SPE-183248-MS

Successful Implementation of Flare Gas Recovery Systems in Gasco Plants

JagannathRao P Allamaraju and Rahul Mukherjee, Abu Dhabi Gas Industries Ltd-GASCO

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 7-10 November 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
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consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
Environmental issues such as global warming and economic considerations have resulted in the use of flare
gas recovery systems to reduce flaring by capturing and either compressing the flare gases for other uses
or recycling the flare gases to low-pressure process equipment.
Gasco requirement is to recover the flare gases of the three hydrocarbon flares instead of being
continuously burnt. This should be through the installation of Flare Gas Recovery Systems (FGRS). This
recovered gas should be either used as a fuel gas or injected back into the processing facilities.
World Bank has introduced the initiative "Zero Routine Flaring by 2030". In line with the above initiative,
within Gasco there are KPIs which aim at reducing flaring and to recover the flared gases.
This is achieved through the successful implementation of Flare Gas Recovery Systems (FGRS) at
GASCO Plants A, B and C.
Targeting Process Safety (PS), enhancement in HSE and performance monitoring, starting 2008, Gasco
embarked on an ambitious Project requiring state of the art Flare gas recovery systems.
This Paper details the stages involved and detailed plan, i.e. Study, FEED and EPC. Optimization
methodology necessary when designing or operating a reliable Flare Gas recovery Systems on existing Gas
Plants to recover hydrocarbon gases over wide range of gas compositions without affecting the existing
facilities.
A study was conducted on Hydrocarbon Flares of Gasco Plants A, B and C in order to predict the various
continuous flow rates through the three Hydrocarbon Flare headers. It was predicted that for each of above
plants the recovered gas could be in the order of ~1 to 2 MMscfd.
In FEED, considering the future additional flare gases, the design capacity of the individual flare gas
recovery systems fixed at 5 MMscfd per train for each of above plants. EPC Package was developed to
execute project on turnkey basis.
Proper FEED, EPC Detailed Design Review, HAZOP and SIL sessions produced an inherently safe
Design.
In 2013 the project was successfully commissioned. The FGR system was found capable of operating at
flowrates up to the design flowrate across the full range of molecular weights.
Actual recovery of Flare Gas post implementation on a yearly average basis for a period of three years
(2013/2014/2015) are reproduced below:
Plant A - 1.40 / 1.75 / 2.17 MMscfd
2 SPE-183248-MS

Plant B - 1.58 / 1.78 / 1.86 MMscfd

Plant C - 1.36 / 1.65 / 1.81 MMscfd

Introduction
The Plant A, B and C are operated by GASCO.
GASCO Plants are operationally segregated into areas namely Plant-A, Plant-B and Plant-C. These Plants
operates three elevated and dedicated hydrocarbon Flares namely Plant-A, Plant-B and Plant-C hydrocarbon
flares.
It is ADNOC HSEIA policy to minimize the gas flaring as much as possible using plausible industrial
techniques.
The Three flares in the subject Paper to be used for Flare gas recovery are:

Flare Tag Number Plant Area Design Capacity (MMSCFD)

Hydrocarbon Gas Flare 71-ME-102 Plant-A 680
Hydrocarbon Gas Flare 71-ME-501 Plant-B 1308
Hydrocarbon Gas Flare 71-ME-701 Plant-C 1500

In order to minimize the flaring of hydrocarbon gases to the environment from the Plant-A, Plant-B
and Plant-C, new Flare Gas Recovery facilities are added to these existing flare systems (71-ME-102, 71-
ME-501 and 71-ME-701) to recover and recycle this gas. The new facilities will recover the hydrocarbon
flare gases and compress the recovered streams to the required pressure for injecting back into the processing
facilities. Recovered liquids from the new flare gas Recovery system are sent to Sour Water Stripper for
treatment.

Flare Gas Reduction

Flare Gas Recovery systems reduce flaring by recovering flare gases before they are burnt by the flare.
In reality, a Flare gas recovery system collects gas from the flare header before it reaches the flare,
compresses the gas and cools it before injecting back into the processing facilities. GASCO recognized
that implementing this flare gas recovery system required detailed technical evaluation of existing flare
scenarios, operations and design of Flare Gas Recovery systems. Therefore, GASCO developed a Project
strategy covering three stages namely Study, FEED and EPC.

Study Stage
GASCO contacted a team of flare gas recovery Experts with substantial experience in Flare gas recovery
to do initial Technical assessment and Feasibility study.
This Expert team carried out tests on Plant-A, Plant-B and Plant-C Flares to collect operating data of
existing Flares and reviewed existing Flare Header and its equipment configuration to establish a flare gas
recovery systems that effectively reduces Flaring.
The Study addressed the possibility of recovering the flare gases and a comprehensive analysis to cover
the following objectives:

• To provide the Design Basis for the system.

