Flare System - Types, Segregation, Tips, Purge System and More

7/26/2017 Flare System: Types, Segregation, Tips, Purge System and More
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Table of contents: Flaring is de ned as a process of + 682

1. Types of Flare controlled burning of exhaust gases which
2. Segregation of Flares generates heat and noise. Flaring is a
3. Flare Knock-Out Drum common practice in oil/gas exploration, SUBSCRIBE UPDATES. IT'S FREE!
4. Flare KOD Liquid Removal production and processing operations. A
are system consists of a are stack and Your email:
5. Flare KOD sizing depends on two aspects
pipes that feed gas to the stack. The type Enter email address...
6. Liquid Seal Drum
and amount of gas or liquids in the are
7. Purge reduction seals Subscribe
stack governs the sizing & brightness of
8. Flare Purge system
the are.
9. Flare stack
10. Flare Structure There are many function & reason for Popular Recent Comments
11. Flare Tip aring, few reasons for aring are:
Piping Layout Drawings Abbreviations and
12. Ringlemann Chart
1. During well production testing after drilling Legends
13. Pilot burner is completed July 12, 2017
14. Pilot Ignition
2. For safety and during emergencies and Nozzle Orientation Drawing
15. Other Accessories July 12, 2017
maintenance
3. For managing gas during compression and Centrifugal Pump Piping Design Layout
processing July 12, 2017
4. Flaring at well sites to recover oil Tank farm: Types, Design Considerations,
Plot Plan Arrangement, Dyke Enclosure-
Part 1
July 12, 2017
7 Excel Functions You Must

Know to Work Smarter
1. Types of Flare July 12, 2017
1. Elevated Flare
2. Ground Flare
1. Enclosed Flare
2. