FLARE TOXIC DISPERSION

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FLARE TOXIC DISPERSION STUDY

PROJECT : ARL UPGRADATION PROJECT 2013

LOCATION : MORGAH, RAWALPINDI, PAKISTAN

COMPANY : ATTOCK REFINERFY LIMITED

A 03 Dec. 15’ Issue For Information DHK DGL JHC

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

HYUNDAI ENGINEERING
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REVISION LOG
REV. NO. REV. DATE REVISED PAGE REVISION DESCRIPTION

A 03 Dec. 15’ - Issue for Information

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TABLE OF CONTENTS

1. INTRODUCTION...................................................................................................................................... 4

2. REFERENCES......................................................................................................................................... 4

3. INPUT DATA ............................................................................................................................................ 4

3.1 Main Flare Stack (FLS-ST-101) .............................................................................................................. 4

3.2 Acid Gas Flare Stack (FLS-ST-100) ...................................................................................................... 5

3.3 Weather Conditions ............................................................................................................................... 5

4. CRITERIA FOR H2S CONCENTRATION LIMIT ..................................................................................... 6

4.1 NEQS Limit ............................................................................................................................................. 6

4.2 OSHA Limit ............................................................................................................................................. 6

4.3 Reference ................................................................................................................................................ 6

5. MODELING RESULTS ............................................................................................................................ 7

5.1 Main Flare Stack (FLS-ST-101) .............................................................................................................. 7

5.2 Acid Gas Flare Stack (FLS-ST-100) ...................................................................................................... 7

6. ATTACHMENTS ...................................................................................................................................... 7
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1. INTRODUCTION
The toxic gas dispersion modeling for main flare stack (FLS-ST-101) and acid gas flare stack (FLS-ST-
100) have been investigated for emergency flame out cases.

For the modeling, the PHAST (by DNV) has been used.

2. REFERENCES
(1) Vol-8D-5 Feed Package for Flare System_Rev-1

(2) PDS-PR-FLS-ST-101_Rev.1 Process Data Sheet for FLS-ST-101 Main Flare Stack

(3) PDS-PR-FLS-ST-100_Rev.1 Process Data Sheet for FLS-ST-100 Acid Gas Flare Stack

(4) VD-FLS-ST-101-304_Rev.0 Vendor Data for Flare Tip Assembly (FLS-ST-101)

(5) VD-FLS-ST-100-305_Rev.0 Vendor Data for Flare Tip Assembly (FLS-ST-100)

3. INPUT DATA

3.1 Main Flare Stack (FLS-ST-101)

Unit Design Case Remarks

Relieving Inventory kg/hr 657555

Toxic
mol% 0.1 Note (1)
gas composition
Stack Height m 78

Flare Tip Diameter m 1.016

Note (1) For dispersion calculation of the main flare vent 01% H2S is consider of the total flow. This is
very conservative approach as there will be very little amount of H2S in relieves gases.
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3.2 Acid Gas Flare Stack (FLS-ST-100)

Actual Case
Unit Design Case Remarks
(AMU S/D)
Relieving Inventory kg/hr 7948 4700
Toxic
mol% 16 15
gas composition
Stack Height m 78 78

Flare Tip Diameter m 0.406 0.406

3.3 Weather Conditions

Cases Worst Case (1.5/F) Typical Case (5/D) Remarks

Wind velocity 1.5 m/s 5 m/s
Pasquill Stability F (very stable) D (neutral stable)
Site Temperature 47.2 deg.C 47.2 deg.C
Humidity 75 % 75 %

The Purpose of this Test shall be to demonstrate that the Process Plants (New & Revamp) meet the
performance requirements laid-down in the relevant process guarantee agreement of licensors and on
the basis of material balance of Plant feed and corresponding output products with coordination of
licensors.

The plant shall be operated for seventy two (72) hours or as advised by the licensor continuous running
Performance Test with design capacity. The procedure agreed by COMPANY and CONTRACTOR should
be followed for the purpose of ascertaining whether CONTRACTOR met the Performance Guarantee.
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4. CRITERIA FOR H2S CONCENTRATION LIMIT

4.1 NEQS Limit

The National Environmental Quality Standards sets maximum allowable emission concentration for H2S
to 10 ppm for continuous industrial emission. For occasional or emergency release there is no clearly
defined guideline.

4.2 OSHA Limit

Occupational Safety & Health Association (OSHA) defines the time weighted average limit for emissions.
The threshold limiting value (TLV), acceptable limit for 8 hours exposure, of H2S is 10 ppm. Exposure to
H2S shall not exceed 20 ppm (ceiling) with the following exception: if no other measurable exposure
occurs during the 8 hours work shift, exposures may exceed 20 ppm, but not more than 50 ppm (peak),
for a single time period up to 10 minutes.

The emergency venting through vent stack is of course not a continuous service. If SOPs are properly
followed by the operator the venting duration should not be longer. Venting can only be prolonged if the
plant remains unattended after PSVs popping, which is not likely. Considering this H2S limit can be set to
20 or 50 ppm. (As per Vol-8D-5 Feed Package for Flare System_Rev-1)

4.3 Reference

The maximum allowable ground level concentration of H2S for facilities shall be in accordance with the
Eight Hour Time Weighted Average Threshold Limit Value (TLV-TWA) as stated by the American
Conference of Governmental Hygienists.

Level of Concentration
Averaging Time Effect
Concern ppm mg/m3

8 hours a day Repeated exposure day after day

TLV-TWA 10 14
/ 40 hour working week without adverse health effects
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5. MODELING RESULTS

5.1 Main Flare Stack (FLS-ST-101)

During the flame-out case, 10 ppm concentration of H2S in unlit gas is not reached on ground level
regardless of the weather conditions. (Refer to figure 1 and 2)

5.2 Acid Gas Flare Stack (FLS-ST-100)

During the flame-out case, 10 ppm concentration of H2S in discharge gas is not reached on ground level
regardless of the weather conditions. (Refer to figure 3 ~ 6)

6. ATTACHMENTS
Figure.1 – Main Flare (Design Case) for 1.5/F

Figure.2 – Main Flare (Design Case) for 5/D

Figure.3 – Acid Gas Flare (Design Case) for 1.5/F

Figure.4 – Acid Gas Flare (Design Case) for 5/D

Figure.5 – Acid Gas Flare (Actual Case) for 1.5/F

Figure.6 – Acid Gas Flare (Actual Case) for 5/

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<Figure.1 – Main Flare (Design Case) for 1.5/F>

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<Figure.2 – Main Flare (Design Case) for 5/D>

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<Figure.3 – Acid Gas Flare (Design Case) for 1.5/F>

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<Figure.4 – Acid Gas Flare (Design Case) for 5/D>

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<Figure.5 – Acid Gas Flare (Actual Case) for 1.5/F>

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<Figure.6 – Acid Gas Flare (Actual Case) for 5/D>