BHGE Approach to Flare

Control

Confidential. Not to be copied, distributed, or reproduced without prior approval. © 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Agenda
OVERVIEW OF REGULATIONS
NSPS, 40 CFR Part 60, Subpart Ja
Refinery Sector Rule 63.670

GE RSR SOLUTION

BHGE flare.IQ Technology Overview

2
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Refinery Sector Rule (RSR)
63.670

IMPLEMENTATION TIMELINE

2015 Publish 2019 Compliance

DECEMBER Date JANUARY Requirement Date

OVERVIEW OF REGULATION
• Includes ALL sources, not just new sources
• Flares must control, maintain and demonstrate a 96.5% combustion efficiency or a 98% destruction efficiency
• Flares must maintain a minimum combustion zone Net Heating Value of 270 BTU/scf and report values every 15 minutes
• Flares must operate with no visible emissions, except for periods not to exceed a total of 5 minutes during any 2 consecutive
hours
• Flare tip pilot flame must be maintained and velocities may not exceed 400 ft/s
• Operators must measure and control all assist flows to assure that the combustion zone stays above the minimum Net
Heating value
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RSR (continued)
TABLE 13 - CALIBRATION AND QUALITY CONTROL REQUIREMENTS FOR CPMS
Parameter Minimum accuracy requirements
Temperature ±1% over normal measured range or 2.8 ˚C, whichever is greater

Flow rate for all flows other than
flare vent gas
Flare vent gas flow rate
Pressure
±5% over normal measured range or 0.5 GPM, whichever is greater for liquid flow
±5% over normal measured range or 10 CFM, whichever is greater for gas flow
±5% over normal measured range for mass flow
±20% of flow rate at velocities raging from 0.1 to 1 ft/s
±5% of flow rate at velocities greater than 1 ft/s
±5% over normal operating range or 0.12 kilopascals, whichever is greater

Net heating value by calorimeter ±2% of span

Net heating value by gas

As specified in performance specification 9 of 40 CFR part 60, appendix B
chromatograph

Hydrogen analyzer ±2% over the concentration measured or 0.1 volume percent, whichever is greater

4
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Challenges for Flare Control
Multivariable
Control Scheme
Proper flare operation
requires accurate
demand of Steam and
Supplemental Gas in order
to maintain combustion
efficiency and smokeless
operation
Variables are interdependent
Automated Steam
Control
Automatically maintain
smokeless operation while
balancing NHVcz > 270
BTU/scf
Avoid manual control with
operator over-steaming
Requires leading indicator
with real-time feedback
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Technology
Limitations
Measurement latency
associated with process
analyzers
No practical method for
monitoring of NHVcz –
requires fast response
feedback of NHVvg,
Qsteam, Qfuel, and Qflare
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GE RSR Solution
Generalized schematic of flare control

flare.IQ

DCS
ETHERNET

Control Valve
Meter
STEAM/AIR
CONTROL VALVE FLOW Fuel
Meter

Flare FUEL GAS

Meter
FLOW
FLARE GAS
BTU FLOW
MEASUREMENT
BTU Measurement

6
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flare.IQ Field Validation Testing
DEMONSTRATED ACCURACY: 3-5% against Mass Spectrometer Reference

1500

1400

1300 HHV, Mass Spectromer HHV, FlareIQ

1200

1100

1000

900
BTU/SCFH

800

700

600

500

400

300

200

100

0
0 500 1000 Time (min) 1500 2000 2500 3000

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Nitrogen Purge flare.IQ Performance
DEMONSTRATED ACCURACY: 6% against Mass Spectrometer Reference

NHV Mass Spec NHV flare.IQ N2 Concentration

1200 60

1000 50

800 40

N2 CONCENTRATION
NHV

600 30

400 20

200 10

0 0

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flare.IQ Field Validation Testing
DEMONSTRATED ACCURACY: 3-5% against GC with time corrected data

