Near zero flaring with HIPPS

Near zero flaring can be achieved in several ways depending on plant-layout and gas processing possibilities.

Since flares play a critical role as safety device in the different hydrocarbon facilities it is not a simple exchange of application when looking for alternatives. If Flare Gas Recovery (FGR) is at stake a HIPPS can be a good/possible alternative safety system making the flare an assist system.

On your way to net-zero a HIPPS is often an important part of systems to reduce flaring. The obvious one being the standard HIPPS is not to open a relief to flare but shut-down the source of overpressure. Alternatively Mokveld can offer a Fail Open HIPPS as part of an FGR system.

The aim to achieve zero routine flaring by 2030 is initiated with the Global Gas Flaring Reduction Partnership (GGFRP) of the Worldbank, supported by the UN’s Climate Initiatives Platform. If all the gas that was flared in 2019 was converted to electricity, it would be enough electricity for the entire African continent. The Global Warming Potential of this amount of gas is immense.

Mokveld HIPPS can be part of the solution to achieve your net-zero goals. In many countries worldwide legislation requires near zero flaring, for instance Rule 32 of the RRC in Texas but also the EU prepares regulations to reduce flare emissions.

The industry (like IOGP, OGCI, Methane Guiding Principles) is looking at several options to achieve the net-zero sustainability goals.

Flare Gas Recovery with a fail open HIPPS
With Flare Gas Recovery (FGR) the flare gas is recompressed. This gas could be brought back into the process, or even in trucks for further usage elsewhere. Normally flow to the flare is blocked. All equipment upstream of the booster compressor is designed at low pressure. In case of increased flow to the flare header, the flow shall be directed to the flare while the booster capacity is too low. A High Integrity Pressure Protection System (HIPPS) senses the increasing pressure and opens the fast opening valve to avoid over-pressure in the upstream process. The flow to the flare is opened and the flare can be ignited.

Figure 1. Flare Gas Recovery

Bubble tight shut-off is required to avoid fugitive emissions to the flare and atmosphere. Mokveld’s patented sealing system assures this bubble tightness over the lifetime of the valve, even if solids (e.g. rust particles from the pipes) are present in the flow.

Third party certified failure data for fail open applications are available confirming suitability to achieve a SIL3 protection level using Mokveld axial flow HIPPS valves complete with actuators. These data apply to complete final elements opening in less than 2 seconds.

Near zero flaring with fail close HIPPS
In cases where regular flaring occurs due to limited production capacity downstream, HIPPS are a safe and very cost effective solution. For indstance, the addition of extra wells to separators may result in regular unwanted flaring (figure 2.). HIPPS then close the source of the over-pressure rather than to open a relief valve to a flare system and as such reduce emissions by flaring (figure 3).

Figure 2

Figure 3

Third party certified failure data are available confirming suitability to achieve a SIL3 protection level using Mokveld axial flow HIPPS valves complete with actuators. These data apply to complete final elements closing in less than 2 seconds.

In case of more interest or a request for Mokveld assistance in designing the full system to achieve zero routine flaring, click on the ‘Contact Mokveld’ button below the engineering assistance information text.

Mokveld engineering assistance

Mokveld FS Engineers can provide support in an early phase of the project. We can assist in defining suitable HIPPS architecture, fault tree analysis, determining the pressure rise in the protected volume and the required stroking times and set points of the entire system.

Contact Mokveld