquid

fractions
Methodology for modelling BD segments in Hysys Dynamics
Methodology for modelling and simulating Flare network
Provides a more realistic and accurate approach to Flare design
Better understanding of the dynamic behaviour during blow down
Easier to evaluate need and/or effect of sequential blow down

A fire model is also included.

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Any questions?

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Dynamic Flare Model Platform ESD blowdown

Backup slides

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Dynamic Flare Model - Backup

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Dynamic Flare Model Results (backup)

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Dynamic Flare Model Results(backup)

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Copyright and disclaimer

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