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(Mass Basis)
Table of Contents
1.0 Introduction.........................................................................................................2
1.1 How to Use These Guidelines........................................................................2
2.0 Required Accuracy of Flare Reporting...............................................................4
2.1 Flare categories..............................................................................................4
2.2 Assessment of Flare Category.......................................................................4
2.3 Methods for Achieving Required Accuracy.....................................................5
3.0 Flare Mass by Difference (Material Balance).....................................................6
3.1 Flow measurement of fuel gas streams, oil and gas export...........................6
3.2 Well testing frequency and standard..............................................................6
3.3 MW scenarios to be considered.....................................................................7
3.4 Sampling strategies........................................................................................7
3.5 Validated Process Model................................................................................7
3.6 DTI Position....................................................................................................7
4.0 Flare Mass from Volume Flow Measurement and Density................................8
4.1 Accuracy of Metering Instrumentation............................................................8
4.2 Event logging..................................................................................................8
4.3 MW scenarios to be considered.....................................................................8
4.4 Sampling strategies........................................................................................9
4.5 Validated Process Model................................................................................9
4.6 Validation.........................................................................................................9
5.0 Flare Mass from Mass Flow Measurement......................................................10
5.1 Accuracy of Metering Instrumentation..........................................................10
5.2 Event logging................................................................................................10
5.3 Validation......................................................................................................10
1.0 Introduction
In 2001 the DTI intimated that they wanted flare reporting in mass rather than volume
units. Expressing flaring on a mass basis gives a more consistent measure of
calorific value, and hence energy loss. In addition mass reporting is typically a better
fit with atmospheric emissions reporting e.g. the EEMS database and the IPPC
regime. A UKOOA workgroup was set up to bring some consistency within the
industry given the move to mass reporting. This set of guidelines has been
developed by the UKOOA workgroup in consultation with DTI and endeavours to
provide:
· A structured approach to flare quantification;
· Improved consistency of reporting across the industry;
· Emphasis on greater accuracy in reporting the flares of greater magnitude.
The guidelines consist of an approach for determining the appropriate method for
quantification of flaring. Then for each of these methods guidelines are presented on
the minimum standards for flare calculation. Although these guidelines do not
specifically deal with venting, the same principles can be applied to venting
quantification.
Assess the current method used to quantify the flare in that category
– does this result in a H, M or L level of accuracy as defined by Figure
3
End
1
As a first pass, in the absence of more specific data, a molecular weight of 21kg/kmol may be
assumed for the flare gas i.e. a gas density of 0.9kg/Sm 3.
2
Where the molecular weight does not vary by more than 10% for different scenarios a single
molecular weight can be considered to achieve the same level of accuracy as the Various Molecular
Weights method.
3.1 Flow measurement of fuel gas streams, oil and gas export
The accuracy of the flare determination by conducting a material balance will critically
depend on the flow measurement of the other streams. The metering should be
regularly validated and maintained. The fiscal measurement of the export streams
will be validated in accordance with agreed procedures. The fuel gas stream
measurement should be validated on at least an annual basis.
3
Example: Produced gas = 460 tonnes/day 5% (437-483)
Export gas = 300 tonnes/day 1% (297-303)
Fuel gas = 100 tonnes/day 5% (95-105)
The range of values which could be obtained for flare gas given the inaccuracies of the various stream
quantifications: Flare gas = Produced gas – Export gas – Fuel Gas
from = 437 – 303 – 105 = 29 tonnes/day
to = 483 – 297 – 95 = 91 tonnes/day
4.6 Validation
There are two aspects of validation that need to be considered, that is metering and
the process model. The metering should be maintained and validated on a regular
basis at least annually.
When a process model is used to obtain flare compositions it should be validated.
The validation should consist of checking the simulation with platform operating
conditions, temperature, pressure, flows, compressor power usage etc. A review of
the model should be conducted annually and changes in operating conditions should
be incorporated. Significant changes in the flare gas compositions, greater than ±
10% of the molecular weight, should result in updates.
5.3 Validation
The metering should be maintained and validated on a regular basis at least
annually.
The density of the flare gas is determined by the meter. Validation of the density
measurement can either be performed using a validated process model or by
sampling.
Appendix 1
Position Paper and Discussion of Areas to be Addressed in the Move to
Mass Reporting
Volume Flow Quantification
Around 70% of the flares on offshore platforms have some form of flow metering
installed4. The remaining 30% calculate the flare volume. This is an approach where
fuel gas usage, gas export and gas re-injection is subtracted from the expected gas
production derived from well tests.
Installation of effective flare gas metering on the installations which currently use
calculation methods would cost approximately £100K for a single meter. Although it
may be possible to install on a live production system, this would not be the preferred
method. Flare meters installed on a live system have greater inaccuracies than
those installed during a shutdown5. In addition to the cost of the meters, it is almost
certain that a shutdown would be required with associated costs and deferred
production. This may be particularly onerous for installations with low production or
those coming to the end of field life.
The accuracy of quantification by difference will be affected by the frequency of well
testing. This not only varies from operator to operator but for the same operator from
field to field. How the other gas streams, such as fuel gas, are quantified and the
accuracy of their quantification is another factor to be considered. The percentage of
flare to overall gas production will impact accuracy, as the difference between two
similar large numbers to give a flare flow several orders of magnitude lower will not
be accurate. Purge and pilot flows are likely to be a very low proportion of the total
gas flow and thus absolute quantification will be difficult. Quantification of flows for
blowdown and under upset conditions are a greater percentage of the total and will
therefore show smaller errors. Process models and calculations of inventory may be
used to derive flowrates for the blowdown and operational upset scenarios. The
accuracy of the models and the frequency with which they are verified will therefore
impact accuracy of volumes reported.
The flow meters already installed also have inherent inaccuracies. The flow range is
very wide going from purge and pilots to full scale blowdown. A meter will not have
the same degree of accuracy across the whole range of measurement required. In
some cases the flow may even be off the scale of the meter. It is also not unknown
for a flow to register when the facility is isolated. Furthermore under severe
blowdown conditions the flow might become two phase which further reduces the
accuracy. If there is no temperature and pressure compensation then this will
introduce further inaccuracies. Manufacturers quote an accuracy of 5% on volume
for the modern ultrasonic flare meters under ideal conditions in the laboratory. In the
field it is believed that the accuracy will be lower. Typically there is no means of
calibrating flare meters once installed and hence this will result in further
inaccuracies.
Mass Quantification
4
According to responses received to UKOOA Flare Questionnaire January 2002.
5
Panametrics Model 7168 Specifications Section 1.4 System Performance gives an volumetric
accuracy of ±2% of for a spoolpiece installation and ±5% for a hot tap installation.
Converting the volume quantity to mass will depend on the molecular weight of the
gas being flared. Purge and pilot is likely to be fuel gas which will have a reasonably
constant molecular weight that is unlikely to change significantly for a given
installation. However on blowdown the composition of the gas will change and hence
will affect the molecular weight and the conversion of volume to mass. Furthermore
operational problems may result in compressor shutdowns and will impact the
molecular weight of the flare gas, if the low pressure compressor is shutdown then
the molecular weight of the flare gas may even double. The degree of molecular
weight fluctuations is very dependent on the process and reservoir characteristics.
Selecting a single molecular weight to use for conversion from flow to mass may
introduce large inaccuracies in the estimate. Depending on the complexity of the
process and possible flare scenarios, a number of representative gas compositions
may be required. In order to ensure that the process of reporting is not too onerous,
some simplification may be required. Process models may be used to derive the
composition of the flare gas under each scenario. The accuracy of the models and
the frequency with which they are verified will therefore impact accuracy of mass
reported.
Sampling of flare gas may be used to derive compositional information. Sample
points should be properly located to obtain a representative sample of the stream.
Often, instrument tappings are used instead and as they may not be ideally located,
will not always give representative samples. Sampling during blowdown conditions is
likely to be impractical and the composition will change as the blowdown progresses.
If the flow is two phase then the sample is unlikely to be representative. This may
occur under operational upset conditions. Samples taken offshore may have to be
sent to a laboratory onshore for analysis. Continuous analysis would be difficult to
implement.
Some of the existing flare meters have the capacity to report directly in mass terms.
Less than 10% of the flares on offshore platforms have mass meters installedError:
Reference source not found. The quoted accuracy of the meters is 10% in
laboratory conditions and all the reservations associated with volume measurement
are also applicable. Furthermore additional inaccuracies in the density measurement
are likely if the flow is two phase.
Differences between Onshore and Offshore Measurement
Onshore sites have been reporting on a mass basis for a number of years. Onshore
installations are likely to show a much higher accuracy in the determination of flare
volumes and densities for the following reasons:
· Uptime onshore >99% offshore <98%
· Fewer upsets, less disturbances, e.g. slugging
· More stable feedstock and process
· Better access and easier maintenance
· Specialist support is more readily available, e.g. laboratory facilities
Appendix 2
Definition of Flaring Categories
Category 1 – Base Load Flare
Category 1 includes all the gas used for safe 6 and efficient operation of the process
facility and flare system under normal operating conditions.
Category 1 also includes any gas that has to be discarded as part of the platform
process and is discharged to flare. Typical examples are the off-gas from the glycol
regeneration plants and acid gas discharged from MDEA and other acid gas removal
plants, where these are fed to the flare system for combustion. This category also
includes flaring from a platform with no gas export facilities.
As soon as the platform is in a safe condition following an emergency
shutdown/process trip (category 3) once all equipment is returned to normal
operation the flaring is considered category 1.
