Simulation of flare systems | weyer special
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Simulation of flare systems | weyer special

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The weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating from ...

The weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating from
the on-site findings of the flare system to the simulation and the weak-point analysis to the point of the planning and implementation of appropriate plant-specific adaptations. The calculation of the process data for gas and vapour pipe systems for
smaller plants does generally not bring about significant problems if only one relevant source blowing-off has to be considered.
If, however, for large plants like, e.g. crude-oil-processing plants or chemical installations several sources blowing-off
have to be taken simultaneously into consideration, the complexity of the simulation alone will generate substantial challenges.
The weyer-group disposes of an extensive treasure trove of experience in deploying self-developed as well as commercial
simulation tools for the calculation and simulation of flare systems and the identification of weak points in gas and
vapour pipe systems. Besides analyzing the existing system, the connection of new plant components to the system and addition
to capacity can be checked with regard to the expected results as well. In doing so, the process and safety-related
maintenance of your flare system will be an easy task. The deployment of the simulation has been tried and tested in many
cases and it stands out by a high degree of flexibility in terms of application in quite a lot of different areas.

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Simulation of flare systems | weyer special Simulation of flare systems | weyer special Document Transcript

  • FLARE SYSTEMSweyer groupweyer special | simulation of flare systemsallround. smart.www.weyer-group.com
  • Each piece of equipment which is embed-ded in the flare system will be integratedinto a classification system. Thus, it willbe easy to methodically and swiftly orientyourself within complex systems.The objective is to display the entire iso-metric drawing of the flare gas networkwithin a nodular system. The followingterms are defined as nodes:• Sources (emergency valves/burstdiscs)• Junction of two pipes• Cross-sectional variations within pipesystems• Pressure variations, e.g. by means ofa dip pipe or flow rate controllersThe weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating fromthe on-site findings of the flare system to the simulation and the weak-point analysis to the point of the planning and imple-mentation of appropriate plant-specific adaptations. The calculation of the process data for gas and vapour pipe systems forsmaller plants does generally not bring about significant problems if only one relevant source blowing-off has to be consid-ered. If, however, for large plants like, e.g. crude-oil-processing plants or chemical installations several sources blowing-offhave to be taken simultaneously into consideration, the complexity of the simulation alone will generate substantial chal-lenges. The weyer-group disposes of an extensive treasure trove of experience in deploying self-developed as well as com-mercial simulation tools for the calculation and simulation of flare systems and the identification of weak points in gas andvapour pipe systems. Besides analyzing the existing system, the connection of new plant components to the system and ad-dition to capacity can be checked with regard to the expected results as well. In doing so, the process and safety-relatedmaintenance of your flare system will be an easy task. The deployment of the simulation has been tried and tested in manycases and it stands out by a high degree of flexibility in terms of application in quite a lot of different areas.What we offer:À On-site analysis of yourflare systemÀ Determination of theflow rates to be relievedÀ Simulation of the flaresystemÀ Identification of bottle-necksÀ Engineering for the eli-mination of bottlenecks1 On-site analysis of yourflare systemThe computerized simulation of the flaresystem requires the elaboration of the net-work topology of all sources embedded inthe flare system.If isometric drawings are available, thecurrent as-built status will be investigatedon-site. If no significant differences be-tween the isometric drawings and the ac-tual pipe run are to be found, the networktopology will be displayed on the basis ofthe isometric drawings.If no isometric drawings are available, thenetwork topology will be determined on-site by means of recording the pipelinesystem and the built-in components.Is your flare system approaching its capacity limit?weyer special | simulation of flare systems | page 2weyer special | simulation of flare systems
  • 2 Determination of theflow rates to be relievedIn order to perform the process calculationof the flare system, the so-called design orblow-off cases, with regard to the corre-sponding volume supplied, will be estab-lished after consult-ing the plant operator.Typical design cases are:• Fire• Operating errors• Regional power breakdown• Breakdown of the process controlsystem• Malfunction within the cooling systemFurthermore, it will be necessary to estab-lish concurrences for the individual plantsand plant components respectively.The simulation can be executed after thedetermination of the process data:• Blow-off pressures• Operating temperatures• Molecular weight• Mass flow rates3 Simulation of the flaresystemThe above mentioned specifications willput the simulation program in the positionto perform the calculation of the requiredprocedural parameters for all nodes, like:• Flow velocity• Velocity of sound and critical velocityratio• Absolute pressure• Resistence factors (zeta-value)• Temperature• Mass and volume flow rate• Molecular weight• DensityBased on the results, an analytical evalua-tion of the complete system and possibleweak points will be carried out.Simultaneously, possible connections ofnew plant components or additions tocapacity can be examined with respect totheir impacts on the overall system.weyer special | simulation of flare systems | page 3weyer groupallround. smart.4 Identification of bottle-necksThe simulation program considers in a flaresystem the activation of individual safetyvalves. In doing so, both real blowing-offevents can be reconstructed or simulatedand statistical mounds of data to gain anoverall picture of the network with regardto bottlenecks can be drawn up.5 Elimination of bottlenecksThe bottlenecks indicated by the programwill now be observed more closely. Gener-ally, bottlenecks come into being due to:• Inadequately dimensioned emer-gency valves• Insufficiently sized pipelines• Increase in flow rate due to the con-nection of new plant componentsThe elimination of such weak spots entailsvirtually always an intervention into the ex-isting technical installations and demandsa great deal of the engineering and theimplementation of the envisaged meas-ures. In the course of the past 30 years,the weyer-group has been collecting ex-tensive expert knowledge in the most var-ied areas of plant layout. We will make useof this treasure trove of experience to yourbenefit when it comes to the planning oftechnically and commercially optimizedsolutions with regard to the elimination ofbottlenecks. The concepts concerning theplant-specific adaptation will be support-ed by our team of experienced engineersin the following areas of expertise:• § 29a BlmSchG (Law Concerning theProtection against Harmful Effectson the Environment through Air Pol-lution, Noise, Vibrations and SimilarFactors), dealing with safety-relatedinspections• VAwS (Ordinance on installations han-dling materials hazardous to water),dealing with the prevention of waterpollution• Authorized personnel in conformitywith BetrSichV (Regulations of Occupa-tional Safety) for pressure equipment• Approval procedure referring to envi-ronmental protection• Determination and accounting ofbuilding costsYour benefits:À Integrated documentationÀ Modular flare modelÀ Capacity optimization of the flaresystemÀ Verification of the flare capacity incase of plant extension
  • weyer groupallround. smart.Your contactwww.weyer-group.comwww.weyer-group.comReferences:À Boehringer Ingelheim Pharma GmbH &Co.KG, DE - Ingelheim/RheinÀ DHC Solvent Chemie GmbH,DE - Mülheim a. d. RuhrÀ H&R Ölwerke Schindler GmbH,DE - HamburgÀ PCK Raffinerie GmbH, DE - SchwedtÀ Sekundärrohstoff VerwertungszentrumGmbH (SVZ), DE - Schwarze PumpeÀ Shell Deutschland Oil GmbH, RheinlandRaffinerie Werk DE - WesselingÀ TOTAL Raffinerie Mitteldeutschland GmbH,DE - LeunaÀ Wilhelmshavener Raffineriegesellschaft mbH,DE - WilhelmshavenImage source: © Matthias Krüttgen | © christian42 - Fotolia.com 05/2013The weyer group is a group-independent corporate association of engineering and con-sulting companies in Germany, Austria, Switzerland, Poland and the Netherlands.Since its establishment over 30 years ago, the weyer group has developed a wide range ofexpertise which has always been based on the expectations and wishes of our clients.