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

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

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

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