Warren Kennedy

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Warren Kennedy
Senior Vice President/Marketing and Sales Director
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P: 816-822-3384
F: 816-822-3416

Flare Gas Recovery Unit

Flare Gas Recovery Unit

Location: Ponca City, Okla.

Client: ConocoPhillips

Burns & McDonnell provided detailed engineering and procurement services for the installation of a flare gas recovery unit (FGRU) in the Ponca City Refinery South Plant. The installation included John Zink modularized skids for the compressors and separator drum. The project also analyzed and modified the existing 48-inch flare header for the installation of a new seal drum.

  • Front-end project planning, stage 3 (FEP-3)
  • Detailed engineering
  • Instrument/electrical and pipe procurement

Burns & McDonnell provided FEP-3 estimates, detailed engineering and procurement support for the project. The FGRU, designed to reduce hydrocarbon losses and sulfur dioxide emissions, included the following major equipment:

  • Two 1.5 million standard cubic feet/day compressors
  • Separator drum
  • Service water cooler
  • Seal drum

John Zink skidded the compressors with the separator drum and provided this equipment and the service water cooler as an ISBL unit, which also included steel and piping. Burns & McDonnell provided ISBL foundation design and utility piping within the John Zink supply along with OSBL design and procurement. The seal drum, also supplied by John Zink, shipped separately for OSBL installation.

Burns & McDonnell evaluated stress issues in the existing flare knockout drums and header and designed improvements for the existing header system stress condition. This work included modifications to all existing supports between the knockout drum and flare.

  • Modular inside battery limits (ISBL) construction
  • Revamped outside battery limits (OSBL) integration
  • Flare header flexibility solutions