Category 2 – Operational/Mode Changes
Category 2 includes gas flaring resulting from the start up and planned shut down of
equipment during production, gas not meeting export specification, maintenance of
equipment and equipment outages. This category also includes flaring that is caused
by the temporary lack of access to a third party gas export pipeline or similar.
As soon as the platform is in a safe condition following an emergency
shutdown/process trip (category 3) but with additional flaring as a result of equipment
outages the flaring is considered category 2.
Category 3 – Emergency shutdown/Process Trips
Category 3 includes any gas flared during an emergency shutdown/process trip of
equipment or the platform including shut-in of the wells. As soon as the platform is in
a safe condition, i.e. trip/shutdown complete, flaring becomes either category 1 or 2.
Category 4 – Un-ignited Vents
Inert gases, traces of hydrocarbons or gas resulting from regeneration etc may give
rise to a gas stream which is piped to an atmospheric vent.
The reporting of flare in the different categories is mutually exclusive i.e., category 2
or 3 flare quantity is the total flare for that period including any base load flare. For
example on a given day an installation was operating on a base load flare of
0.2tonne/hr until midday when the compressor tripped, and 2 tonnes of compression
system inventory flared as result of the trip and once the system had stabilised the
flaring was 20tonnes/hr for the rest of the day.
The flaring reported for that day would be:
6
Care should be taken not to cause “burn back” or other hazardous situations in the flare tip, riser or
other equipment. Where necessary, suitable hazard analysis should be conducted to evaluate any
proposed engineering design, operational or other changes to ensure that a minimum safe flare is
maintained.
Appendix 3
Example of an Event Log
The guidelines recommend that an event log is maintained so that the flare mass can be more readily calculated. The log should state, as a minimum, event
type, start and finish time, planned or emergency, average projected composition and total flow. The following is one example of a possible format for an
event log.
10/01/2003 11:00 10/01/2003 11:15 3 Platform ESD Emergency 31.8 1.34 4800000 2.69 64.31
The flare gas molecular weights and densities are taken from the following table which gives the flare gas properties for the different flaring scenarios.
LP compressor trip 47.3 2.00 1.18 0.04 10.11 88.67 1.13 98.87
LP compressor
46.3 1.96 1.40 0.06 12.58 85.96 1.37 98.63
shutdown
HP/LP compressor trip 36.1 1.52 2.01 0.28 34.52 63.19 2.79 97.21
HP/LP compressor
35.8 1.51 2.25 0.32 36.77 60.66 3.01 96.99
shutdown
Platform ESD 31.8 1.34 2.30 0.60 49.54 47.56 4.01 95.99
Export/HP/LP
27.5 1.16 2.29 0.90 60.19 36.62 4.59 95.41
compressor shutdown
Appendix 4
Example on Application of Guidelines
The HP flare on Platform A burns the following gas quantities:
Category 1 14 tonnes per day annualised average
Category 2 25 tonnes per day annualised average
Category 3 3 tonnes per day annualised average
TOTAL 42 tonnes per day i.e. the flare should be reported by category
as per DTI Guidelines.
The flare currently has installed an orifice plate to measure gas volume and a single
molecular weight is used to convert this to a mass. The molecular weight of the flare
gas is assumed to be equivalent to that of the export gas.
Category 1 Assessment: Figure 2 indicates that a low level of accuracy is required for
a flare of this magnitude. The orifice plate is considered to give a sufficiently
accurate volume measurement at this flowrate, hence in Figure 3 the accuracy
achieved by the current method (single MW) is defined as low.
Conclusion: when in a Category 1 flaring condition the current method provides an
adequate level of accuracy.
Category 2 Assessment: Figure 2 indicates that a medium level of accuracy is
required for a flare of this magnitude. The orifice plate is considered to give a
sufficiently accurate volume measurement at this flowrate, hence in Figure 3 the
accuracy achieved by the current method (single MW) is defined as low.
Conclusion: when in a Category 2 flaring condition the current method does not
provide an adequate level of accuracy as the molecular weight is assumed to be a
single composition. The molecular weight scenarios would have to be assessed to
determine whether or not this is a valid assumption (i.e. MW varies by less than 10%
for different scenarios) in which case the method would be deemed as medium
accuracy and be adequate. Alternatively definition of the various MW scenarios and
event logging would be required to achieve a method of medium accuracy.
Category 3 Assessment: Figure 2 indicates that a low level of accuracy is required for
a flare of this magnitude. The orifice plate is not considered to give a sufficiently
accurate volume measurement at the instantaneous flowrates experienced during
blowdown, hence in Figure 3 the accuracy achieved by the current method is defined
as low (volume by difference where flare <20% production rate and conversion to
mass by single MW).
Conclusion: when in a Category 3 flaring condition the current method provides an
adequate level of accuracy.