Optimising safety relief and fare systems

O
ver the past decades, the
refning industry has contin-
uously moved towards
higher levels of crude conversion
and more stringent product specif-
cations. When they are combined
with aromatics production in partic-
ular, refnery schemes have become
more complex. Additionally, name-
plate capacity limits for grassroots
plants have been gradually pushed
upwards.
At the same time, along with
dieselisation of the European vehi-
cle feet and the strengthening of
product specifcations, the refning
scheme of European refneries has
become increasingly complex. The
addition of new units to an existing
refning scheme affects fare
Understanding the behaviour of refnery units by dynamic modelling of
emergencies enables the prediction of realistic relief loads
AlbAn Sirven and JeAn GrOSclAUde Technip
Jeremy SAAdA Invensys Systems
systems, leading to a revamp of the
existing fare network or to the
addition of a new fare network and
the consequences of altering the
network.
Flare systems are primarily sized
with regard to common failure
modes. General electrical power fail-
ure (GEPF) results in a simultaneous
loss of condensation for most proc-
ess systems, and all corresponding
individual relief loads are summed
up to determine the required capac-
ity of the fare systems.
In the context of both an increased
number of interconnected process
units and higher processing capaci-
ties, fare systems approach critical
sizes when industry-standard calcu-
lation methods for the determination
of individual relief loads are
applied. To overcome the related
issues in terms of mechanical and
structural design, supply and
constructability, as well as to satisfy
the requirements of refnery turna-
round and scheduled maintenance,
the confguration of the relief
disposal system for grassroots
designs should consist of several
fare systems, the largest with a
main header diameter as wide as
100in or more and a fare stack as
high as 200m.
The cost of providing adequate
protection systems for any refning
complex is substantial. At this
point, understanding and model-
ling the dynamic behaviour of
refnery units in emergency
www.eptq.com PTQ Q2 2011 43
Cumu|ative
re|ief |oads
Unit 2
Unit 1
Unit 4
Unit 2
Unit 1
t=0
Unit 3
Unit 3
Unit 4
Unit 2
Unit 1
Unit 3
Unit 4
Tota| Tota|
Cumu|ative
re|ief |oads
Cumu|ative
re|ief |oads
Semi-dynamic approach Conventional approach Dynamic approach
Figure 1 Comparison of three methods for sizing fare systems
situations becomes necessary to
assess the required capacity of fare
systems more accurately than
conventional calculations methods,
which tend to produce conservative
results.
modelling refnery equipment
behaviour in emergency conditions
The sizing of refnery fare systems
requires prediction of the behaviour
44 PTQ Q2 2011 www.eptq.com
of equipment (or refnery subsys-
tems). Calculation methods used
for the determination of relief loads
have, since the beginning of the
refning industry, required static
and semi-dynamic calculations.
conventional approach
The conventional approach is based
on the use of process data shown in
the unit heat and mass balance,
corresponding to steady-state oper-
ating conditions.
Semi-dynamic methods
Semi-dynamic calculations require
the enhanced use of static model-
ling tools such as Pro/II to better
model upset scenarios. This method
will correct the results of static
methods, accounting for basic
equipment design data or the
change of key fuid properties
between operating and relief condi-
tions. This type of analysis also
aims to evaluate the relief start/end
time for critical equipment and
systems. The result is less conserva-
tive relief loads than with static
calculations, but the analysis cannot
account for complex phenomena
related to the transient responses of
process systems to major upsets.
dynamic methods
With the increasing performance of
calculation tools, dynamic process
simulators are now able to work on
desk computers with reasonable
computation time. Process dynamic
simulations are based on validated
thermodynamic models as well as
heat and mass transfer equations.
They also consider the response
times of control loops, thereby
predicting more realistic relief
scenarios. Figure 1 shows a compari-
son of the accumulated relief loads
used for sizing a fare system,
obtained by these different methods.
In addition to the reduction in
relief loads, dynamic simulation
offers the advantage of evaluating
the impact of different system
response times on accumulated
relief loads.
However, dynamic modelling is
time consuming compared to earlier
calculation methods. This is due in
particular to the amount and diver-
sity of input data that must be
defned for the description of any
system; for instance:
Defnition of process streams
Operating conditions based
whenever applicable on licensor
information
Detailed equipment design and
geometry data based on vendor
information
Instrumentation, automation and
safeguarding data.
