Rationalization of Flares at Terminal Island

Abstract

This study aims to assess potential opportunities for optimizing the number of flares operated by COMPANY at the Terminal Island with oil and gas processing, storage and export facilities, while considering ongoing and future developments on the island and possible integration with flare network of other downstream Company. The different flare systems cater to flaring requirements of HP, MP and LP systems in oil and gas processing plants at the island. The fundamental drivers for flare systems rationalization study are disadvantages associated with greater number of flares such as: More plot area usage for flares at expense of industrial expansion Increased HSE risks in terms of thermal radiation and dispersion of toxic gases More fuel gas consumption as purge and pilot gas Higher operational and maintenance costs In this study, existing flares at Terminal Island were studied and options were developed for each flare system with the aim of rationalizing the number of flares. These options included demolition of flares, diversion and redistribution of respective flare loads to other flares. Relocation of flares to offshore platforms / reclaimed areas in sea and replacement of elevated flare with enclosed ground flare, which has negligible thermal radiation was also considered. The rationalization options developed for each flare system were evaluated on the basis of factors such as recovered sterile area, reduction in purge gas (Hydrocarbon and Nitrogen) and pilot gas consumption, maintenance cost, operation cost, number of flares and estimated investment as CAPEX (for modification scope). The current and future flare loads were taken into account while developing these options. The flare design capacities, available capacities for accommodating additional flare loads, sterile area freed along with minimization of associated dispersion and thermal radiation effects at ground level after demolition of flares were also considered for generation of suitable rationalization options. A simplified and optimized flaring network at Terminal Island operated by COMPANY was developed by reducing the number of flares based on techno-economic screening, while safeguarding the operational and safety requirements. As concluded from the study, eight (8) nos. of flares occupying significant sterile radii can be demolished out of total fourteen (14) nos. of existing flares. The sterile area recovered (approximately 77,000 m2) as result of flares rationalization is of great value and importance for building new facilities. The land recovered can be used for future developmental projects on the island instead of opting for land reclamation. In addition, COMPANY's objectives to reduce environmental impact, associated HSE risks and thermal radiation intensity at surrounding areas / facilities will also be achieved.