Requirement for branch connection at flare header

Branch Requirement at Flare Header

What is flare system?

In simple word, the waste gases from all the services in the process
plant are directed to flare headers made of piping that run around the
process plant carries up to the chimney to burn it before exposing to
atmosphere.

Requirement for branch:
When taking a branch from the flare system, the connection shall be at
45 degree inclined in line with flow direction of the header. The flow
direction of branch line at the point of contact on header shall be the
flow direction of the header. Reason to have an inclination at the branch
line is to disseminate the hammering effect of thrust comes from branch
cause reverse flow in the header when the branch is at 90 degree
pointing perpendicular to the axis of the header.

Recommended tapping orientation:
Preferred : Tapping on top of the header.
A general practice for all the connections made in flare system.

Accepted : Tapping from side of header
This orientation is also fairly accepted in gaseous service where
impurities at the header are quiet less. This practice is not suitable for 2-
phase medium where condensates are expected to be more in quantity
in which connection from side could cause the fluid flow from header to
the branch. It is advisable to have a healthy discussion with process
engineers to understand flow, density, condensate quantity, or other
impurities before choosing this option.

Avoid : Tapping from bottom
Reaction forces and Remedies:
Flare system is one of the critical systems to be given vital importance in
the process plant. The process lines of different temperatures and
pressures are connected with flare headers that cause serious impact on
piping which needs to be considered carefully. Basically a stress analysis
is required to balance the forces and moments acting on it. Here you
find the basic requirement to full fill the branch connection.
In process plant, all the PSV discharge lines are sent to flare header. The
discharge condition of PSV is the point at which the pressure exceeds
the maximum set pressure and exposed to discharge line which in turn
generates reaction force and that transferred to the flare header. The
force due to psv reaction force , vibration, expansion of discharge acts
at the joint that connects branch and header. Therefore, the weakest
point is the point of contact of the branch with the header. The force
acting at this point could damage the header pipe. Hence it is necessary
to provide reinforcement at the joint.

Thumb Rule for Reinforcement pad sizing:

Reinforcement area = 3 times X Diameter of the branch pipe
Pad thickness shall be same as the header pipe thickness (schedule).

Reinforcement calculation shown here gives value more than the actual
requirement. To find out actual area Refer ASME 31.3 chapter II (Design)
section 304.3.3 nomenclature for detail calculation. The calculation based
on ASME comes around twice the diameter of the branch that means it
is one time less than the above shown thumb rule . Hence it is helpful in
a large scale project to minimize the material cost.