Qualitative
analysis
Conventional
approach
Review of
the system
characteristics
Implementation of flare
loads mitigation measures
Screening and
identification
of large relief
loads
Semi-dynamic
approach for
these large
relief loads
Dynamic
simulation
of the
system. New
relief loads
Quantitative
analysis
Does this
system match
Technip criteria
for dynamic
simulation?
Sizing of
flare systems
Dynamic
simulation
.O
9ES
Figure 2 Dynamic simulation within fare study methodology
Technip developed a methodol-
ogy for targeting opportunities for
dynamic simulations and set up a
list of criteria to select candidate
systems for the use of dynamic
simulation. This methodology for a
refnery fare study (GEPF scenario)
is detailed in Figure 2.
dynamic simulation software
Computer simulations were made
using the SimSci-Esscor Dynsim
tool from Invensys as the dynamic
process simulator. The program
provides a series of capabilities that
enable the modelling of rigorous
transient processes and facilitate the
development of dynamic simula-
tions for applications from process
studies through to operator training
systems.
The equipment models are rigor-
ous dynamic models. A library of
unit operations, equipment types,
control functions and other algo-
rithms have been developed,
enabling the specifcation of models
for high-level concepts.
In dynamic relief load calcula-
tions, the user can often come
across unexpected operating condi-
tions and effects. The provision of
accurate thermodynamic predic-
tions enables these effects to be
modelled correctly. Ranges of rigor-
ous thermodynamic methods enable
the user to predict phase behaviour
and so achieve accurate simulations
of real processes.
Other features that make the soft-
ware suitable for relief load analysis
are the interactive run control and
scenario handling options. These
include the ability to change from
one operating condition to another
quickly and easily, speed up or slow
down the execution of the simula-
tion, and record/play back operating
scenarios. These features enable the
user to investigate how relief loads
are impacted by different emergency
situations, initial conditions and
operating procedures. The software
also includes a basic data historian
and options for trending and storing
process variables so that relief load
scenarios can be viewed and
recorded for future analysis.
Dynamic simulations were built
using the software. One of the tech-
nical challenges of applying process
www.eptq.com PTQ Q2 2011 45
dynamic simulations lies in the
capacity of having a system descrip-
tion capable of supporting the
generation of a realistic transient
response of process equipment and
systems during upset and emer-
gency scenarios.
Throughout the studies, several
of the default modules available
with the software were analysed
not to have suffcient descriptive
capabilities and functionalities so it
was mandatory to incorporate user
models. For example, the default
furnace module has been improved
by providing a reliable furnace
model for the simulation of the
furnace behaviour under process
upsets.
dynamic simulation results
dynamic simulation of furnace
shutdown
The vapours generated in column
reboiling furnaces are major
contributors to fare relief loads if
the column condensation is stopped
(single condensation failure or
common mode of failure such as
GEPF). In the specifc scenario of
GEPF, the feed to the furnace is
stopped if the reboiler feed pump is
electric motor-driven or may be
continuously pumped in the case of
a steam turbine driver. Even when
furnace fring is shut down (the
normal scenario for fred heaters
equipped with a forced-draft fan),
heat transfer and vapour generation
continue as a result of thermal iner-
tia of the radiant box walls.
For these reasons, a reliable repre-
sentation of the furnace is necessary.
The softwares default furnace
module enables simulation of the
furnaces thermal inertia. However,
this module is unable to model the
response of the liquid inventory in
furnace coils during upsets. Thus,
Technip has developed in-house
modelling modules and techniques
for furnaces, based on Dynsims
default furnace module, to have a
proper and realistic representation
of the key parameters affecting the
determination of relief rates.
There are no standard criteria
regarding the residual heat duty
transferred to the process in the
case of trip of process feed and/or
furnace fring. The industry consid-
ers values as high as 100% of
normal duty if heater fring is main-
tained. This results in substantially
conservative relief fow rates to the
fare.
The case study in this context
evaluates the behaviour (residual
duty transferred to process) of a
reformate splitter furnace in three
different confgurations:
Charge stopped and fring
maintained
Charge and fring stopped
Charge maintained and fring
stopped.
