Project Synopsis
Process Engineering Associates, LLC (PROCESS) was contracted by the client, a chemical and active pharmaceutical ingredient (API) manufacturer, to perform an evaluation of the a Flare Header at their Southeastern production facility.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by the client, a chemical and active pharmaceutical ingredient (API) manufacturer, to perform an evaluation of the a Flare Header at their Southeastern production facility. This evaluation includes the identification of global relief scenarios, development of a working flare model in Aspen Flare System Analyzer, and an evaluation of the flare equipment against good engineering practice for flare and relief system design.
The project was performed after PROCESS had helped the client complete their re-validation of existing pressure relief devices. To start the project, PROCESS visited the client site to obtain necessary information, such as equipment information and sketching out flare header isometrics. With this new information, PROCESS developed a model of the site flare and flare header in Aspen Flare System Analyzer (“FlareNet”).
The flare model used required relief rates and relief capacities from the sites completed PRD evaluation. PROCESS used this information to develop the global scenarios for the flare system, including pool fire, cooling water failure, power failure, and instrument air failure scenarios. Large single relief events, such as reactive reliefs from runaway reactions, were also evaluated. Flare knock out pots were evaluated for adequate separation and holdup volume per API 521 for each scenario. Compatibility of the flared fluids was also considered as part of the evaluation. PROCESS made recommendations to the client to ensure the flare header met recognized and generally accepted good engineering practice (RAGAGEP).
The flare stack was evaluated for compliance with OSHA regulations and API 521 recommendations, including velocity, BTU requirements, and flare radiation. PROCESS worked closely with the flare manufacturer to ensure limits were maintained as well.
Lastly, PROCESS evaluated the possibility air ingress into the flare through the flare stack after a hot release or during a rainstorm. PROCESS developed a custom heat transfer model as part of the project. This model predicted the transient flare header temperature and air ingress during these scenarios.
Industry Type
Active Pharmaceutical Ingredient (API) Manufacturing
Utilized Skills
- Flare header sizing evaluation
- KO pot sizing evaluation
- Flare sizing evaluation
- Custom heat transfer model.