• Flame Photographs were taken for a number of weeks to understand flow rates pattern based on
wind directions to predict the various flow rates through the three Flare headers.
SPE-183248-MS 3

• Collecting all possible data regarding the flare system (type, size, tip type, etc.)

• Estimation and sizing of the future Flare Gas Recovery Systems and their design.

• To conduct a FEED for the installation of these facilities in order to minimize continuous flaring
and respecting the most rigorous rules for environment.
The estimated flow rates of the FGRS during the study phase are as below:
Case 1 MW 29: Plant –A / B / C = 0.8 / 1.16 / 0.53 MMscfd.
Case 1 MW 19.8: Plant –A / B / C = 1.06/ 1.88 / 0.83 MMscfd.

FEED stage
FEED covered the following major engineering activities:
1) Review of the Existing Plant-A, Plant-B and Plant-C Flare System and understanding Process
conditions and requirements to form a Design Basis and to evaluate options for Flare gas recovery
systems.
2) Evaluate Flare Gas Composition-During FEED, GASCO provided laboratory Analysis of Gas
Samples to determine flare gas composition, Molecular weights.
3) Identify Use for Recovered Gas
4) Analysis of Available Back Pressure and Water Seals Adequacy.
FEED Team reviewed the design and operations of all three existing Plant-A, Plant-B and Plant-C Flares
to determine possible integration issues between the existing Flare headers and the new flare gas recovery
units.
FEED Team identified modifications to the existing Plant-A, Plant-B and Plant-C Flare Headers that
includes addition of Liquid Seal Drums across Flare Header, Suction KOD, Flare Gas Recovery Compressor,
Intertsage Cooler, Interstage KOD, Discharge Cooler and Discharge KOD and controls required for
integrating and sustaining optimum performance of the flare gas recovery systems.
Once FEED was finalized, FEED team developed and presented Process Flow schemes, P&IDs and
execution methodology to the GASCO. The detailed FEED helped GASCO to easily implement it in EPC
phase.

EPC stage

Description for Plant-A Flare Gas Recovery System

Refer Figure 1 Process Flow Diagram for Plant-A Flare Gas Recovery System:
4 SPE-183248-MS

Figure 1—Typical Process Flow Diagram for Plant-A Flare Gas Recovery System

The Flare Gas Recovery Unit is designed to minimize routine flaring by recovering and compressing
flare gas to a pressure suitable for recycling back to the existing MP Booster Compression Units. Recovered
liquids are pumped to the Sour Water Treatment Units.
Gas from flare gas system is withdrawn from the flare gas header downstream of the flare knockout
drum (71-V-102A/B) via a new tie-in. This gas is routed to the Suction KO Drum (771-V-002), where any
entrained liquid is removed before it is fed to the Flare gas recovery Compressor. The gas then flows to the
Flare Gas Recovery Compressor (771-C-001) where it is compressed to 5.3 barg in a two stage machine
with Interstage Cooler (771-E-002) and KO Drum (771-V-003). Compressed gases from the second stage
discharge are finally cooled in a Discharge Aftercooler (771-E-003) to 55 °C, and liquids separated in the
Discharge KO Drum (771-V-004), before being routed to the MP Gas Separators on the suction of the
MP Booster Compressors. Liquids recovered in the Interstage and Discharge KO Drums are at sufficiently
higher pressure than the Suction KO Drum and are routed back to the Suction KO drum by the pressure
differential from where they are intermittently pumped by the Sour Oily Water Pumps 771-P-004 A/B to
the Sour Water Stripper Units.
The Flare Gas Recovery Compressor will normally be operating continuously, regardless of the amount
of flare gas produced. An automatic spillback (first stage and second stage recycle valves) will open if the
flare gas supply is lower than the minimum compressor throughput. Both the 1st and the 2nd stage recycles
are cold recycles taken from downstream of the Interstage and Discharge KO Drum respectively.
Also Refer Figure 2 Typical Process Flow Diagram for Liquid Seal Drum and Flare Gas Recovery unit
SPE-183248-MS 5

Figure 2—Typical Process Flow Diagram for Liquid Seal Drum and Flare Gas Recovery unit