Dynamic simulations have
demonstrated that, if the process
feed to the furnace is stopped, the
residual duty transferred to the
fuid drops immediately (see
Figure 3). It then does not exceed
a peak value of 40% of normal
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Charge stopped, firing stopped
Charge maintained, firing stopped
Charge stopped, firing maintained
Figure 3 Furnace behaviour in three shutdown cases
crude distillation column
dynamic simulation
The use of dynamic simulations
helps in an understanding of the
behaviour of crude distillation units
(CDU) after process upsets, as well
as the importance of the appropri-
ate confguration of pressure safety
valves (PSV) to reduce relief fow
rates.
Actual PSV relief fow rates
depend mainly on two factors:
Dynamic behaviour of the equip-
ment itself
PSV confguration (number, size,
set pressure stepping).
The case study in this context
considers a crude distillation unit
of 250 000 b/d capacity and
compares the benefts of optimisa-
tion using dynamic simulation
against a conventional approach.
results of a conventional approach
The sizing of the relief installed
capacity (orifce area) by means of a
conventional approach using heat
and material balances leads to the
following results:
Refux failure: 860 t/h (sizing
case)
GEPF: 200 t/h
PSV confguration: 12 PSV/T
orifce/balanced bellows/set pres-
sure = 3.5 barg
Installed orifce area: 2020 cm
2
.
Optimisation of installed orifce
area using dynamic simulation
The conventional approach gives an
over-sized installed orifce area.
Dynamic simulation of the system
under upset may help in optimising
the required installed orifce area.
The installed orifce area has been
optimised down to 930 cm
3
, corre-
sponding to 9 PSV (Orifce R).
Figure 4 shows that the relief fow
rate in the event of refux failure
would be stable at around 414 t/h,
compared to the 860 t/h initially
envisaged. With regard to these two
cases, dynamic simulation shows a
reduction of relief loads of about
50%. It is also noticeable that the
number of PSVs can be reduced,
leading to a reduction in capital
and maintenance costs.
Staggering of safety valve set
pressures
Safety valve staggering is most of
the time neglected in conventional
calculations, but dynamic simula-
tion shows that it is a key parameter
in a correct estimation of fow rates.
Even if the installed orifce area is
reduced, as shown previously,
dynamic simulation does not show
chattering conditions for non-sizing
scenarios such as GEPF.
Figure 5 shows this chattering
situation in the event of GEPF,
where peak relief fow rates reach
about 400 t/hr, the average relief
load being about 110 t/h. The stag-
gering of the PSV avoids chattering
situations and cancels high peak
fows. Table 1 shows the selected
confguration of the PSV complying
with refux failure and GEPF
requirements.
46 PTQ Q2 2011 www.eptq.com
duty. Averaged over a few
minutes, it does not exceed 30%
of normal duty. These values
correspond to the fact that
drastic changes in fow patterns,
resulting from the interruption of
process feed to the furnace coils,
affect heat transfer coeffcients.
Vapour generation is signifcantly
reduced, even if furnace fring
were to be maintained. This reduc-
tion is more signifcant if both
process feed and furnace fring are
stopped.
Dynamic simulations have also
demonstrated that the heat duty
transferred to the process decreases
more sharply if the furnace feed
pump is stopped, compared to the
furnace feed being maintained.
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Re|ief ow rate
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rst 3 PSVs
Figure 4 CDU behaviour under refux failure after optimisation of the installed orifce area
3.00
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2.80
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Re|ief ow rate
Figure 5 Chattering during GEPF
Figure 6 shows that, by imple-
menting this confguration, the
relief fow rate would now be stable
around 110 t/h in the event of
GEPF, compared with 200 t/h
initially envisaged with the conven-
tional approach. In this case, a
reduction of about 50% in relief rate
is indicated.
mitigation measure: design pressure
selection with dynamic simulation
Common failure modes such as
GEPF are generally sized into the
fare system (main fare header, KO
drums, fare stack and tip, radiation
calculations). Avoiding any relief
situation during GEPF for the CDU
column would contribute to reduced
aggregate refnery fare loads.
Dynamic simulation offers this
possibility, for new designs, by opti-
mising the column design pressure.
In the case under study, increas-
ing this design pressure to 4.3 barg
enables the relief fow rate to be
cancelled during GEPF (see Figure
8). Table 2 shows the selected PSV
confguration in the event of a set
pressure increase, the sizing case
corresponding to refux failure.
