An introduction to Shell in Canada Shell Canada Novel Flare Volume Estimation Boudewijn ( Ben ) Benthem Energy Efficiency and GHG Coordinator Royal Dutch Shell - Upstream Americas Wednesday, November 4, 2009
What is Flare Estimation? Flared volume estimation is a formula/calculation used to determine and track the amount and composition of operational flaring at our upstream facilities in Alberta. This happens with a Flare Management System that is used to: Estimate and track flared volumes for internal and external use Estimate and track the composition of the flared gas Ensure regulatory flaring and reporting guidelines are met Improve awareness, leading to reduced flaring and associated emissions Identify leak sources or meter issues Help ensure operational integrity of facilities and infrastructure (e.g. identify leaking PSVs)
Presentation Overview What is Flare Estimation? History of Flare Estimation Shell s Novel Approach to Flare Estimation Shell s Flare Management System: Benefits How it works? Case Study Demonstration Questions
History of Flare Estimation at Shell In the early days, flared volumes were manually calculated by cross referencing a vendor flow profile of each type/size of pressure control valve. Flare meter discrepancies were used to calculate flare volumes. Today, the amount and composition of gas being flared is being estimated on a virtual real time basis, while the tool is also used to estimate the H2S concentration of the gas being flared.
Shell s Approach to Flare Estimation In 2000, a novel Flare Management System was developed at Shell. The system included an advanced template that estimates flared volumes from all sources for each minute, the hour, the day, the month and the year using valve/control outputs and other flare flow data (P,T, Compositions). The template is built in Excel and uses a series of formulas, readings and worksheets. The estimated flared volumes are reconciled to the ultra sonic flare meter. The system is currently used within all Shell s sour gas and in-situ operations. The tool is managed by the lead control room operator and verified by the operations coordinator.
Shell s Approach: Benefits The automated calculation and estimation process is proven to be more efficient and accurate (increased consistency, less time and resources required). Accountability with volume estimation and reporting. Confirms the correct volumes of hydrocarbons are being used in estimates. Notifies the operator of potential regulatory contraventions and/or reporting requirements. Improved awareness of flared volumes, which led to reductions in flared volumes and associated emissions.
Shell s Approach: Benefits Assists operator in mitigating potential ground level SO2 concentrations by estimating emission rates. Produces consistent, detailed reports for auditing and analyzing purposes (across all facilities). Tracks and analyzes trends that can lead to strategies for flaring and associated emission reductions (identifying leaks). Identifies the sources and causes of flaring. Ensures flaring is reported to regulators according to limit guidelines.