The Flare Header Liquid Seal Drum (771-V-001) is located between the flare knockout drum (71-
V-102A/B) and the flare stack (71-ME-102). A positive pressure is maintained in the flare network by a
water seal Drum in the vessel (771-V-001). Under normal operation any flare gases are recovered by the
Flare Gas Recovery Compressor (771-C-001) and recycled to the process units. In the event that the flaring
rate increases above the capacity of the Flare Gas Recovery Compressor (771-C-001), the pressure in the
system will rise and the water seal will be broken, allowing the gas to smoothly flow to the flare stack and
be safely burnt.
A control valve in the bypass line of Flare Gas Seal Drum is provided with its pressure control in manual
mode (and valve in closed position) in all plant operations except shutdowns and start-ups whereby high
flow rates are expected to be flared for longer time, or whenever it is deemed necessary by the operator,
whereby the valve can be opened manually by operator intervention or the pressure control can be put in
auto mode.
Control Valve is thus normally closed with 771-PIC-3000 in manual mode in normal plant operations
except shutdowns and start-ups if deemed necessary by the operator.
As there is a possibility of having flaring scenarios which can cause freezing of the water in the Liquid
Seal Drum and thus blocking the path to the flare, a temperature override is provided in order to open the
bypass control valve in case low temperature is sensed by the temperature transmitter in the Flare header
upstream of the Seal Drum and hence reducing the possibility of freezing in the Liquid Seal Drum. This
temperature control will override all modes (manual/auto) of operation of the bypass control valve.
To ensure a positive path to the flare, an ultimate protection is provided by installing a buckling pin relief
valve (BPRV) in order to bypass the Seal Drum. The BPRV is designed for the design flow of the Flare and
opens at the set pressure that the pin is certified to buckle at.
The line downstream of flare gas seal drum will be continuously purged using fuel gas.
6 SPE-183248-MS

Design and Operation Considerations

The Plant Flare Gas Recovery Facilities consists of three Flare Knockout Drums and three Flare liquid Seal
Drums dedicated one for each of Plant-A, Plant-B and Plant-C Hydrocarbon Flare systems.
The Knockout drum protects both the flare and flare gas recovery compressor unit from liquid carryover.
The Liquid seal Drum enables safe operation of the FGR system and provides backpressure in the flare
header, which is necessary for the optimum performance of FGR system.

Flare Header Liquid Seal Drum Control philosophy

Refer Figure 1 Process Flow Diagram for Plant-A Flare Gas Recovery System:
The Flare Header Liquid Seal Drum provides a means for preventing the flow of flare gas from the flare
header to the flare stack until the differential pressure across the drum is sufficiently high to overcome the
static head of the liquid in the drum. Hence the Liquid Seal Drum effectively provides a means of providing
a back pressure on the existing flare header and provides an additional safety layer by preventing air ingress
in the event that the header pressure were to fall below atmospheric pressure.
During normal operation, one of the two Seal Drum Overflow Drum pumps 771-P-002 A/B runs
continuously and there is a constant recirculation of water to the Seal Drum via the restriction orifice 771-
FO-1001 on Seal Drum Overflow Pump (771-P-002A/B) discharge. The constant feed of water causes the
Seal Drum to overflow back to the Seal Drum Overflow Drum (771-V-005) through a side nozzle on the
Seal Drum. In the event that the liquid level in the Seal Drum falls (e.g. after the release of gas to the flare
system that has resulted in a high rate of water entrainment) or blow dry conditions then 771-LV-2002 will
fully open on low liquid level and close on high liquid level to reinstate the liquid level.
Seal Drum Overflow Drum (771-V-005) level is controlled by 771-LIC-2005.
On low liquid level 771-LV-2005A opens to reinstate normal liquid level by Utility water make-up and
closes on normal liquid level. On high liquid level 771-LV-2005B opens to send the water to Unit 72/172
and closes on normal liquid level to reinstate liquid level.
A sample connection is provided in the 771-P-002 A/B pumps discharge line going to the Seal Drum for
periodic testing of the contamination level (Hydrocarbon, pH…etc.) within the recirculated water. An online
pH meter is also provided in the same line to alert the operator in case of a low pH level. When contamination
is above acceptable limits then 771-LV-2005B is opened manually to dump the liquid inventory to Unit
72/172, following which LV-2005A is opened to reinstate liquid level.
The Seal Drum Overflow Drum is provided with an Interface displacer type Level Transmitter 771-
LT-2037 to measure the interface level (HC/water) in case of HC accumulation. In presence of any
hydrocarbon (HC), this LT will measure the interface level of HC/water. In absence of any HC, this LT will
measure the water level. A high difference of readings between LT-2037 and LT-2004 (which measures
water level at all times) indicates high level of accumulation of HC in the vessel. In case of high level of HC
accumulation, the water in the vessel 771-V-005 will be dumped to sour water treatment unit by manually
closing the utility water make-up level control valve 771-LV-2005 A and manually opening the level control
valve 771-LV-2005B. The residual HC in the drum is to be pumped out by Vacuum truck / Mobile pump
under the supervision of operator.

Existing Flare Header modifications

Existing Plant Flare Header is without Flare Liquid Seal Drum and hence, New Flare Liquid Seal Drum is
added to the existing Flare Header with inlet, Outlet and full size bypass manual isolation valves.

