SLUGGING IN A FLARE HEADER
Dynamic simulation of
Crude Flash Drum when
blocking outlets during operation
Runar Sther (TEX Stavanger)
Leif Ernstsen (AkerSolutions)
1 - Classification: Internal
2013-03-01
Content of Presentation
System description
Simulation tools
The OLGA model
Simulated scenario
Simulation technical challenges
Calculation of forces in pipe bends
Results
OLGA volume errors: How to avoid them How to
filter them off
Concluding remarks
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3D Model of Sture Plant
Flare Header
Flash Drum
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System Sketch
Rupture disc, SP = 7 barg
PSV, SP = 5
barg
Gas outlet
PC
VA20300
SP= 1.5 barg
To compressor
To flare
Un-stabilized oil
cavern
Crude Oil Loading Pumps
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2013-03-01
Flash Drum
Flare header
The Crude Oil Flash Drum
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System Description
View showing part of 24 inch
Flare Header with expansion loop
One of the Sture caverns.
Length 314 m, height 33 m, width 19 m.
Capacity ~ 160 000 m3
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Simulation Tools
HYSYS V7.1, Static and Dynamic
- for defining fluid
- for heat exchanger dynamics
Flarenet V7.1
- for examining previous modelling work
PVTsim 17.0.0
- for PVT file generation for OLGA
OLGA 5.3.4.4 with precalculated fluid file
- for dynamic modelling of upset scenario
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OLGA Model Elevations
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Blocked Outlet Scenario
Normal operation
Upset start: Control system error or stop of Flash Drum pump
Flash Drum liquid outlet closes
Flash Drum primary protection (HH liq.) fails
Puts demand on secondary protection (PSV, RD)
Full Flash Drum Compressor trip Gas outlet blocked
PSV opens at 5 barg Fully open at 5.5 barg RD opens at 7 barg
Multiphase liquid and gas flow through Flare Header Slugging
Simulation run for 15 minutes after upset start
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2013-03-01
Simulation Technical Challenges
Cavern pump modelled as an OLGA well
OLGA well adjusted to match pump curve with:
RESPRESSURE=24.15 BARA
PRODI=0.000000660 Sm3/s/Pa
Operating
area
Pump located
here
Sketch of cavern elevations
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Pump curve
Simulation Technical Challenges
Separator modelling
Real separator:
Horizontal vessel, rounded ends
T/T length 25 m, diameter 5 m
Inlets in both ends, outlets in the middle
Separator as modelled with OLGA:
Horizontal vessel, flat ends
Inlet and outlet in opposite ends
Main part of normal liquid content excluded to avoid
implications of instantaneous gas/liquid equilibrium
as modelled by OLGA.
Length 13.3 m, diameter 4.09 m
Heat content conserved by adding an artificial oil wall
layer to separator.
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Simulation Technical Challenges
Separator modelling
Real Flash Drum
OLGA separator model
Cross section
Cross section
These gas
volumes are
equal
4.09 m
5m
3.17 m
Horizontal, 26,6 m long
(rounded ends included)
349 m3
liquid
0.13 m
1.7 m3
liquid
Horizontal, 13,3 m long
(rounded ends included)
OLGA separator is modeled with 347 m3 less
liquid content than the real Flash Drum to minimise
OLGA error of instantaneous gas/liquid equilibrium
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Simulation Technical Challenges
Separator modelling
OLGA separator model
Cross section
Wall layers added for heat
conservation
Separator content
1 millimeter wall with very
good heat conduction
4.09
m
1.5 m
1.7 m3
liquid
1m
Horizontal, 13,3 m long
(rounded ends
included)
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Annulus shaped oil layer
with volume 347 m3 added
to conserve heat
1 m insulation layer added to
minimise heat loss to ambient
Simulation Technical Challenges
Separator modelling
Temperature of artificial oil layer
Flash Drum outlet temperature
Flash Drum inlet temperature
Temperature development while filling separator.
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Simulation Technical Challenges
Separator modelling
Liquid level oscillations in full separator Separator bypassed
Artificial bypass heater Realistic temperature development
Separator temperature profile extrapolated
Disturbance during
switch over to
bypass
OLGA-LEAK connection used as bypass
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Continued temperature profile
by artificial bypass heating
Extrapolation of separator outlet temperature after bypassing
Simulation Technical Challenges
OLGA volume errors
Volume error = VOL = | m/ Vsect| / Vsect
where: m = total mass in section
= bulk density in section
Vsect = volume of section
VOL should ideally be zero, but may be > 0 due to discretization
rounding in PVT file, especially when close to bubble point curve
VOL > ~1 Pressure increase Acceleration of fluid
VOL > 0 will not violate mass balance, but result in shift from equlibrium
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Simulation Technical Challenges
OLGA volume errors, contd
Volume errors have occurred in several cases.
