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Case Study: Flare Management Plan

Posted by Dustin Smith, P.E. on Dec 6, 2018 4:38:59 PM

The Opportunity:

A major United States refinery, with a significantly high Nelson Complexity Index rating, had nine flare stacks and multiple engineering contractors working within the facility which made managing their flare design and documentation a challenge.

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Topics: Case Study, Flare Study, Refinery, Flare Header, Flare System, Flare Management, Flare System Documentation, Evergreening

Case Study: Flare Modifications Due to Rate Increase

Posted by Dustin Smith, P.E. on Dec 6, 2018 4:28:04 PM

The Opportunity:

A major United States refinery was in the process of installing a site-wide rate increase and hired a competing engineering firm to perform the feasibility study. The engineering firm sized their crude fractionator and recommended new relief devices that would require modifications to their existing flare header. The refinery’s corporate office called Smith & Burgess and asked us to perform a third-party review on the engineering firm’s recommendations. 

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Topics: Case Study, Flare Study, Refinery, Engineering Review, Flare System, Third Party Review, Flare Header

Case Study: Relief Systems Evaluation and Mitigation

Posted by Dustin Smith, P.E. on May 1, 2018 6:04:00 PM

The Opportunity:

A major United States Refinery hired Smith & Burgess to perform a site-wide revalidation.

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Topics: Case Study, Pressure Relief Valves, PRV Study, Engineering Review, Relief Systems, PRV, Relief System Design, Refinery, Relief Systems Revalidation, Undersized PSVs

Case Study: Elimination of a Remote Flare System

Posted by Dustin Smith, P.E. on Mar 4, 2018 6:09:00 PM

The Opportunity:

An offshore floating production facility was originally designed with two flares: one on a boom riser and the other remotely located. Due to the design, the remotely located flare required large amounts of gas to operate. The site was interested in reducing operational costs and emissions by consolidating the two flares into the flare on the boom riser, eliminating the remotely located flare. However, there were concerns with the feasibility of such a flare consolidation, the effects of thermal radiation, and the possibility that system changes would increase the backpressures on the relief devices. Smith & Burgess was hired to review this system.

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Topics: Case Study, Flare Study, Refinery, Flare Header, Flare System, Flare Management, Engineering Review, Flare Optimization, Flare Analysis, Flare Mitigation

Case Study: LOPA Action Item Review

Posted by Dustin Smith, P.E. on Feb 1, 2018 5:58:00 PM

The Opportunity:

A recent Layers of Protection Analysis (LOPA) of a cavern storage facility identified several equipment installations requiring safety system upgrades. While the facility management wanted to follow proper review procedures, these proposed mitigation options seemed excessive. As a result, the site hired Smith & Burgess to review the safety systems upgrades to ensure the installations were needed and met regulatory requirements.

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Topics: Case Study, Refinery, Mitigation, Action Item Resolution, PSM Review, PSM Audit, PSM, LOPA, Layers of Protection Analysis, OSHA

Case Study: Wellhead Gathering System Overpressure QRA

Posted by Dustin Smith, P.E. on Jan 1, 2018 5:58:00 PM

The Opportunity:

A review of the “overpressure protection plan” for a wellhead gathering pipeline found that the potential for “multiple simultaneous well shutdown system failures” had been overlooked. The flowing pressure on the inlet to the well choke valve exceeded the allowable pressure in the gathering system. If multiple well safety systems failed, there would be an unacceptable potential for large-scale loss of containment. A Quantitative Risk Assessment of the entire system was needed to determine if the existing overpressure protection system, as a whole, met corporate and regulatory requirements. Initially, the protection plan suggested additional shutdown hardware and increased testing frequency. Smith & Burgess was hired to review this system.

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Topics: Case Study, Detailed Engineering, Quantitative Risk Assessment, QRA, Overpressure Protection, Regulatory Compliance

Case Study: SIL Design

Posted by Dustin Smith, P.E. on Dec 2, 2017 6:05:00 PM

The Opportunity:

As part of a relief valve study, a competing engineering firm recommended a major United States refinery to replace multiple relief valves and modify the associated piping on a column system in order to mitigate for a higher flare load. The proposed changes would have cost the refinery approximately $300,000. Unsure of the recommendations and associated expenses, the refinery reached out to Smith & Burgess to review the EPC’s findings.

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Topics: Case Study, Refinery, Pressure Relief Valves, PRV Study, Overly Conservative Assumptions, Third Party Review, SIL Design, SIS Design

Case Study: Third Party Relief Valve Mitigation Review

Posted by Dustin Smith, P.E. on Nov 1, 2017 6:03:00 PM

The Opportunity:

A major US refinery used a competing engineering contractor to perform a flare and relief systems analysis. Upon completion of the project, the refinery was left with a list of facility upgrades that management deemed excessive. Smith & Burgess was hired to review the relief and flare systems documentation and provide engineering solutions that met corporate and industry requirements.

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Topics: Case Study, Pressure Relief Valves, PRV Study, Third Party Review, Engineering Review, Relief Systems, PRV, Relief System Design, Refinery, Overly Conservative Assumptions, Relief Valve Mitigation, Flare Mitigation, Mitigation, Action Item Resolution, Relief Systems Revalidation

Case Study: Facility Siting

Posted by Dustin Smith, P.E. on Sep 8, 2017 6:06:00 PM

The Opportunity:

A major United States refinery was recommended to spend $2 Million on a temporary blast proof tent during turnaround from a facility siting study conducted by a third-party contractor.

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Topics: Case Study, Engineering Review, Engineering Analysis, Refinery, Third Party Review, Overly Conservative Assumptions, RAGAGEP, Facility Siting

Case Study: Gas Plant Detailed Relief System Design Review

Posted by Dustin Smith, P.E. on Sep 1, 2017 6:04:00 PM

The Opportunity:

A recent audit of a “rebuild” design package for a major Asian gas plant identified that the EPC may have failed to follow company or industry standards. The owner needed an engineering review of the entire facilities’ relief systems designs prior to their start up in two months. Any deficiencies in company or industry standards needed to be addressed prior to the facilities’ start up.

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Topics: Case Study, Pressure Relief Valves, PRV Study, Third Party Review, Engineering Review, Relief Systems, PRV, Relief System Design, Gas Plant

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