Flare Gas Recovery system Design

Refer Figure 1 Process Flow Diagram for Plant-A Flare Gas Recovery System:
The Flare Gas Recovery Facilities consists of three 100% trains of compression, one for each of Plant-
A, Plant-B and Plant-C Hydrocarbon Flare systems.
SPE-183248-MS 7

The Flare Gas Recovery compression train comprises 1 × 100% machine, normally operating under
pressure control.
The controls for compressor will prevent the machine from tripping and ensure optimal operation in
accordance with the available gas flow. For control reasons, the compressor unit is equipped with a variable
speed drive and four pressure control valves.
These are:
1. Suction Pressure Control Valve (PV-3010)
2. First Stage Recycle Control Valve (PV-3017)
3. Second Stage Recycle Control Valve (PV-3015)
4. Discharge Control Valve (PV-3023)
Since the pressure in the flare header is susceptible to large variations, a suction pressure control valve
(PCV) 771-PV-3010 is installed upstream of the Suction K.O. Drum to control the inlet pressure to the
FGR Compressor Unit.
The Suction Pressure Control Valve PV-3010 is controlled by the following two controllers:
– Signal (0-100%) from Suction pressure controller PIC 3010 and
– Signal (0-100%) from First Stage Compressor Suction pressure controller PIC 3013
The position set point signal to PV-3010 is the result of a MIN selector from above controller outputs.
PV-3017 is controlled by signal (0-100%) from first stage discharge pressure controller PIC 3017.
PV-3015 is controlled by signal (0-100%) from second stage suction pressure controller PIC 3015.
PV-3023 is controlled by signal (0-100%) from second stage discharge pressure controller PIC 3023.
The compressor is essentially subject to three operating modes:

• Low flow conditions – Recycle controls; Compressor operates at min speed.

• Intermediate flow conditions – Recycle Controls; compressor speed varies under the control of a
variable speed drive.
• High flow conditions – Recycle closed, Compressor at maximum speed, Suction throttling.

The flow of the compressor unit is controlled between 0% and 100% by combination of speed variation
and bypass recycling. The interstage pressure is kept constant by means of an individual recycle line around
each compressor stage, thus optimizing over and under compression for the required wide variation in
temperature and molecular weight of the compressed gases.
Low flow conditions occur when there is little or no gas being discharged to the flare system (i.e. 0 ≤
Flow ≥ ~3.0 MMSCFD). Under these circumstances the compressor is intended to operate at minimum
speed, with the interstage pressure 771-PT-3017 regulated to maintain their respective set point by means
of adjusting the amount of gas recycled through modulation of the 1st stage recycle valve 771-PV-3017
and 2nd stage recycle valve 771-PV-3015.
Intermediate flow conditions occur when the gas discharge rate into the header is in the approximate
range of 3.0 to 5.0 MMSCFD. Under these circumstances the compressor is intended to operate at speeds
greater than the minimum speed. Whilst it may be possible to maintain direct control of the 1st stage suction
pressure 771-PT-3013 via usage of the variable speed drive alone, it is expected that due to the high and
sudden flowrates variation that are expected to occur it is likely that the speed of response will be too slow
to ensure effective and tight control of the suction pressure. Therefore, during intermediate flow conditions
the compressor control regulates the speed of compressor to maintain the 1st stage suction pressure 771-
PT-3013 whilst adjusting the amount of gas recycled through modulation of the 1st and 2nd stage recycle
valves (771-PV-3017 and 771-PV-3015 respectively) in order to have a constant interstage pressure.
8 SPE-183248-MS

High flow conditions occur when the flowrate in the flare header is greater than 5.0 MMSCFD. Under
these circumstances the gas inlet rate exceeds the nominal design capacity of the compressor and the
compressor is not capable of handling the increased flow in the flare header. As a result the pressure in the
flare header upstream of the Seal Drum will start rising. The Suction Pressure Control Valve 771-PV-3010
will throttle to maintain the pressure at the inlet of the FGR Unit. However, pressure at the upstream of the
Liquid Seal Drum will rise causing the liquid seal maintained by the Seal Drum to be broken and allowing
the excess flow to pass to the flare. As such in this operating mode the compressor operates at maximum
speed.
In the event that the pressure in the flare header upstream of the Seal Drum 771-PT-3001 increases further
(e.g. as a result of a major flaring event), the FGR compressor is tripped at a pressure of 1 barg. This is done
to avoid jeopardizing FGR unit due to the emergency flaring scenario.

Compressor Selection
In view of FGR system design Basis and intended flare gas recovery compressor capacity, GASCO has
selected two stage screw compressor. The best suited compressor for the flare gas recovery depends on
many factors, such as Process requirements, reliability, availability, maintainability requirements.
GASCO Team selected three two stage screw compressors each dedicated for Plant-A, B and C
Hydrocarbon Flares. Refer Figure-3 Compressor Selection Chart.

