Flare Minimization Plan Regulation 12-12 Flare Minimization Plan Benicia Refinery Public Information Revision #5.2 Revision date: 11/8/2010 Flare Minimization Plan November 8, 2010 Revision 5.2 Table of Contents Certification ...................................................................................................................... i Executive Summary ........................................................................................................ ii Overview ....................................................................................................................... ii Current FMP Progress ................................................................................................. v 1 Technical Data ................................................................................................... 1-1 1.1 General Refinery and Flare System Background Information ........................... 1-1 1.1.1 Refining/Refinery Overview ........................................................................ 1-1 1.1.2 Refinery Fuel Gas Production ..................................................................... 1-2 1.1.3 Refinery Flare Gas Recovery and Flare Systems ....................................... 1-4 1.2 Typical Base Load Conditions to the Flare Gas Header .................................... 1-7 1.3 Current Reasons for Flaring .............................................................................. 1-7 1.3.1 Planned and Unplanned Maintenance Activities ......................................... 1-8 1.3.2 Fuel Gas Quantity and Quality .................................................................. 1-12 1.3.3 Equipment Failure and Malfunction .......................................................... 1-13 1.4 Current Flare Minimization Procedures ........................................................... 1-14 1.4.1 Planning for Maintenance Activities that May Result in Flaring ................. 1-15 1.4.2 Flaring Event Review Program ................................................................. 1-18 1.4.3 Flare Minimization Through Reliability Improvement ................................ 1-18 1.5 Technical Data ................................................................................................. 1-19 1.6 Refinery Flare Gas Recovery System ............................................................. 1-19 1.6.1 Process Unit Liquid KO Drums and Flare Gas Header ............................. 1-23 1.6.2 Flare Gas Compressors, C-2101 A/B ....................................................... 1-24 1.6.3 Fuel Gas Unit ............................................................................................ 1-28 1.6.4 Flare Water Seal Drums, D-2105 and D-2112 .......................................... 1-32 1.6.5 Flares, South and North ............................................................................ 1-33 1.7 Acid Gas Flare System .................................................................................... 1-34 1.7.1 SGU Liquid KO Drum, D-2107 and Acid Gas Flare Line ........................... 1-34 1.7.2 Acid Gas Flare Water Seal Drum, D-2106 & Liquid Accumulator Drum, D-2108 ..................................................................................................... 1-35 1.7.3 Acid Gas Flare .......................................................................................... 1-35 Flare Minimization Plan November 8, 2010 Revision 5.2 1.8 Monitoring Equipment ...................................................................................... 1-36 1.8.1 Flare Volumetric Flow Rate Monitoring ..................................................... 1-36 1.8.2 Pilot and Purge Gas Monitoring ................................................................ 1-37 1.8.3 Pilot Monitoring ......................................................................................... 1-38 1.8.4 Flare Video Monitoring .............................................................................. 1-38 1.8.5 Flare Seal Drum Monitoring ...................................................................... 1-38 1.8.6 Flare Gas Composition Monitoring ........................................................... 1-39 1.8.7 Flare Gas Compressor Monitoring ............................................................ 1-39 2 Flaring Reductions Previously Realized ............................................................ 2-1 3 Planned Flaring Reductions............................................................................... 3-1 3.1 Management Practices that Result in Flare Minimization .................................. 3-1 3.2 Specific Improvements that Result in Flare Minimization .................................. 3-2 3.3 Flare Minimization for the Newly Planned Hydrogen Plant ................................ 3-4 3.4 Flare Minimization for the New Scrubber and New CO Furnaces ..................... 3-5 3.5 Flare Minimization for the New Alky Guard Bed Reactors ................................. 3-5 4 Prevention Measures ......................................................................................... 4-1 4.1 Prevention Measures – Maintenance Activities ................................................. 4-1 4.1.1 Background Information Regarding Maintenance Activities ........................ 4-2 4.1.2 Flaring During Major Maintenance Activities ............................................... 4-3 4.1.3 Measures Considered to Minimize or Eliminate Maintenance Flaring ........ 4-8 4.1.4 Benicia Refinery Maintenance Planning and Preparation ......................... 4-19 4.2 Prevention Measures – Fuel Gas Quantity and Quality ................................... 4-21 4.2.1 Existing Flare Gas Recovery Capacity at Benicia Refinery ....................... 4-23 4.2.2 Evaluation of Options for Additional Flare Gas Recovery, Scrubbing and Use ................................................................................................... 4-25 4.3 Prevention Measures – Equipment Failure and Malfunctions .......................... 4-32 4.3.1 Benicia Refinery Preventative Maintenance ............................................. 4-32 4.3.2 Recurrent Failure ...................................................................................... 4-33 4.4 Prevention Measures – Use of Production Cuts to Minimize Flaring ............... 4-34 Appendix A ...................................................................................................................... 1 Appendix B ...................................................................................................................... 1 Appendix C ...................................................................................................................... 1 Flare Minimization Plan November 8, 2010 Revision 5.2 Table 1-1 – Flare Gas Compressor Trip Set Points ................................................... 1-27 Table 1-2 – Flare Water Seals ................................................................................... 1-33 Table 1-3 – Flare Seal Drum Level Monitors .............................................................. 1-38 Table 1-4 – Water Seal Monitors ................................................................................ 1-38 Table 2-1 – Flaring Reductions Previously Realized .................................................... 2-1 Table 3-1 – Planned Flaring Reductions ...................................................................... 3-3 Table 4-1 – Flaring During Major Maintenance Activities – 5 Year Lookback .............. 4-5 Table 4-2 – Evaluation of Prevention Measures to Minimize or Eliminate Maintenance Flaring .......................................................................................................................... 4-9 Table 4-3 – Summary of Benicia Refinery Flare Gas Recovery System Capacity ..... 4-24 Table 4-4 – Summary of Estimated Cost for Flare Gas Recovery System Expansion4-29 Table 4-5 – Summary of Estimated Cost Effectiveness for Flare Gas Recovery System Expansion Based on NMHC Emissions ..................................................................... 4-31 Table 4-6 – Summary of Estimated Cost Effectiveness for Flare Gas Recovery System Expansion Based on Emissions of SO2, NOX, CO, and PM10 ................................... 4-32 Flare Minimization Plan November 8, 2010 Revision 5.2 Figure 0-1 – Flare Vent Gas Volume ...............................................................................vi Figure 0-2 – Flare Vent Emissions ................................................................................. vii Figure 1-1 – Benicia Refinery Simplified Operations Flow Diagram ............................. 1-4 Figure 1-2 – Flare Minimization Flowchart ................................................................. 1-17 Figure 1-3 – Flare Gas Recovery System .................................................................. 1-23 Figure 1-4 – Fuel Gas Unit ......................................................................................... 1-29 Figure 4-1 – Flare Minimization Flowchart for Maintenance ....................................... 4-22 Figure 4-2 – Typical Fuel Gas Recovery System ....................................................... 4-26 Figure 4-3 – Flare Gas Recovery System .................................................................. 4-28 Flare Minimization Plan November 8, 2010 Revision 5.2 Executive Summary Overview On July, 20, 2005, the Bay Area Air Quality Management District’s (BAAQMD)