flare.IQ

Complete plug-and-play solution tomeet RSR 63.670 compliance
Introduction

Passed by the Environmental Protection Agency (EPA)in December 2015, the Maximum Achievable Control
Technology (MACT) Petroleum Refinery Sector Rule (RSR)
Part 63.670 requires refiners to be in full complianceby January 30, 2019. The rules apply primarily to flow
measurement and burn efficiency of a flare and include
many key provisions. For specific MACT RSR 63.670 details,
refer to the EPA website, www3.epa.gov.

Ensure compliance to RSR 63.670

Given the potential complexities, complications andoverwhelming risks associated with developing an allencompassing flare system solution, operators caneliminate this burden by partnering with Baker Hughes.

SOSSteam

NHV

flare.IQ
FuelGasIncrease efficiency of the complete
flare systemflare.IQ is pre-programmed with all required algorithms
necessary to address the most difficult aspects of properflare control. Baker Hughes’s patent pending SmartSteamcontrol algorithm may be customized to the uniquefingerprint of each flare system. The program utilizes
surrogate modeling to draw correlations between flare flow
conditions and the required steam input to operate with novisible emissions.
Combining our domain knowledge and proven trackrecord in flare gas flow measurement with our world-classcontrols expertise, the flare.IQ is a complete plug-and-playsolution to meet RSR 63.670 compliance. Fully equippedwith the software algorithms required, there is no need foradditional long-term development work. Our softwarebased solution is housed in a convenient Windows® basedindustrial controller that easily and seamlessly interfaces
with your existing DCS. With flare.IQ, the flare system can becontrolled to operate within the requirements of RSR 63.670
and comes backed with a letter of compliance with Baker
Hughes signatory.

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flare.IQ also employs patented technology to address BTU
measurement latency resulting from gas chromatograph(GC) technology. The BTU readings of the flare flow system
obtained by the gas chromatograph are a critical input
to achieve the required destruction efficiency in theflare combustion zone. flare.IQ utilizes sound speed tohelp bridge the GC’s infrequent BTU readings with nearcontinuous feedback, improving operator control of theentire flare system.

The BTU measurement is typically updated every 15 minutes
based on the latency inherent in the gas chromatographsampling. flare.IQ includes a tuning algorithm that provides
course adjustments to the make-up/supplemental gas andsteam flow which allows the flare to operate within a tighter
control window between the 15-minute updates from thegas chromatograph, as illustrated schematically in thefigure on the right. This better optimizes the use of make-up
gas and steam to maintain the proper BTU level in the flare
combustion zone. When the GC updates, flare.IQ’s tuningalgorithm learns and adjusts its control set-point values.
As seen in the chart below, flare.IQ (green line) provides anaccurate estimation of net heating value (NHV) comparedto the on-line analyzer (red line). flare.IQ even serves as a
back-up when the on-line analyzer is off-line for calibrationor maintenance as seen between the 1000-minute and1500-minute interval. Once the on-line analyzer is returned
to service, it can be seen that the heating value estimate
from flare.IQ is in agreement with the real time data fromthe on-line analyzer.

1200
1100

2500

Reported NHVNHVcz BTU/SCF

1000

004812162024700
600
500
4003002001000500

1000

1500

Time (min)

2000

2500

HHV, Mass Spectromer HHV, FlareIQ

Reduce cost, time, and risk

Baker Hughes’s patent-pending process optimization
algorithms which provide near-continuous feedback onflare performance will help drive down operational costwith reduced steam and supplemental gas consumption.
Employing Baker Hughes’s patent-pending algorithms
will also reduce the need for further capital investment inmeasurement assets such as calorimeters or hydrogen
analyzers (if a gas chromatograph is being used for BTU
measurement).
flare.IQ helps the control engineer better manage theschedule and implementation risk to meet the January
30, 2019. With all the algorithms to control the entire flaresystem, flare.IQ allows the control engineer to focus on
optimizing the control of the process by removing theneed to spend valuable time and money implementing
the regulatory requirements in the programming. flare.
IQ provides a synergistic approach to deploy a system orenterprise-wide solution for flare control.

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Copyright 2020. Baker Hughes Company. This material contains oneor more registered trademark of Baker Hughes Company and its
subsidiaries in one or more countries. All third-party product andcompany names are trademarks of their respective holders.

BHA32856

3236404448

525660Blue = Under-steamed condition, potentially resulting in asmoking flare or consumption of excess supplemental gas.
Green = Potential over-steam condition. The flare.IQ
controller reduces or eliminates these control gaps so that theflare operates and responds to NHV changes in real time.

Detailed Hardware SpecificationsProcessorInstallation••

19” rack mountable•

Operating TemperatureIntel 1.66 GHz 64 bit

Memory800

28Time in Minutes

embedded processor

900

BTU/SCF

1500

500

1000

0Calculated NHV

2000

•

DDR2 667/800 MHz 1GB•

2 GB Flash MemoryConnectivity•

1 GBps redundant UDH
connections (Ethernet)•

0°C to + 60°C•(extended temperaturevariants on request)

LED Indicators•

Diagnostic Display

Power

1 GBps redundant IOnet•connections (Ethernet)

Otherfor Modbus TCP/IP•

Redundant 24v DC Input

QNX real-time operatingsystem