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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: 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

Case Study: Flare Bid Review Package

Posted by Dustin Smith, P.E. on Jul 25, 2017 6:02:00 PM

The Opportunity:

A major United States refinery was in the process of purchasing a new flare system and needed assistance reviewing the bid package from the vendors. The refinery decided that the system was needed based on the outcome of a facility-wide flare study and flare QRA. The new flare system was specified by an EPC and then bid by a major flare vendor. This refinery heard of Smith & Burgess’ flare design expertise and decided to hire us in order to review their vendor’s design package.

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Topics: Case Study, Flare Study, Refinery, Detailed Engineering, Engineering Review, Flare System

Case Study: Flare Gas Recovery Equipment Review

Posted by Dustin Smith, P.E. on May 23, 2017 6:08:00 PM

The Opportunity:

In order to meet the minimum corporate and regulatory requirements, a major United States refinery was implementing a Flare Gas Recovery Unit (FGRU) and needed assistance to ensure that the proposed equipment was suitable for their location. The EPC company selected for the project was skilled at refinery greenfield and upgrade projects, but had limited experience with complex flare systems. Smith & Burgess was hired to provide owners with an engineering review of the detailed engineering package prior to final acceptance and construction.

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Topics: Case Study, Flare Study, Refinery, Flare System, Flare Management, Engineering Review, Flare Analysis, Flare Gas Recovery, Engineering Standards, FGRU

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

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

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