This set pressure increase makes
recondensation of hydrocarbon vap-
ours more important. Consequently,
the relief fow rate observed during
the refux pump failure will be
smaller (113 t/h versus 414 t/h, see
Figure 7).
dynamic simulation results for a
cdU case study
Dynamic simulation shows its value
in optimising relief valve design and
confguration for a CDU column
through the following main results:
Installed orifce area and relief
fow rates can be decreased by
about 50% in any upset case by
choosing the proper PSV confgura-
tion (number, size and staggering)
Relief fow rates and installed
orifce area can be further signif-
cantly reduced by increasing the
design pressure of the CDU column.
In this case, relief fow rates during
GEPF can be cancelled.
The potential benefts of the
selected PSV confguration can be
estimated as follows:
Reduction in investment and
maintenance costs (fewer PSVs,
www.eptq.com PTQ Q2 2011 47
reduction in fare header size and
fare height as a consequence of
relief fow rates reduction)
Reduction in chattering inducing
a reduction in pipe stress.
Potential savings for grassroots or
upgraded refneries
General overview
The approach in this case is to use
dynamic simulations to predict
Set pressure, barg PSv number/type installed orifce area
Conventional calculations 3.5 12 T 2020 cm
2
Dynamic simulation optimisation 3.5 3 R
9 R

930 cm
2
3.7 6 R
Selected PSv confguration
Table 1
Set pressure, barg PSv number/type installed orifce area
Conventional calculations 3.5 12 T 2020 cm
2
Dynamic simulation optimisation 4.3 3 Q 210 cm
2

Selected PSv confguration with new set pressure
Table 2
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Re|ief ow rate
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3 PSV open 111.3 t/hr
3.50 barg
Stripping steam
maintained
Figure 6 CDU behaviour in the event of GEPF with selected confguration
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4.56 barg
113 t/hr
Overhead pressure
Re|ief ow rate
Figure 7 CDU behaviour in the event of refux failure with increased set pressure
emergency situations applied to
grassroots or revamp projects. For
grassroots refnery projects, the
establishment as early as possible
of a clear philosophy regarding the
optimisation of fare systems is
benefcial in terms of capital spend-
ing. Flare header size, fare stack
height and the dimensions of fare
KO drums can be reduced
signifcantly.
For refnery upgrading projects,
the use of dynamic simulations
becomes especially meaningful
when assessing the capacity of
existing fare systems to accommo-
date additional relief loads from
new and revamped units. The
contribution of dynamic simulation
can lead to important reductions in
relief loads to the fare and to the
conclusion that it is not necessary
to implement additional fare
network. When the objective is to
connect relief valves previously
discharging to atmosphere to the
existing fare network, dynamic
simulations produce realistic
predictions of the new relief fow
rates and confrm whether or not
the existing fare network is
under-sized.
case study for a grassroots refnery
with an aromatic complex
Technips methodology for opti-
mising fare network sizes was
applied to a grassroots refnery
including an aromatic complex.
Relief loads were drastically
reduced (2700 t/h from 6500 t/h),
as well as fare header size
(76in from 130in) and fare stack
height (180m from 280m). In this
case, expected capital spending
approached 20 million.
3.20
4.00
3.60
4.80
4.40
2.80
2.40
0.0 5.0 10.0 15.0 20.5 25.0 30.0 35.0
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Time, min
2.00
300
500
400
600
200
100
0
Overhead pressure
Re|ief ow rate
2.5 7.5 12.5 17.5 22.5 27.5 32.5 37.5
Upset
4.21 barg
Figure 8 CDU behaviour in the event of GEPF with increased set pressure
From
other units
From
other units
GP
NHT
Naphtha
splitter
CDU
VDU
VB
FCC
11 t/h
265 t/h 275 t/h 275 t/h
90 t/h
89 t/h
28 t/h
185 t/h
180 t/h
From
other units
HDS
489 t/h
310 t/h 330 t/h
530+ 230 t/h
500 t/h
540 t/h
1300 t/h
37 API
0.8% S
From
other units
ISOM diH
Gasoline
Kero
Diesel
Heating
oil
FG
LPG
REF
ALKY
HDS
FO
Figure 9 Case study for refnery upgrading scheme (before revamp)
46 PTQ Q2 2011 www.eptq.com
case study for a refnery upgrade
This study considers upgrading an
existing 1300 t/h capacity European
topping/reformer/catalytic cracker
(TRC) refnery with new conversion
units to achieve higher conversion
and desulphurisation. Figure 9
shows the refnerys block fow
diagram before and after the
revamp. New units included a
hydrocracking complex (supple-
mented by the required hydrogen
plant), whereas existing CDU
bottoms and VDU units needed to
be revamped. This upgrading solu-
tion is a good approach to
processing heavier and higher-
sulphur crude to meet the current
European specifcations.
