The weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating from the on-site findings of the flare system to the simulation and the weak-point analysis to the point of the planning and implementation of appropriate plant-specific adaptations. The calculation of the process data for gas and vapour pipe systems for smaller plants does generally not bring about significant problems if only one relevant source blowing-off has to be considered. If, however, for large plants like, e.g. crude-oil-processing plants or chemical installations several sources blowing-off have to be taken simultaneously into consideration, the complexity of the simulation alone will generate substantial challenges. The weyer-group disposes of an extensive treasure trove of experience in deploying self-developed as well as commercial simulation tools for the calculation and simulation of flare systems and the identification of weak points in gas and vapour pipe systems. Besides analyzing the existing system, the connection of new plant components to the system and addition to capacity can be checked with regard to the expected results as well. In doing so, the process and safety-related maintenance of your flare system will be an easy task. The deployment of the simulation has been tried and tested in many cases and it stands out by a high degree of flexibility in terms of application in quite a lot of different areas.

1. FLARE SYSTEMS
weyer groupweyer special | simulation of flare systems
allround. smart.
www.weyer-group.com

2. Each piece of equipment which is embed-
ded in the flare system will be integrated
into a classification system. Thus, it will
be easy to methodically and swiftly orient
yourself within complex systems.
The objective is to display the entire iso-
metric drawing of the flare gas network
within a nodular system. The following
terms are defined as nodes:
• Sources (emergency valves/burst
discs)
• Junction of two pipes
• Cross-sectional variations within pipe
systems
• Pressure variations, e.g. by means of
a dip pipe or flow rate controllers
The weyer-group will solve this problem be means of engineering methods tailored to your particular needs: Emanating from
the on-site findings of the flare system to the simulation and the weak-point analysis to the point of the planning and imple-
mentation of appropriate plant-specific adaptations. The calculation of the process data for gas and vapour pipe systems for
smaller plants does generally not bring about significant problems if only one relevant source blowing-off has to be consid-
ered. If, however, for large plants like, e.g. crude-oil-processing plants or chemical installations several sources blowing-off
have to be taken simultaneously into consideration, the complexity of the simulation alone will generate substantial chal-
lenges. The weyer-group disposes of an extensive treasure trove of experience in deploying self-developed as well as com-
mercial simulation tools for the calculation and simulation of flare systems and the identification of weak points in gas and
vapour pipe systems. Besides analyzing the existing system, the connection of new plant components to the system and ad-
dition to capacity can be checked with regard to the expected results as well. In doing so, the process and safety-related
maintenance of your flare system will be an easy task. The deployment of the simulation has been tried and tested in many
cases and it stands out by a high degree of flexibility in terms of application in quite a lot of different areas.
What we offer:
À On-site analysis of your
flare system
À Determination of the
flow rates to be relieved
À Simulation of the flare
system
À Identification of bottle-
necks
À Engineering for the eli-
mination of bottlenecks
1 On-site analysis of your
flare system
The computerized simulation of the flare
system requires the elaboration of the net-
work topology of all sources embedded in
the flare system.
If isometric drawings are available, the
current as-built status will be investigated
on-site. If no significant differences be-
tween the isometric drawings and the ac-
tual pipe run are to be found, the network
topology will be displayed on the basis of
the isometric drawings.
If no isometric drawings are available, the
network topology will be determined on-
site by means of recording the pipeline
system and the built-in components.
Is your flare system approaching its capacity limit?
weyer special | simulation of flare systems | page 2
weyer special | simulation of flare systems

3. 2 Determination of the
flow rates to be relieved
In order to perform the process calculation
of the flare system, the so-called design or
blow-off cases, with regard to the corre-
sponding volume supplied, will be estab-
lished after consult-ing the plant operator.
Typical design cases are:
• Fire
• Operating errors
• Regional power breakdown
• Breakdown of the process control
system
• Malfunction within the cooling system
Furthermore, it will be necessary to estab-
lish concurrences for the individual plants
and plant components respectively.
The simulation can be executed after the
determination of the process data:
• Blow-off pressures
• Operating temperatures
• Molecular weight
• Mass flow rates
3 Simulation of the flare
system
The above mentioned specifications will
put the simulation program in the position
to perform the calculation of the required
procedural parameters for all nodes, like:
• Flow velocity
• Velocity of sound and critical velocity
ratio
• Absolute pressure
• Resistence factors (zeta-value)
• Temperature
• Mass and volume flow rate
• Molecular weight
• Density
Based on the results, an analytical evalua-
tion of the complete system and possible
weak points will be carried out.
Simultaneously, possible connections of
new plant components or additions to
capacity can be examined with respect to
their impacts on the overall system.
weyer special | simulation of flare systems | page 3
weyer group
allround. smart.
4 Identification of bottle-
necks
The simulation program considers in a flare
system the activation of individual safety
valves. In doing so, both real blowing-off
events can be reconstructed or simulated
and statistical mounds of data to gain an
overall picture of the network with regard
to bottlenecks can be drawn up.
5 Elimination of bottlenecks
The bottlenecks indicated by the program
will now be observed more closely. Gener-
ally, bottlenecks come into being due to:
• Inadequately dimensioned emer-
gency valves
• Insufficiently sized pipelines
• Increase in flow rate due to the con-
nection of new plant components
The elimination of such weak spots entails
virtually always an intervention into the ex-
isting technical installations and demands
a great deal of the engineering and the
implementation of the envisaged meas-
ures. In the course of the past 30 years,
the weyer-group has been collecting ex-
tensive expert knowledge in the most var-
ied areas of plant layout. We will make use
of this treasure trove of experience to your
benefit when it comes to the planning of
technically and commercially optimized
solutions with regard to the elimination of
bottlenecks. The concepts concerning the
plant-specific adaptation will be support-
ed by our team of experienced engineers
in the following areas of expertise:
• § 29a BlmSchG (Law Concerning the
Protection against Harmful Effects
on the Environment through Air Pol-
lution, Noise, Vibrations and Similar
Factors), dealing with safety-related
inspections
• VAwS (Ordinance on installations han-
dling materials hazardous to water),
dealing with the prevention of water
pollution
• Authorized personnel in conformity
with BetrSichV (Regulations of Occupa-
tional Safety) for pressure equipment
• Approval procedure referring to envi-
ronmental protection
• Determination and accounting of
building costs
Your benefits:
À Integrated documentation
À Modular flare model
À Capacity optimization of the flare
system
À Verification of the flare capacity in
case of plant extension

4. weyer group
allround. smart.
Your contact
www.weyer-group.com
www.weyer-group.com
References:
À Boehringer Ingelheim Pharma GmbH &
Co.KG, DE - Ingelheim/Rhein
À DHC Solvent Chemie GmbH,
DE - Mülheim a. d. Ruhr
À H&R Ölwerke Schindler GmbH,
DE - Hamburg
À PCK Raffinerie GmbH, DE - Schwedt
À Sekundärrohstoff Verwertungszentrum
GmbH (SVZ), DE - Schwarze Pumpe
À Shell Deutschland Oil GmbH, Rheinland
Raffinerie Werk DE - Wesseling
À TOTAL Raffinerie Mitteldeutschland GmbH,
DE - Leuna
À Wilhelmshavener Raffineriegesellschaft mbH,
DE - Wilhelmshaven
Image source: © Matthias Krüttgen | © christian42 - Fotolia.com 05/2013
The weyer group is a group-independent corporate association of engineering and con-
sulting companies in Germany, Austria, Switzerland, Poland and the Netherlands.
Since its establishment over 30 years ago, the weyer group has developed a wide range of
expertise which has always been based on the expectations and wishes of our clients.