weyer special | simulation of are systems

weyer group
allround. smart.

FLARE SYSTEMS

www.weyer-group.com

weyer special | simulation of are systems

Is your are system approaching its capacity limit?

The weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating from
the on-site ndings of the are system to the simulation and the weak-point analysis to the point of the planning and implementation of appropriate plant-specic adaptations. The calculation of the process data for gas and vapour pipe systems for
smaller plants does generally not bring about signicant 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 are systems and the identication 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 are 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 exibility in terms of application in quite a lot of different areas.

What we offer:
On-site analysis of your
are system

Determination of the
ow rates to be relieved

Simulation of the are

system

Identication of bottlenecks
Engineering for the elimination of bottlenecks

weyer special | simulation of are systems | page 2

1 On-site analysis of your

are system
The computerized simulation of the are
system requires the elaboration of the network topology of all sources embedded in
the are system.
If isometric drawings are available, the
current as-built status will be investigated
on-site. If no signicant differences between the isometric drawings and the actual pipe run are to be found, the network
topology will be displayed on the basis of
the isometric drawings.
If no isometric drawings are available, the
network topology will be determined onsite by means of recording the pipeline
system and the built-in components.

Each piece of equipment which is embedded in the are system will be integrated
into a classication system. Thus, it will
be easy to methodically and swiftly orient
yourself within complex systems.
The objective is to display the entire isometric drawing of the are gas network
within a nodular system. The following
terms are dened as nodes:
Sources (emergency valves/burst
discs)
Junction of two pipes
Cross-sectional variations within pipe
systems
Pressure variations, e.g. by means of
a dip pipe or ow rate controllers

weyer group
allround. smart.

2 Determination

of the
ow rates to be relieved
In order to perform the process calculation
of the are system, the so-called design or
blow-off cases, with regard to the corresponding volume supplied, will be established after consult-ing the plant operator.
Typical design cases are:

Fire
Operating errors
Regional power breakdown
Breakdown of the process control
system
Malfunction within the cooling system
Furthermore, it will be necessary to establish concurrences for the individual plants
and plant components respectively.
The simulation can be executed after the
determination of the process data:

Blow-off pressures
Operating temperatures
Molecular weight
Mass ow rates

3 Simulation of the are

4 Identication

of bottle-

necks
The simulation program considers in a are
system the activation of individual safety
valves. In doing so, both real blowing-off
events can be reconstructed or simulated
and statistical mounds of data to gain an
overall picture of the network with regard
to bottlenecks can be drawn up.

5 Elimination of bottlenecks
The bottlenecks indicated by the program
will now be observed more closely. Generally, bottlenecks come into being due to:
Inadequately dimensioned emergency valves

ied areas of plant layout. We will make use

of this treasure trove of experience to your
benet when it comes to the planning of
technically and commercially optimized
solutions with regard to the elimination of
bottlenecks. The concepts concerning the
plant-specic adaptation will be supported by our team of experienced engineers
in the following areas of expertise:
29a BlmSchG (Law Concerning the
Protection against Harmful Effects
on the Environment through Air Pollution, Noise, Vibrations and Similar
Factors), dealing with safety-related
inspections
VAwS (Ordinance on installations handling materials hazardous to water),
dealing with the prevention of water
pollution
Authorized personnel in conformity
with BetrSichV (Regulations of Occupational Safety) for pressure equipment
Approval procedure referring to environmental protection
Determination and accounting of
building costs

system
The above mentioned specications will
put the simulation program in the position
to perform the calculation of the required
procedural parameters for all nodes, like:
Flow velocity
Velocity of sound and critical velocity
ratio
Absolute pressure
Resistence factors (zeta-value)
Temperature
Mass and volume ow rate
Molecular weight
Density
Based on the results, an analytical evaluation of the complete system and possible
weak points will be carried out.
Simultaneously, possible connections of
new plant components or additions to
capacity can be examined with respect to
their impacts on the overall system.

Insufciently sized pipelines

Increase in ow rate due to the connection of new plant components
The elimination of such weak spots entails
virtually always an intervention into the existing technical installations and demands
a great deal of the engineering and the
implementation of the envisaged measures. In the course of the past 30 years,
the weyer-group has been collecting extensive expert knowledge in the most var-

Your benets:
Integrated documentation
Modular are model
Capacity optimization of the are

system
Verication of the are capacity in

case of plant extension

weyer special | simulation of are systems | page 3

weyer group
allround. smart.

Your contact

www.weyer-group.com

The weyer group is a group-independent corporate association of engineering and consulting companies in Germany, Austria, Switzerland, Poland and the Netherlands.
Since its establishment over 30 years ago, the weyer group has developed a wide range of
expertise which has always been based on the expectations and wishes of our clients.

References:
Boehringer Ingelheim Pharma GmbH &

Co.KG, DE - Ingelheim/Rhein
DHC Solvent Chemie GmbH,

DE - Mlheim a. d. Ruhr
H&R lwerke Schindler GmbH,

DE - Hamburg
PCK Rafnerie GmbH, DE - Schwedt
Sekundrrohstoff Verwertungszentrum

GmbH (SVZ), DE - Schwarze Pumpe

Shell Deutschland Oil GmbH, Rheinland

Rafnerie Werk DE - Wesseling

TOTAL Rafnerie Mitteldeutschland GmbH,

DE - Leuna
Wilhelmshavener Rafneriegesellschaft mbH,

DE - Wilhelmshaven

Image source: Matthias Krttgen | christian42 - Fotolia.com

05/2013

www.weyer-group.com