1400
NHV_Flare.IQ NHV_GC
1300

1200

1100

1000

900

800

700

600

500

400
1110 1120 1130 1140 1150 1160 1170 1180

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BHGE flare.IQ Technology
Overview

Confidential. Not to be copied, distributed, or reproduced without prior approval.

flare.IQ Logic Overview
FLARE INPUTS STEAM INPUTS FUEL INPUTS GAS CHROMATOGRAPH INPUTS:
Qflare Qsteam Qfuel XH2, XN2, XCO2, XH20, NHVvg
From Pressure Pressure Pressure
Temperature Temperature Temperature or
DCS
Sound Speed
CALORIMETER INPUTS: NHVvg

OUTPUT:
USER INPUTS: Qsteam_req CALCULATE:
Qsteam (min,max)
Qfuel (min, max)
Qfuel_req
MW
NHVcz
Cmeasured to MWm to NHVm
H2 Compensated NHVvg =
Vtip

CALCULATE: CALCULATE: COMPARE:

Qsteam Qfuel Vtip < Vtip_max To
demand demand NHVcz > 270 BTU/scf DCS

= = =
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NHVvg from flare.IQ and GC in Customer Site
(GC output update rate ~ 10min)

DEMONSTRATED ACCURACY: <+/-5% against Gas Chromatograph Reference

1300

1280 GC FlareIQ

1260
NHV (BTU)

1240

1220

1200 GC off line due to calibration

1180
12:00 PM 6:00 PM 12:00 AM 6:00 AM 12:00 PM

Time

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 NHV from flare.IQ and Gas Chromatograph at Flare Upset Event
(GC output update rate ~ 10min)

FLARE.IQ’S FAST RESPONSE TO UPSET EVENT

2500 35

30
2000 NHV from Gas Chromatograph NHV from FlareIQ
25

Iso-Butane (%)
iso-Butane
NHV (BTU)

1500
20

15
1000

10
500
5

0 0
9:36:00 AM 2:24:00 PM 7:12:00 PM 12:00:00 AM 4:48:00 AM 9:36:00 AM 2:24:00 PM
Time

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 NHV from flare.IQ and Gas Chromatograph at Flare Upset Event
(GC output update rate ~ 10min)

FLARE.IQ’S FAST RESPONSE TO UPSET EVENT

2300

2100
NHV from Gas Chromatograph NHV from FlareIQ
1900

1700
NHV (BTU)

1500

1300

1100

900

700

500
6:57:36 PM 7:12:00 PM 7:26:24 PM 7:40:48 PM 7:55:12 PM 8:09:36 PM 8:24:00 PM
Time

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 NHVcz with flare.IQ Control in Customer Site
(NHVcz Lower Limit = 300 BTU/SCF)

NHVcz CONTROLLED ABOVE LOWER LIMIT

340

330

320

310
NHVcz

300

290

280
NHVcz NHVcz lower limit

270
12:00 PM 6:00 PM 12:00 AM 6:00 AM 12:00 PM

Time

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 Vtip from flare.IQ and Vtip_upper_limit

TIP VELOCITY CONTROLLED BELOW UPPER LIMIT

70

60

50
Vtip (ft/s)

40

30

20 Vtip Upper Limit Vtip from FlareIQ

10

0
12:00 PM 6:00 PM 12:00 AM 6:00 AM 12:00 PM
Time

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flare.IQ Steam Model vs Steam from Incipient Smokeless Test

FLARE.IQ STEAM MODEL QUALITATIVELY AGREES WITH TEST RESULT

14000 Flare.IQ Steam Model

12000
Flare.IQ Steam Model (PPH)

Required Steam for Incipient Smokeless

10000 Point (test data)
8000
6000
4000
2000
0
0 2000 4000 6000 8000 10000 12000 14000
Required Steam for Incipient Smokeless Point (test data)

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Thank You

Questions?

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