Shell s Approach: How it works All pressure control valves to flare in plant are identified: DATE & TIME: 12-Apr-2009 00:11 Inlet Purge FG 5313 PW Area Purge FG 5312 80.0 Sm3/d Proc Bldg Purge FG 5311 78.0 Sm3/d 88.0 Sm3/d PCV 1121-B PCV 1121-A FI-5123G Mixed Gas 0.25 % H2S Scrubber 0.0 OP 28.8 OP PCV 1141-B 40.978 Se3m3/d 354.0 kpag 224.1 kpag ORION FLARE SCHEMATIC PRODUCED GAS SEPARATOR FUEL GAS PM-2027 RUNNING PM-2028 Offline IGF Vapors 0.0 OP 11,587.4 Sm3/d 0.04 % H2S VRU VRU 5201 0.0 Sm3/d 5221 ON OFF FIT-1141 PCV 1141-A XV-5221 224.4 kpag DiILUENT RECOVERY SEPARATOR 0.64 Sm3/d 0.0 OP CLOSED LP Flare Purge FG 5220 Blanket Gas T-2000 Skim Tank 80.0 Sm3/d Sweep Gas T-2002 Slop Oil Tank 110.0 Sm3/d 60.0 Sm3/d 115.0 Sm3/d TANK FARM T-2026 De-Oil Tank 200.0 Sm3/d T-3005 T-2037 Backwash Tank 110.0 Sm3/d T-6001 Sales Oil Tank 240.0 Sm3/d Evap Feed Tk T-6002 Sales Oil Tank 240.0 Sm3/d T-6003 Sales Oil Tank 240.0 Sm3/d T-6004 Diluent Tank 200.0 Sm3/d Total: 1,420.0 Sm3/d
Shell s Approach: How it works Flow profile for each valve is established: VALVE FLOW PROFILE CALCULATION Eg: #3 SULFINOL CONTACTOR to Flare Gather Valve Data: Field Verification of: Type, Size, Rating, Model and Make. Collect LAB Data: Calculate Specific Cravity (G) Collect Process Data: Temperature (T) Upstream Pressure P1 (Setpoint) Downstream Pressure P2 (0 kpa) Find Cg and C1 from FISHER "First Vue" Program: Cg = Gas Sizing Coefficient Cv = Liquid Sizing Coefficient C1 = Cg/Cv Ratio FLOW EQUATION: Q = (520/G/T)^0.5*Cg*P1SIN((3417/C1)*(((P1-P2)/P1)^0.5)) FT3/H VALVE FLOW PROFILE
Shell s Approach: How it works Valve Data is gathered and entered in the flow equation: % OPEN Cg C1 Q=FT3/H critical flow Q= MMscfd Q= E3M3/D 10 200.00 34.00 177,718.9 99.63 90 1.000 4.27 120.78 20 374.00 32.10 332,334.4 105.53 90 1.000 7.98 225.86 30 587.00 31.90 521,605.0 106.19 90 1.000 12.52 354.49 40 970.00 31.90 861,936.8 106.19 90 1.000 20.69 585.78 50 1580.00 31.60 1,403,979.5 107.20 90 1.000 33.70 954.15 60 2520.00 31.40 2,239,258.4 107.88 90 1.000 53.74 1521.81 70 4100.00 32.60 3,643,237.8 103.91 90 1.000 87.44 2475.96 80 5890.00 34.20 5,233,822.2 99.05 90 1.000 125.61 3556.93 90 7040.00 34.10 6,255,706.0 99.34 90 1.000 150.14 4251.40 100 7580.00 33.60 6,735,547.0 100.82 90 1.000 161.65 4577.51 Updated: 16-Sep-04 12:15 FLOW EQUATION: Q= (520/G/T)^0.5 * Cg* P1SIN((3417/C1)*(((P1-P2)/P1)^0.5)) FT3/H VALVE DATA G 0.610202933 VALVE NO: PV 410 T 564.99 R 40.7 C TI400_2.PV-G3-GT SERIAL NO: CN280384 P1= 723.54 PSIA 4900 KPAG PC410.SP-G3-GT MODEL: 667ET P2= 12.48 PSIA 0 KPAG TYPE: ET Globe delta P= 711.06 SIZE: 4"
TYPES: "D" Body FISHER FIRST VUE Data FLOW COEFFICIENTS NORMAL FLOW Equal Percentage Characteristics Km Flow Body Size Port Size Ttl Travel Valve Travel, Percent at Max Coefficients Inches Inches Inches 10 20 30 40 50 60 70 80 90 100 Travel 1/4 3/4 0.07 0.115 0.164 0.224 0.315 0.45 0.641 0.921 1.28 1.66 0.76 1 3/8 3/4 0.155 0.26 0.407 0.596 0.858 1.21 1.65 2.22 3 4.03 0.71 1/2 3/4 0.273 0.436 0.631 0.911 1.3 1.84 2.57 3.65 5.08 6.51 0.71 3/4 3/4 0.483 0.775 1.25 1.97 2.89 4.13 5.87 8.16 10.9 12.3 0.85 Cv (Liquid) 1/4 3/4 0.07 0.115 0.164 0.224 0.315 0.45 0.641 0.921 1.28 1.66 0.76 3/8 3/4 0.155 0.26 0.407 0.596 0.858 1.21 1.65 2.22 3 4.03 0.71 2 1/2 3/4 0.348 0.505 0.709 0.998 1.38 1.92 2.69 3.82 