Figure 3—Compressor Selection Chart

SPE-183248-MS 9

Figure 4—FGR system Simulation of Plant –A (Typical scheme)

Each compressor was specified prudently for a capacity of 5.0 MMscfd at a discharge pressure of 5.3 bar
g, considering the future expansion / expected additional flare gases. Higher recovery rates can be clearly
seen in attached Trends (Ref Figures 5 to 13).

Figure 5—Recovered Flare Gas Flow Rate of Plant-A Year 2013-2014:

10 SPE-183248-MS

Figure 6—Recovered Flare Gas Flow Rate of Plant-B Year 2014-2015:

Figure 7—Recovered Flare Gas Flow Rate of Plant-C Year 2015-2016:

Figure 8—Recovered Flare Gas Flow Rate of Plant-A Year 2013-2014:

SPE-183248-MS 11

Figure 9—Recovered Flare Gas Flow Rate of Plant-B Year 2014-2015:

Figure 10—Recovered Flare Gas Flow Rate of Plant-C Year 2015-2016:

Figure 11—Recovered Flare Gas Flow Rate of Plant-A Year 2013-2014:

12 SPE-183248-MS

Figure 12—Recovered Flare Gas Flow Rate of Plant-B Year 2014-2015:

Figure 13—Recovered Flare Gas Flow Rate of Plant-C Year 2015-2016:

Gas Composition
The flare gas recovery system shall be designed for the compositions range identified in Table 1, with typical
compositions shown in Table 2.

Table 1—Flare Gas Composition Range

Component Min (Mol %) Max (Mol %)

H2S 0 11.9

CO2 1.9 6.7

H2O Sat Sat

Nitrogen 0.3 0.7

Methane 30 95.5

Ethane 0.7 8.3

(continued on next page.)

SPE-183248-MS 13

Table 1—(continued).

Component Min (Mol %) Max (Mol %)

Propane 0.0 12.9

i-Butane 0.0 4.4

n-Butane 0.0 10.7

i-Pentane 0.0 4.5

n-Pentane 0.0 5.3

C6+ 0.0 5.4

Mercaptans, Thiols and Sulfides 0 0.8

Mol. Wt. 16.9 40

Table 2—Flare Gas Typical Compositions

Component Light (Mol %) Middle (Mol %) Heavy (Mol %)

Note1 Note 2 Note3

H2S 0.0 7.72 11.93

CO2 1.97 4.66 3.28

H2O 0.0 0.57 3.56

Nitrogen 0.32 0.34 0.05

Methane 95.45 66.67 29.67

Ethane 2.23 7.4 8.29

Propane 0.03 5.29 12.85

i-Butane 0.0 1.30 4.40

n-Butane 0.0 2.93 10.70

i-Pentane 0.0 0.98 4.45

n-Pentane 0.0 1.09 5.29

C6+ 0.0 1.06 5.43

Mercaptans, Thiols and Sulfides 0.0 0.0 0.08

COS 0.0 0.0 0.01

Mol. Wt 16.9 25.1 40.0

Notes:
(1) Composition based on Sales Gas
(2) Composition based on Feed Gas Compression Discharge Gas
(3) Composition based on MP Compressor Suction Gas

Process Simulations
Process Simulations were carried out in EPC Phase to verify and Validate FEED gas compositions and carry
out equipment sizing for implementation.

SIMULATION CASES
The following cases have been considered for the HYSYS Simulation:
– Case A: Dry, Sweet & Lean Case with inlet temperature of 39.5°C
14 SPE-183248-MS

– Case B: Wet & Sour Case with inlet temperature of 35°C

– Case C: Wet, Sour & Rich Case with inlet temperature of 30.5°C
– Case D: Dry, Sweet & Lean Case with inlet temperature of 59°C

SIMULATION METHODOLOGY

SUCTION KO DRUMS
The Suction KO Drums (771-V-002/102/202) are two phase separators and have been modelled by
specifying inlet gas pressure, temperature, molar flow rate and feed composition. Any entrained liquid is
removed and sent to the sour water stripper units.

FLARE GAS RECOVERY COMPRESSORS, INTERSTAGE COOLERS & INTERSTAGE KO

DRUMS
The gas product from the suction KO drum flows to the Flare Gas Recovery Compressor (771-
C-001/101/201) where it is compressed in a two stage machine. In the first stage the gas is compressed to
approximately 2.287 barg. The gas is then sent to an Interstage Cooler (771-E-002/102/202) and Interstage
KO Drum (771-V-003/103/203) where it is cooled to 55 °C. In the second stage the gas is further compressed
up to 5.3 barg. Any liquid separated in the Interstage KO Drum are sent to the Suction KO Drums. The
discharge temperature of each stage is input based on selected vendor performance data and consequently
the compressor efficiency is calculated by HYSYS.

DISCHARGE COOLER
Compressed gas from the second stage compressor discharge is finally cooled in a Discharge Cooler (771-
E-003/103/203) to 55 °C.

