osenbroch dynamic flare
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Public © 2013 Aker Solutions Preferred partner
Preferred partner
Dynamic modelling and simulation of Flare Systems
Flow Assurance and Dynamic Simulations Seminar, Stavanger 29.10.2013
Jørgen Osenbroch | Process Specialist Engineer, Aker Solutions MMO
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Introduction
14 November, 2013Slide 2
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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
14 November, 2013Slide 4
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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
14 November, 2013Slide 5
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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
14 November, 2013Slide 7
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
14 November, 2013Slide 10
■ 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
14 November, 2013Slide 11
■ 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
14 November, 2013Slide 12
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A typical BD system
14 November, 2013Slide 13
Output from
segment to
full model
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HP Flare system - zoomed
14 November, 2013Slide 14
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HP Flare system
14 November, 2013Slide 15
KO Drum
Flare tip
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Simulation results
14 November, 2013Slide 16
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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
14 November, 2013Slide 17
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Dynamic Flare Model – Results (Massflow)
14 November, 2013Slide 18
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M a s s f l o w
[ k g / h ]
Time [s]
Accumulated System Massflow
Flare Tip 43-FC01
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Dynamic Flare Model – Results (Massflow)
Zoomed
14 November, 2013Slide 19
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M a s s f l o w [ k g / h ]
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Accumulated System Massflow
Flare Tip 43-FC01
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Dynamic Flare Model – Results (Massflow)
14 November, 2013Slide 20
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M a s s f l o w
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Accumulated System Massflow
Flare Tip 43-FC01
Accumulated System Massflow
Flare Tip 43-FC01
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Dynamic Flare Model - Results
14 November, 2013Slide 21
KO Drum
Up-stream
meteringstation
XX FlareManifold
Upstream
flare tip
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Dynamic Flare Model – Results (Pressure)
14 November, 2013Slide 22
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P r e s s u r e
[ b a r a ]
Time [s]
KO Drum 43-VD01Upstream Flare Metering station
Upstream Flare Tip 43-FC01
XX Flare Manifold
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Dynamic Flare Model – Results (Pressure)
Zoomed
14 November, 2013Slide 23
0
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0 50 100 150 200 250 300 350 400 450 500
P r e s s u r e [ b
a r a ]
Time [s]
KO Drum 43-VD01
Upstream Flare Metering station
Upstream Flare Tip 43-FC01
XX Flare Manifold
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Dynamic Flare Model – Results (Pressure)
14 November, 2013Slide 24
0
2
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0 200 400 600 800 1000
P r e s s u r e
[ b a r a ]
Time [s]
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
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Dynamic Flare Model - Results
14 November, 2013Slide 25
DynamicSimulation
Steady StateSimulation
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 againstfield measurements
14 November, 2013Slide 26
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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
14 November, 2013Slide 27
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Dynamic Flare Model – ESD blowdown
14 November, 2013Slide 28
■ Well & Condensate segments - Pressure
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Sleipner Dynamic Flare Model – Sleipner ESD blowdown
14 November, 2013Slide 29
■ Well & Condensate segments Pressure
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Summary
14 November, 2013Slide 31
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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
14 November, 2013Slide 32
■ A fire model is also included.
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Any questions?
14 November, 2013Slide 33
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Dynamic Flare Model – Platform ESD blowdown
Backup slides
14 November, 2013Slide 34
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Dynamic Flare Model - Backup
14 November, 2013Slide 35
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Dynamic Flare Model – Results (backup)
14 November, 2013Slide 36
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