5.25 6.82 0.66 3/4 3/4 0.613 0.952 1.44 2.06 2.92 4.13 5.87 8.16 11.1 14.1 0.66 1 3/4 1.2 1.68 2.44 3.53 5.05 7.28 10.5 14 18.4 23.7 0.67 1 1/4 3/4 1.32 1.76 2.5 3.66 5.42 8.25 12.7 20.6 29 34.5 0.72 1/4 3/4 2.65 4.07 5.66 7.47 9.96 14.1 20 28.8 40 51.9 0.76 1 3/8 3/4 4.9 7.61 11.9 17.5 25.1 35.4 48.4 64.9 87.9 118 0.71 1/2 3/4 8.96 14 20.2 28 40 56.4 78.7 109 147 193 0.71 3/4 3/4 14.6 24 36.3 54.2 81.1 119 172 232 304 390 0.85 Cg (Gas) 1/4 3/4 2.65 4.07 5.66 7.47 9.96 14.1 20 28.8 40 51.9 0.76 3/8 3/4 4.9 7.61 11.9 17.5 25.1 35.4 48.4 64.9 87.9 118 0.71 2 1/2 3/4 10.9 16 21.7 30.3 41.5 57.1 78.7 109 147 193 0.66 3/4 3/4 18.7 29.9 43.9 63.1 89 125 174 240 323 410 0.66 1 3/4 34.5 50.7 73 104 149 214 299 399 524 676 0.67 1 1/4 3/4 38.1 52.8 74 107 153 234 378 599 840 1050 0.72 1/4 3/4 0.1325 0.2035 0.283 0.3735 0.498 0.705 1 1.44 2 2.595 0.76 1 3/8 3/4 0.245 0.3805 0.595 0.875 1.255 1.77 2.42 3.245 4.395 5.9 0.71 1/2 3/4 0.448 0.7 1.01 1.4 2 2.82 3.935 5.45 7.35 9.65 0.71 3/4 3/4 0.73 1.2 1.815 2.71 4.055 5.95 8.6 11.6 15.2 19.5 0.85 Cg (Steam) 1/4 3/4 0.1325 0.2035 0.283 0.3735 0.498 0.705 1 1.44 2 2.595 0.76 3/8 3/4 0.245 0.3805 0.595 0.875 1.255 1.77 2.42 3.245 4.395 5.9 0.71 2 1/2 3/4 0.545 0.8 1.085 1.515 2.075 2.855 3.935 5.45 7.35 9.65 0.66 3/4 3/4 0.935 1.495 2.195 3.155 4.45 6.25 8.7 12 16.15 20.5 0.66 1 3/4 1.725 2.535 3.65 5.2 7.45 10.7 14.95 19.95 26.2 33.8 0.67 1 1/4 3/4 1.905 2.64 3.7 5.35 7.65 11.7 18.9 29.95 42 52.5 0.72 1/4 3/4 35.2 35.2 34.3 33.1 31.4 31.2 31 31.1 31.1 31.1 0.76 1 3/8 3/4 31.4 29.1 29.1 29.2 29.1 29.1 29.2 29.1 29.1 29.1 0.71 1/2 3/4 32.6 31.9 31.8 30.5 30.6 30.5 30.4 29.7 28.8 29.5 0.71 3/4 3/4 30 30.8 28.9 27.3 27.9 28.6 29.1 28.3 27.7 31.5 0.85 C1 1/4 3/4 35.2 35.2 34.3 33.1 31.4 31.2 31 31.1 31.1 31.1 0.76 3/8 3/4 31.4 29.1 29.1 29.2 29.1 29.1 29.2 29.2 29.1 29.1 0.71 2 1/2 3/4 31.1 31.5 30.4 30.2 29.9 29.6 29.1 29.1 27.8 28.1 0.66 3/4 3/4 30.3 31.2 30.3 30.4 30.3 30.1 29.5 29.5 28.9 28.9 0.66 1 3/4 28.6 30 29.7 29.3 29.3 29.2 28.3 28.3 28.3 28.3 0.67 1 1/4 3/4 28.7 29.8 29.4 29.1 28.1 28.2 29.6 29.6 28.8 30.3 0.72
Shell s Approach: How it works Valve flow profile is established: % OPEN Q in e3m3/d 0 0.00 10 120.78 20 225.86 30 354.49 40 585.78 50 954.15 60 1521.81 70 2475.96 80 3556.93 90 4251.40 100 4577.51 Q in e3m3/d 5000 4000 3000 2000 1000 0 Valve Flow Profile 0 10 20 30 40 50 60 70 80 90 100 Valve Opening
Shell s Approach: How it works After the flow data of each pressure control valve to flare is entered into the system, the flare report is generated in Excel for the minute, hour, day, month and year. Ultimately, the sum of the estimated flows are reconciled (scaled to match) to the actual ultrasonic flare flow meter reading. ESTIMATED FLARED VOLUME from VALVE OP ACID GAS RECONCILED FLARED VOLUME ULTRA SONIC FLARE METER VOLUME RECYCLE GAS ACID GAS RECYCLE GAS DILUTION GAS DILUTION GAS