DISCHARGE KO DRUM
The cooled gas is sent to the Discharge KO Drums (771-V-004/104/204) and liquids separated are sent back
to the Suction KO Drums. The final gas stream will be fed to MP Gas Booster Compressors.

Table 3—Simulation Conditions for Input Data

Condition

Compressor first stage suction pressure 0.04 barg

Compressor first stage discharge pressure 2.3 barg

Compressor second stage discharge pressure 5.3 barg

Interstage cooler outlet temperature 55 °C

Discharge cooler outlet temperature 55 °C

Table 4—Compressor Discharge Temperatures

CASE Compressor Discharge Temperature

1St Stage 2nd Stage

A 163 °C 143 °C

B 137 °C 127 °C

C 99 °C 105 °C

D 185 °C 143 °C
SPE-183248-MS 15

Case A: Dry, Sweet & Lean Case with Inlet Temperature of 39.5 deg C

Table 5—Simulation Results for Case A: Dry, Sweet & Lean Case with Inlet Temperature of 39.5 deg C

Stream 001 003* 005 006* 014 007* 009 009* 010 011

Vapour Fraction 1 1 1 1 1 1 1 1 1 1

Temperature [C] 39.5 40.2 153.8 54.9 54.9 54.9 143 142.9 55 54.9

Pressure [kPa] 121.3 105.3 330 281 280 280 631.3 621 591.8 581.3

Molar Flow [kgmole/h] 249.5 264 264 264 14.51 249.5 249.5 249.5 249.5 249.5

Mass Flow [kg/h] 4230 4475 4475 4475 246 4230 4230 4230 4230 4230

MMscfd 5.0 5.291 5.291 5.291 0.2908 5.0 5.0 5.0 5.0 5.0

Std. Gas Flow (STD_m3/hr) 5899 6242 6242 6242 343.1 5899 5899 5899 5899 5899

Act. Gas Flow (ACT_m3/hr) 5334 6519 2835 2551 140.7 2419 1362 1383 1139 1160

Interstage cooler Duty 0.2058 Gcal/hr

Discharge cooler Duty 0.2104 Gcal/hr

Gas Power 569 Kw

Case B: Wet & Sour Case with Inlet Temperature of 35 deg C

Table 6—Simulation Results for Case B: Wet & Sour Case with Inlet Temperature of 35 deg C

Stream 001 003* 005 006* 014 007* 009 009* 010 011

Vapour Fraction 1 1 1 1 1 1 1 1 1 1

Temperature [C] 35 35.9 124.4 54.9 54.9 54.9 143 142.9 55 54.9

Pressure [kPa] 121.3 105.3 330 281 280 280 631.3 621.8 591.8 581.3

Molar Flow [kgmole/h] 249.5 264 264 264 14.51 249.5 249.5 249.5 249.5 249.5

Mass Flow [kg/h] 6260 6624 6624 6624 364 6260 6260 6260 6260 6260

MMscfd 5.0 5.291 5.291 5.291 0.2908 5.0 5.0 5.0 5.0 5.0

Std. Gas Flow (STD_m3/hr) 5899 6242 6242 6242 343 5899 5899 5899 5899 5899

Act. Gas Flow (ACT_m3/hr) 5242 6414 2629 2537 140 2406 1354 1375 1126 1147

Interstage cooler Duty 0.219 Gcal/hr

Discharge cooler Duty 0.2682 Gcal/hr

Gas Power 621 Kw

16 SPE-183248-MS

Case C: Wet, Sour & Rich Case with inlet Temperature of 30.5 deg C

Table 7—Simulation Results for Case C: Wet, Sour & Rich Case with inlet Temperature of 30.5 deg C

Stream 001 003* 005 006* 014 007* 009 009* 010 011

Vapour Fraction 0.98 1 1 1 1 1 1 1 0.94 1

Temperature [C] 30.5 30.1 88.8 54.8 54.8 54.8 143 142.9 55 54.6

Pressure [kPa] 121.3 105.3 330 281 280 280 631.3 621.8 591.8 581.3

Molar Flow [kgmole/h] 249.5 260.17 260.17 260.17 14.30 245.87 245.87 245.87 245.87 232.74

Mass Flow [kg/h] 10001 10243 10243 10243 563 9680 9680 9680 9680 8801

MMscfd 5.0 5.21 5.21 5.21 0.2866 4.927 4.927 4.927 4.927 4.664

Std. Gas Flow (STD_m3/hr) 5899 6152 6152 6152 338.1 5814 5814 5814 5814 5503

Act. Gas Flow (ACT_m3/hr) 5032 6155 2319 2459 135.6 2332 1310 1330 1018 1037

Interstage cooler Duty 0.153 Gcal/hr

Discharge cooler Duty 0.502 Gcal/hr

Gas Power 745 Kw

Case D: Dry, Sweet & Lean Case with inlet Temperature of 59 deg C

Table 8—Simulation Results for Case C: Dry, Sweet & Lean Case with inlet Temperature of 59 deg C