They hamper the result picture. The OLGA user will have to
examine, if a peak is real, or is caused by a volume error.
Usage of OLGA Compositional Tracking module will not
require PVT file and presumably avoid many of the volume
errors.
Unfortunately this module has not been available in the
project.
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Calculation of Forces in Pipe Bends
F = (WG*UG+WLHL*ULHL+WLWT*ULWT+WD*UD) * DAF * (2*(1 cos()))0,5
GAS
OIL
WATER
DROPS
where:
F
=
WG =
WLHL =
WLWT =
WD
=
UG
=
ULHL =
ULWT =
UD
=
DAF =
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Force on pipework [N]
Gas mass flux [kg/(s*m2)]
Oil film mass flux [kg/(s*m2)]
Water film mass flux [kg/(s*m2)]
Droplet mass flux [kg/(s*m2)]
Gas velocity [m/s]
Oil film velocity [m/s]
Water film velocity [m/s]
Droplet velocity [m/s]
Dynamic amplification factor, a constant in the range [12]
Angle of pipe bend []; =0 ~ a straight pipe F = 0
Creation of Slugs
Flash Drum 9 m vertical inlet pipe Severe slugging
Lower pressure / higher temperature at Flash Drum inlet
More gas Promotes slug formation
Slugs travel downstream and grow in length in Flare Header
Long Flare Header, almost horizontal, slightly down-sloped
Good conditions for hydrodynamic slugging
Slugs, liquid mass flow peaks, and force peaks are closely correlated.
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Slugging in Flare Header
Video clip illustrating typical slugging in Flare Header
during upset situation.
Blue filling indicates liquid holdup. Red lines are slugs.
Rupture disc opens at time 860 s.
(Circle to the right is part of the OlgaViewer system)
Click in picture to start video
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2013-03-01
Slugging in Flare Header
Video clip illustrating typical slugging in Flare Header
during upset situation.
Blue filling indicates slug length. Red lines are slugs.
Rupture disc opens at time 860 s.
(Circle to the right is part of the OlgaViewer system)
Click in picture to start video - Max slug length is 295 m
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Slug Behavior in Flare Header
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Forces in Flare Header Bend close to
Discharge into Cavern
Same simulation as previous slide
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OLGA Volume Errors
Where do they occur ?
How to Avoid them
How to Filter them off
Stagnant fluid Higher chance of having volume errors
Rough discretization in fluid file, especially at bubble point curve
Higher chance of having volume errors
Compositional Tracking Avoid volume errors caused by PVT file
Automatic filtering of volume errors too complex
Best way of filtering is purely manual examination
Example of such manual filtering shown in following slide:
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OLGA Volume Errors
Example of manual filtering
Force peak here
Is caused by
volume error here
Distance between the two
locations is 127 m.
Volume error takes 1.6 s to
travel this distance.
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Poor pipe supporting of Flare Header
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Transient approach:
(OLGA)
Force ~ 10 ton (v2 ~ 0.2 Mill)
API RECOMMENDED PRACTICE 521:
3.10.3 INLET CONTROL DEVICES
opens for dynamic simulations
Steady state approach:
(Flarenet)
Force ~ 70 ton (v2 ~ 1.2 Mill)
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Do you have slugs in
your flare system ?
Relief device
Long pipe
KO DRUM
SEPARATOR
HYDRODYNAMIC SLUGGING
Vertical riser
Multiphase flow
SEVERE SLUGGING
Thanks for
your attention !!
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BACK-UPS
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2011-10-24
The OLGA Model Elevations
Sture Model Piping Elevation Profiles - Total Model
40
LPG-leg
Gas cap in Ballast WaterCavern
20
Heaters
Elevation [m]
0
Flash Drum
Gas cap in Unstabilized Oil Cavern
-20
-40
Pumps in Unstabilized Oil Cavern
-60
-80
-200
200
400
600
Elevation=0 corresponds to sea level
Cavern Pump-Flash Drum-Gas line
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800
1000
1200
1400
1600
1800
2000
Horizontal length [m]
RD-run
PSV-run
Flare Header+cavern gas caps
LPG-leg
2200
2400
The OLGA Model, First Part
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The OLGA Model, Second Part
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Simulation Technical Challenges
LEAK connections used to obtain correct routing of modelled
piping network, see following example:
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Slug Shooting
A special approach tested has been to shoot a single
slug through the rupture disc run + Flare Header:
Loaded slug
Rupture
disc here
Flare Header
Flash Drum
gas outlet
To Cavern
Only shown piping part modelled
34 - Classification: Internal
LEVEL slug feature used
INITIAL CONDITIONS used to load liquid in gas outlet pipe
High upstream pressure will shoot the slug ahead
This approach was left, as the slug deteriorated very fast;
was not deemed realistic.
2011-10-24
