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Top Tips for Using Aspen Flare System Analyzer

We recently hosted a webinar highlighting our top six tips for using Aspen Flare System Analyzer™. Those tips are part of a series to help you get the most out of your process safety tools. Here’s a brief summary of ways to work more efficiently with Aspen Flare System Analyzer.


1.       Expedite model creation by splitting the work.

Did you know that you can use Flare System Analyzer’s import/export tool to build a flare network across multiple people – even multiple companies? Divide an isometric among your team and have each person create their portion of the flare system independently. Once everyone has completed their own section, export each file to *.xml, *.mdb or *.xls. Then, create a master file and import each case into the master. Connect the individual contributions and begin using the new flare system.

2.       Import your source streams, PSVs, and scenarios from Aspen HYSYS® or Aspen Plus®.

On your master flare choose File Menu > Import Sources > Select Source. This can expedite creating compositions of streams entering the file – especially when there are hypothetical components. It also speeds up PSV sources definition and scenarios.

3.       Customize pipe classes.

Customizing your pipe class options will help reduce the time it takes to input new pipes and ensure consistency across users and companies. With fewer alternatives to evaluate, this also expedites design and debottlenecking runs. Use your flare header and sub-header pipe specifications to select the appropriate schedule for pipe in your flare. Customize the schedules depending on the type of steel. Select the “Customize” ribbon and then the “Pipe Classes” icon; choose each schedule, select “OK” and you’re ready.

4.       Use summary input, result forms and printing.

Review piping and other data entry more quickly and easily by customizing the information shown on the flow sheet using the “Manage Labels” button under “File Preferences.” Export the flare information to Excel to complete more detailed analysis or create custom reports. Use the Format Flowsheet Ribbon to print or copy the flowsheet or create specific flowsheet views for easier navigation.

5.       Create imaginary PSV pre-expansion pipes.

Flare System Analyzer requires a piece of pipe after every source, even if the expansion is attached to the PSV as installed. To resolve this issue, add a piece of pipe that has a very short or “0” length. Sometimes, this “ghost pipe” will show a choke error – you can ignore this error.

6.       Monitor flare convergence using “Model Check.”

Most cases — about 95 percent of well-defined flowsheets — will converge. Use the “Model Check” form to catch minor issues and check inputs. If that doesn’t work, there are a few other ways to try to converge:

  • For looped cases, reduce the inner loop pressure tolerance to improve outer loop Jacobian
  • Use damping factors less than 1.0.


We hope these tips will improve your use of Flare System Analyzer. If you’d like to review in more detail, check out the recording of our webinar, Top Flare Tips: Best Practices for Aspen Flare System Analyzer.


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