FLARE REPORT SHELL CANADA LIMITED ORION COMPLEX FLARED GAS REPORT 10.0 5.0 Note: All Values are in E3M3, unless otherwise indicated! 0.0 27-Jul-2009 0.480 %H2S 0.150 %H2S LP FLARE ALL FLARING INCIDENTS REQUIRE A COMMENT Calculated HP Flare Data > HP OH's Flows (Calc) HP FLARE Total Non-Routine Flared Start Time End Time Metered Non-Routine Duration Non-Routine Duration Non-Routine Duration Prod Gas Sep Dil Rec Sep 27-Jul-09 00:00 28-Jul-09 00:00 1.35 0.43 59 min 0.15 40 min 0.59 67 min 0.24 0.02 HP FLARE LP FLARE TOTAL NR FLARED HP OH's Flows (Calc) Start Time End Time Metered Non-Routine Duration Non-Routine Duration Non-Routine Duration Prod Gas Dil Recov 27-Jul-09 00:00 27-Jul-09 05:00 0.253 0.000 0 min 0.000 0 min 0.00 0 min 0.000 0.000 27-Jul-09 05:00 27-Jul-09 17:00 0.801 0.395 44 min 0.152 40 min 0.55 52 min 0.235 0.020 27-Jul-09 17:00 28-Jul-09 00:00 0.299 0.039 15 min 0.000 0 min 0.04 15 min 0.000 0.005 2.5 Other Flr Hdr Purge + Pilot Gas HP Sources HP LP Total 0.25 0.320 0.159 0.48 Other Flr Hdr Purge Gas (Hand Helds) HP Sources HP LP Total 0.000 0.056 0.024 0.08 0.212 0.135 0.060 0.20 0.037 0.079 0.035 0.11 TIME: COMMENT Your Comment Has Been Saved To PI!!! CALCULATED FLARED VOLUMES AND DURATION Total MONTH and YEAR to Date Metered HP Flared: 34.9 585.5 e3m3 Start Time End Time TAG AREA & UNIT e3m3 Minutes 27-Jul-09 14:00 27-Jul-09 15:00 FLARING Non-Routine HP FLARED GAS (Calc ) 0.015 8 FLARING Non-Routine LP FLARED GAS (Calc) 0.056 2 LEAD OP Midnight Reagan Faith PIC-1141B Dil Recov Sep OH's 0.005 7 FLARING Other Sources 0.013 8 XV-5221 XV-5221 OPEN. 2 VRU Vap Recov System "NO FLOW". 2 AEUB Notificationn Required? : N 27-Jul-09 15:00 27-Jul-09 16:00 FLARING Non-Routine HP FLARED GAS (Calc ) 0.298 30 AEUB Notified? : N FLARING Non-Routine LP FLARED GAS (Calc) 0.096 38 PIC-1121A Prod Gas Sep OH's 0.177 30 PIC-1141B Dil Recov Sep OH's 0.014 23 05:00 17:00 00:00 FLARING Other Sources 0.163 30 FOUNTAIN Impact Reporting: 0 0 0 Y XV-5221 XV-5221 OPEN. 43 AEUB Confirmation Num.: 0 0 0 Y VRU Vap Recov System "NO FLOW". 38 27-Jul-09 16:00 27-Jul-09 17:00 FLARING Non-Routine HP FLARED GAS (Calc ) 0.082 6 OPS Coordinator Grant Zellweger PIC-1121A Prod Gas Sep OH's 0.058 3 FLARING Other Sources 0.036 6 TIME COMMENTS 27-Jul-09 17:00 27-Jul-09 18:00 FLARING Non-Routine HP FLARED GAS (Calc ) 0.039 14 27-Jul 14:00 Non-Routine HP FLARED GAS (Calc ) Plant tripped due to IGF low level PIC-1141B Dil Recov Sep OH's 0.004 20 FLARING Other Sources 0.036 14 27-Jul-09 18:00 27-Jul-09 19:00 FLARING Non-Routine HP FLARED GAS (Calc ) 0.000 1 PIC-1141B Dil Recov Sep OH's 0.001 2 FLARING Other Sources 0.000 1 CUSTOM: AEUB NON ROUTINE FLARE REPORTING TOTAL MAX RATE DURATION H2S Content E3M3 E3M3/D HOURS PERCENT 0.59 60.96 1.1 0.1 %H2S
Shell s Approach: Case Study Orion Cold Lake The Orion project is a thermal in-situ production operation located approximately 30 kilometres northwest of Cold Lake in northern Alberta. Production operation started in late 2007
Shell s Approach: Case Study In 2008, Orion started using Shell s Flare Management System for estimating and reporting flared volumes. When data was collected, the facility was able to analyze the flare sources and make corrective actions. As more data and estimates became available into the E3M3/d system, we could ORION clearly HP Flare see a decrease in flaring and 3.5associated emissions. 3.0 2.5 2.0 1.5 1.0 0.5 0.0 Jan 09 Feb 09 Mar 09 Apr 09 May 09 Jun 09 Jul 09 Aug 09 Sep 09 Oct 09 Nov 09 Dec 09
Demonstration and Questions Brief run through of template Questions