Stream 001 003* 005 006* 014 007* 009 009* 010 011

Vapour Fraction 1 1 1 1 1 1 1 1 1 1

Temperature [C] 59 58.6 175.5 54.9 54.9 54.9 143 142.9 55 54.9

Pressure [kPa] 121.3 105.3 330 281 280 280 631.3 621.8 591.8 581.3

Molar Flow [kgmole/h] 249.5 264 264 264 14.51 249.5 249.5 249.5 249.5 249.5

Mass Flow [kg/h] 4230 4476 4476 4476 246 4230 4230 4230 4230 4230

MMscfd 5.0 5.29 5.29 5.29 0.290 5.0 5.0 5.0 5.0 5.0

Std. Gas Flow (STD_m3/hr) 5899 6242 6242 6242 343.1 5899 5899 5899 5899 5899

Act. Gas Flow (ACT_m3/hr) 5669 6905 2981 2551 140.7 2419 1362 1383 1139 1160

Interstage cooler Duty 0.310 Gcal/hr

Discharge cooler Duty 0.210 Gcal/hr

Gas Power 589 Kw

Simulation Results
The FGR system is simulated for various above cases and Results are as under.

• Case C will require maximum Compressor Gas power =745 Kw.

• Case D will maximum Interstage Cooler Heat Duty = 0.310 Gcal/hr

• Case C will maximum Interstage Cooler Heat Duty = 0.5028 Gcal/hr

The gas outlet temperature and Pressure at the battery limit of HFGR System are 55°C and 4.8 barg
respectively.
SPE-183248-MS 17

Additional Design Considerations

Flare Header Operating and Design Temperatures
The temperature of the gases released into the flare systems is inherently variable. In particular, and
depending on the operating state of the upstream facilities, the gas temperature at the off-take to the flare gas
recovery system may be subject to wide and sudden changes. Since, the flare gas recovery and seal system
is intended to be integrated into the existing flare system, it is expected that the seal drums are capable of
effective operation across the full range of temperature conditions while the Flare Gas Recovery Units have
to be tripped at high suction temperatures.

Table 9—Operating and Design Temperatures

Plant Operating Design (Min) (°C) Design (Max) (°C)

Temperature (°C)

Plant A 59 -46 120

Plant B 55 -20 250

Plant C 40 -20 250

Table 10—Flare Header Operating and Design Pressures

Plant CurrentOperating(barg) Design Pressure ofFlare Header Design Pressure ofFlare KO

(barg) drum(barg)

Plant A Nominally above atmospheric 8.0 8.0

Plant B Nominally above atmospheric 7.0 3.5

Plant C Nominally above atmospheric 7.0 3.5

For the design of the flare seal drum a maximum of 0.2 barg constant (static) backpressure is allowed
under normal conditions in the flare header upstream of the liquid seal.
Operation of the Flare Gas Recovery system should not cause pressures at any point in the flare headers to
exceed the design pressure. Operating conditions, including back pressure, for relief, control and blowdown
systems that are connected to the respective flare headers may be affected by the addition of the Flare Gas
Recovery System.

Flare Gas Recovery unit Battery Limit conditions

Table 11—Flare Gas Recovery unit Battery Limit conditions

Temperature (°C) Pressure bar g

Operating Design Min/Max Operating Design Min/Max

Plant A 59 -46/120 0.2 8.0

Plant B 55 -20/250 0.2 3.5

Plant C 40 -20/250 0.2 3.5

FGR Compressor Unit Operating and Design Conditions

The Operating and design conditions of the FGR Compressor Unit are as follows:
18 SPE-183248-MS

Table 12—Flare Gas Recovery Compressor Unit Operating and Design Conditions

Equipment Temperature °C Pressure bar g

Operating Design Min / Max Operating Design Min / Max

Suction KO Drum 30.5 to 59 -46/250 0.2 FV/8.0

FGR Compressor 99 to 185 -46/200 0.2 to 5.3 FV/8.0

st
1 Stage Discharge 99 to 185 -46/230 2.28 FV/8.0

2nd stage Discharge 105 to 143 -46/180 5.3 FV/8.0

Flare gas at a temperature of 63 °C or above will not be recovered as 65 °C is the maximum suction
temperature considered for the mechanical design of the Compressor.

Turndown
In order to address the wide variations in flow rate the recovery system should be capable of sustained
continuous stable operation across the full range of flowrates, 0 to 5 MMSCFD (i.e. 0 to 100% turndown)
at inlet to the Flare Gas Recovery Unit.

