Let's Talk Flare – Centralized Flare Control and Management for Upstream Facilities. Flaring Diagnostic Tool by Deploying Mathematical Model
Authors: Ahmed S. M. , Al Ketbi A. , Al Katheiri G. , Aslam M. , Haider F. , Alhammadi Y. , Ahmed M. S. , Amir M. 
Published: September 2024

This paper presents full-scale deployment of flaring minimizing approach in one the largest Oil Producing Field. With comprehensive detailing of all significant steps involved right from the selection of mode of monitoring, pilot to full scale deployment. This paper also penlights challenges encountered during the course and states how challenges realized into to opportunities and contributed in minimizing flaring in process facilities to protect the environment with Zero flaring mindset aiming reduction in GHG emissions.

The detailed process right from selection of flaring contributing zones / equipment and philosophy of full-scale deployment was executed to establish the way forward. Identifying all flare sources, their characteristics and process parameters to quantify flaring volume.Traffic light system created in Decision model tool in PI Process Book for initiating alerts.Developed different process loops contributing to flare in single dashboard like PCVs / PSVs.Linking real time values and Trends in PI Process Book to visualize daily, weekly and monthly flaring performance.Developed VMB (Visual Management Board) for visibility and effective communication among action parties for timely remedies.

The flare network is complex with several sources and first step in flare reduction was the identification and quantification of the source instantly. The potential flaring sources were evaluated to develop the mathematical model. The developed model resulted in achieving following key benefits. real time monitoring of flaring sources of the plant on single dashboard. Quick identification of flaring source with the activation of alert flash.20% reduction in flaring achieved due to this proactive approach, equivalent to 1050 metric ton / Year.Control room operators can easily identify the PCVs contributing to flaring, further can pin-point the area causing of high flaring.PCV opening outputs are configured in the graphics/sheet to know when the valve gets open.It can further help in investigating the cause of high flaring pinpointing particular PCV.Visual Management boards fixed in stations and can also be displayed on visual screens for effective follow-up on remedial actions. VBM reflects the Facility Flare limit, Daily Flaring, Weekly and Monthly Flare trend, Status of actions with action parties.The results from this tool used in regular site Operation meetings for effective and timely follow up.

This paper demonstrates the benefits of deploying mathematical model to monitor and effectively control of flaring. It reflects how the system can be monitored from a single dashboard and source of flaring can be identified in quick time. The paper will also present the way to develop model, approach and follow ups on flaring diagnostics. The paper will highlight the lessons learned and the best practices for future replication by other Oil and Gas Producers.

The flaring diagnostic tool was developed with the intention of proactive identification and action on the flaring sources. It's kind of centralized dashboard capturing all flaring sources in one page or graphics. The VMB concept was utilized for the management of flaring main sources. Moreover, the dashboard is encapsulated with alerts through deploying Mathematical decision model and configured with the email notification.