Table 3 shows the relief fow rates
to be considered: in the event of
GEPF for the fare system design in
the existing refnery confguration;
for the upgraded refnery confgu-
ration without the implementation
of dynamic simulation; and follow-
ing the implementation of dynamic
simulation.
Considering that the original
refnery fare network is designed
to handle 985 t/h in the event of
GEPF, the use of conventional
calculations after the refnery
upgrade with a new hydrocracker
unit leads to an increase in the fare
networks design fow rate to 1285
t/h (+27%). In this context, it would
be necessary to consider the imple-
mentation of an additional fare
system or expanding the existing
fare system, which are both costly
solutions.
Existing simulation models were
adapted in this case. Relief load
contributors such as crude distilla-
tion columns, vacuum distillation
columns, reformate splitter and
FCC main fractionators were simu-
lated and their associated relief
loads recalculated. In spite of the
introduction of two new units
(hydrocracker and hydrogen plant),
aggregate relief loads to the fare in
the event of GEPF were reduced by
8%, from 985 to 900 t/h, generating
substantial investment cost savings
(around 15 million, or about 4%
of the total investment).
Further benefts of dynamic
simulation
A process model used as a knowl-
edgebase can enable savings in
many areas. The use of a dynamic
simulation rather than a steady-
state representation opens up new
opportunities. The fare study work
reported here targets the capital
cost of construction, with a particu-
lar focus on the materials of
construction. This provides a real
multimillion-dollar return from the
fare system. In the design phase of
any project, the capital expenditure
budget is paramount.
The benefts of simulation are not
limited to design. Dynamic simula-
tion can be used to investigate
specifc implementation tasks and
to assess operability and trip
settings ahead of the plant being
built. More intensive process
design, with wider feedstocks and
narrow product qualities, is making
From
other units
From
other units
GP
NHT
Naphtha
splitter
CDU
VDU
VB
FCC
25 t/h
160 t/h 170 t/h
210 t/h
70 t/h
89 t/h
28 t/h
140 t/h
140 t/h
From
other units
HDS
HCK
70%
H
2
plant
62kNm
3
/h
500 t/h
430 t/h
170 t/h
330 t/h
570+ 200 t/h
510 t/h
540 t/h
1300 t/h
31 API
1.0% S
From
other units
ISOM diH
Gasoline
Kero
Diesel
Heating
oil
FG
LPG
REF
ALKY
HDS
FO
Revamped units
New units
Figure 9 Case study for refnery upgrading scheme (after revamp)
www.eptq.com PTQ Q2 2011 47
process plant harder to operate.
Questions such as Does the opera-
tor have suffcient time to respond
to a disturbance? are increasingly
important. A trip that takes out a
unit in a refnery can cost $0.5
million. If the trip propagates to
other units through the utility
systems, the costs can be even
greater.
In addition, the training of opera-
tors so that they maintain a
well-regulated process and know
how to operate the units for
General electrical power failure Trc refnery Trc refnery upgraded with HcK
20% cut-off failing Conventional Conventional With dynamic
method, t/h method, t/h simulation, t/h
CDU/VDU/gas plant 220 280 190
Gasoline units (NHT/reformer/ISOM/alky) 660 650 515
HDS 50 50 50
FCC complex (inc CatNaphtha HDS) 55 55 0
Visbreaker 0 0 0
HCK (inc H
2
plant) - 220 145
Total 985 1255 900
(+27%) (-8%)
dynamic simulation results for upgraded refnery fare study
Table 3
optimum production, while respect-
ing the alarm and trip aspects of
the process, can regularly improve
production by $10100 000/day.
Every grassroots refnery goes
through a commissioning phase,
not least the control and trip
systems. Checking out the confgu-
ration using a dynamic simulation
provides a more rigorous and
extensive review of the control
systems implementation and
catches confguration, parameter
and design errors before they are
identifed on plant. In general, the
greater the level of automation, the
greater the saving.
biogs
46 PTQ Q2 2011 www.eptq.com
prosim