Smith & Burgess' Blog

Case Study: Flare Maintenance Operations

Posted by Dustin Smith, P.E. on Apr 17, 2017 6:08:00 PM

The Opportunity:

After a routine preventative maintenance inspection, a refinery found that a major flare header was in need of replacement. This header connected two large sections of the refinery, and the management feared that a majority of the facility would need to be shut down to safely replace the header. The site hired Smith & Burgess to perform a Flare Header QRA to determine the minimum amount of necessary shutdowns in order to safely perform the line replacement. The Flare Quantitative Risk Assessment used load probabilities to determine the likelihood of various events, should a power failure occur.

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Topics: Flare Mitigation, Flare Analysis, Flare Study, Case Study, Flare System, Refinery, Engineering Review, Flare Header, Flare Management, Flare Optimization, Engineering Standards, Quantitative Risk Assessment, QRA, Rate Increase

Case Study: Flare System Optimization I

Posted by Dustin Smith, P.E. on Feb 4, 2017 6:09:00 PM

The Opportunity:

A major United States refinery worked with an EPC on the site’s action items where they recommended a new flare worth approximately $30 Million. The refinery wanted a third-party review on the EPC’s recommendation and hired Smith & Burgess to verify their results.

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Topics: Action Item Resolution, Flare Study, Heat and Material Balance, Case Study, Flare System, Refinery, Flare Load Optimization, Flare Revalidation, Third Party Review, Flare Optimization, Overly Conservative Assumptions

Case Study: Action Item Resolution I

Posted by Dustin Smith, P.E. on Feb 1, 2017 6:00:00 PM

The Opportunity:

Over the course of a four year time period, a major United States refinery was inundated with over 1,000 action items and asked Smith & Burgess to provide recommended resolutions.

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Topics: Action Item Resolution, Case Study, Refinery, PSM, PSM Review, PSM Audit, Mitigation

Employee Spotlight: Nicholas Cristea

Posted by Brandon Ring on Feb 1, 2017 5:47:00 PM



Mr. Nicholas Cristea  
|  Technical Lead

Mr. Cristea is a detail oriented Master-degreed chemical engineer specializing in Process Safety Management, with the main focus in Relief Systems Analysis and Documentation. He is a practical problem solver who makes quick, accurate decisions to efficiently solve a client's need in the most cost-effective and safe manner.

Nick has led over 20 domestic and global projects in Tier 1 Upstream and Downstream, Upstream Oil & Gas Operators, and Chemical Manufacturing Facilities with a total direct project revenue of over $10 million and savings generated in the region of $70 million.

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Topics: Smith & Burgess News, Employee Spotlight

Case Study: Action Item Resolution II

Posted by Dustin Smith, P.E. on Jan 1, 2017 5:59:00 PM

The Opportunity:

The Process Superintendent at a large specialty chemical manufacturing complex had over 600 open action items that were past due and needed direction on how to close them. The action items were assigned to the unit engineers who were unable to dedicate the necessary time.

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Topics: Action Item Resolution, Case Study, Refinery, PSM, PSM Review, PSM Audit, Mitigation

Did You Know: Cold Differential Test Pressure (CDTP)...

Posted by Brandon Ring on Jan 1, 2017 5:55:00 PM

 

Did you know, under certain circumstances, you need to verify if the Cold Differential Test Pressure (CDTP) is properly compensated for the superimposed backpressure from the flare header?

Have you come across a conventional pressure relief valve relieving to a flare header? Did you know that, under certain circumstances, you need to verify if the Cold Differential Test Pressure (CDTP) is properly compensated for the superimposed backpressure from the flare header?

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Topics: Did You Know?, Pressure Relief Valves, Flare Header, API 521, PRV, Cold Differential Test Pressure, CDTP, Relief Header, Set Pressure

Case Study: Flare System Velocity Concern Review

Posted by Dustin Smith, P.E. on Nov 16, 2016 6:07:00 PM

The Opportunity:

After reading about flare header failures due to high velocities, an owner of a production platform in the Middle East wanted to ensure that the initial inerting/purging of the platform and pipeline would not result in flare header piping failure. Smith & Burgess was hired to review the flare systems for safe operation under the high flow rates associated with the initial facility start-up.

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Topics: Flare Mitigation, Flare Analysis, Flare Study, Detailed Engineering, Case Study, Flare System, Engineering Review, Flare Management, Flare Optimization, Engineering Analysis, Rate Increase, API 521

Case Study: Flare System Optimization II

Posted by Dustin Smith, P.E. on Aug 9, 2016 6:07:00 PM

The Opportunity:

A major United States refinery was recommended by an EPC to install a new flare worth approximately $60 Million. Unsatisfied with the EPC's recommendations, the refinery asked Smith & Burgess to perform a third-party review to verify their results.

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Topics: Flare Mitigation, Flare Analysis, Flare Study, Case Study, Flare System, Refinery, Engineering Review, Flare Management, Flare Revalidation, Third Party Review, Flare Optimization, Overly Conservative Assumptions, Engineering Analysis

Did You Know: Liquid Service PSVs...

Posted by Brandon Ring on Jul 1, 2016 5:52:00 PM

 

Did you know, a relief device in liquid service does not always mean that the device is liquid-certified?

Liquid-certified devices are mechanically designed and sized by an engineer to relieve liquid. Per UG-125 of ASME Section VIII, "Vessels that are to operate completely filled with liquid shall be equipped with pressure relief devices designed for liquid service, unless otherwise protected against overpressure."

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Topics: Did You Know?, Pressure Relief Valves, API 521, PRV, Liquid Service PSV

Did You Know: Exit Pipe Fitting...

Posted by Brandon Ring on Jun 1, 2016 5:56:00 PM

 

Did you know to exclude the exit pipe fitting in your PSV outlet pressure drop calculations if your PSV discharges to atmosphere?

If you have performed an outlet pressure drop calculation for a PSV relieving to atmosphere, you may have noticed that often a significant portion of the pressure drop is contributed by the exit pipe fitting. This is because the equivalent resistance of the fitting is high relative to a typical length of pipe.

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Topics: Did You Know?, Pressure Relief Valves, PRV, Pressure Drop Calculations, Pressure Drop, Exit Pipe Fitting

 Safety Knowledge Should be Share...

“It should not be necessary for each generation to rediscover the principles of process safety which the generation before discovered. We must learn from the experience of others rather than learn the hard way. We must pass on to the next generation a record of what we have learned.” - Jesse C. Ducommun, Safety Pioneer
 
As Process Safety engineers and consultants, we believe our unique position creates a responsibility for Smith & Burgess to share our years of accumulated safety knowledge.


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