Validation of Simulation Results from CPIMS

Actual recovery of Flare Gas flow rate, Compressor Inlet Suction Pressure, Compressor Inlet Suction
Temperature, Compressor 2nd Stage Discharge Pressure, Compressor 2nd Stage Discharge, Temperature
and Discharge cooler Outlet Temperature on a yearly average basis for a period of three years
(2013/2014/2015) is reproduced below:

Table 13—Flare Gas Flow Rate, Refer Figures 8 to 16 for Trends from CPIMS:

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

MMscfd MMscfd MMscfd

Plant A 1.40 1.75 2.17

Plant B 1.58 1.78 1.86

Plant C 1.36 1.65 1.81

Table 14—Compressor Inlet Suction Pressure

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

bar g bar g bar g

Plant A 0.08 0.05 0.05

Plant B 0.06 0.05 0.06

Plant C 0.05 0.05 0.05

Table 15—Compressor Inlet Suction Temperature

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

°C °C °C

Plant A 36.0 33.0 32.8

Plant B 35.3 35.8 35.9

Plant C 35.6 36.2 36.5

SPE-183248-MS 19

Table 16—Compressor 2nd Stage Discharge Pressure

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

bar g bar g bar g

Plant A 4.66 4.78 5.02

Plant B 4.77 4.77 4.90

Plant C 4.90 4.74 4.87

Table 17—Compressor 2nd Stage Discharge Temperature

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

°C °C °C

Plant A 108.2 107.63 116.71

Plant B 100.58 95.60 107.00

Plant C 118.53 108.60 107.90

Table 18—Discharge cooler Outlet Temperature

Plant Year 2013-2014 Year 2014-2015 Year 2015-2016

°C °C °C

Plant A 34.3 32.3 36.5

Plant B 36.1 37.5 36.9

Plant C 32.0 33.6 34.9

Flare Gas Recovery Benefits

Total Cost benefits for a period of three years from 2013 to 2015: MM US $
(Basis: Price of fuel gas: 1.5 US $/MMBTU, HHV of fuel gas: 1000 BTU/SCF)
Plant A - 2.9
Plant B - 2.8
Plant C - 2.6
Total emissions of CO2 for a period of three years from 2013 to 2015: in KT of CO2
Basis: As per World Bank estimate, approximately 140 billion cubic meters of flare gas burnt annually
across the globe causes more than 300 million Tonnes of CO2 emitted to the atmosphere.)
Thus, 1MMscfd of flare gas burnt will emit approximately 22.14 KT of CO2/year)
Plant A - 117.8
Plant B - 115.6
Plant C - 106.7
Flare Gas recovery Units help achieve significant recovery benefits minimizing hydrocarbon gas flaring
to the environment and thereby reducing carbon footprint in line with the stringent environmental norms.

Conclusions
The key parameters behind successful design and operation of any Flare Gas Recovery System are proper
estimation of flare gas flowrates along with the consideration of a varied range of molecular weights
followed by simulation and selection of proper compressor type.
20 SPE-183248-MS

Above mentioned successful operation of Flare gas recovery system is first of its kind within Gasco.
Project demonstrates tangible and proven benefits to minimize continuous flaring with an operational track
record for over past three years on continuous basis.
Our experience has demonstrated that the methodology used offers a reliable means to recover
hydrocarbon gases over wide range of gas compositions without affecting the existing facilities. Currently
the above FGR system methodology has been adopted at other GASCO Facilities.

Acknowledgement
The authors thank GASCO Management for their support and permission to present this paper.

Nomenclature
ADNOC : Abu Dhabi National Oil Company
ADCO : Abu Dhabi Company for Onshore Oil Operations
API : American Petroleum Institute
BPRV : Buckling Pin Relief Valve
BTU/SCF : British Thermal units / standard cubic feet
EPC : Engineering, Procurement and Construction
FEED : Front End Engineering Design
FGR : Flare Gas Recovery
GASCO : Abu Dhabi Gas Industries Ltd (COMPANY / Operator)
HAZOP : Hazard Operability study
HHV : Higher Heating Value
HSEIA : Health Safety Environmental Impact Assessment
KOD : Knock Out Drum
KT : Kilo tons
MMscfd : Million standard cubic feet per day
MW : Molecular weight
MMBTU : Million BTU
PRV : Pressure Relieving Valve
PRD : Pressure Relief Device
CPIMS : Corporate Process Information Management system
PS : Process safety
SCF : Standard cubic feet
SIL : Safety Integrity Layer

Reference
1. Gasco Plant –A, B and C Process Design Basis.
2. Gasco Plant –A, B and C Process Flow Diagrams
3. Gasco Plant –A, B and C P&IDs
4. Pressure-relieving and Depressuring Systems, API STANDARD 521 SIXTH EDITION,
JANUARY 2014
5. Gasco Corporate Process Information Management system Trends