Concept study for new flare project at Statoil Refinery Kalundborg

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Jan Bo Erichsen, Ramboll Oil & Gas

Jan Bo Erichsen

B.Sc., mechanical eng., Principal Project Manager, Denmark
T: +45 5161 7144
Jan Bo Erichsen, Ramboll Oil & Gas

Jan Bo Erichsen

B.Sc., mechanical eng., Principal Project Manager, Denmark
T: +45 5161 7144
The StatoilHydro Refinery in Kalundborg is flaring directly to the atmosphere from a certain amount of PSV’s. The purpose with the project is to collect all discharge facilities to a new common flare system, Flare-3.

Presently the old basis refinery consisting of Block 1, 2 & Visbreaker Complex is not connected to a closed flare system. Sulfurous relief sources are connected to a flare header which is routed to Flare-1. A blowdown header collects small gas relief sources and liquid relief sources and is connected to Flare-2. The blowdown header can also be routed to a vent in case of turnaround of Flare-2. However medium and large gas relief sources in Block 1, 2 & Visbreaker Complex are currently relieving to the atmosphere. Furthermore, LPG storage tanks in the offsite tank area are relieving to the atmosphere.

Due to HSE, primarily the risk of forming undetected explosive gas clouds, the StatoilHydro refinery wants to install a closed flare system for Block 1, 2 & Visbreaker Complex collecting all hydrocarbon relief sources. Furthermore, LPG storage tanks shall be relieving to the new flare system. It will no longer be allowed to use the vent during turnaround and due to noise and smoke it has been decided to demolish Flare-1.

The new flare system shall have its own dedicated flare (Flare-3). As Flare-1 will be demolished, acid gas shall be collected and sent to both Flare-2 and Flare-3.

The philosophy of the project is to reuse as much as possible of the existing blowdown header and flare header and make a new parallel header system collecting relief sources that cannot be tied-in to the existing headers for various reasons.

The scope of work has been to perform a conceptual study which will justify a cost estimate of +/- 30% of the entire project and also to assess all sort of HSE related issues in connection with the installation of the new flare system.

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