CyboSoft Releases Flare Control System Design Guide to
Help Refineries Comply with EPA RSR-63.670 Rules

May 18, 2017 – CyboSoft (Rancho Cordova, California), the developer of Model-Free Adaptive (MFA) control technology and products, announced today that it has released a Flare Control System Design Guide to help refineries and petrochemical plants meet EPA regulations on flare operations.

CyboSoft CEO Dr. George Cheng said, “The deadline for refinery flare operators to comply with the new EPA refining sector rules (RSR) is approaching. CyboSoft, along with 5 leading companies in different products and services, recently conducted a 3-day Flare Solution Workshop in Houston, Beaumont, and New Orleans. We see an urgent need for people to understand the challenges to comply with these rules. We believe this Flare Control System Design Guide can be valuable.”

The Design Guide includes the following: (1) EPA rules and enforcement actions, (2) Key limits and formulas, (3) Challenges for compliance, (4) Review of control methods, (5) Vent gas heating value and combustion zone heating value control, (6) Assisted steam control, (7) Assisted air control, (8) Net heating value dilution parameter control, (9) Technical approaches, and (10) Recommendations.

As an example, the following diagram shows CyboSoft’s design of controlling a steam assisted flare: (1) An MFA Vent Gas Heating Value Control System controls the NHVvg and can deal with large vent gas flow disturbances and Btu changes caused by nitrogen purge; (2) The MFA Steam Control System controls the steam flow based on the total amount of vent gas and its contained heating value; and (3) The MFA Combustion Zone Heating Value Control System uses an Anti-delay MFA controller to deal with large and varying time delays.

The Design Guide also emphasizes the importance of having an effective technical approach: (1) Develop a general purpose solution capable of dealing with different flares for easier implementation and maintenance; (2) Have a systematic approach to address various challenges; (3) Use standard platforms and products such as DCS, OPC, Modbus, and CyboCon MFA control software; (4) Install online heating value sensors, and (5) Take advantage of available products and services. The Design Guide is in an easy to understand format with graphics, drawings, control trends, comparison tables, etc. It is useful for environmental and control engineers to design flare processes and control systems to meet RSR rules, and can be downloaded from CyboSoft’s website at www.cybosoft.com.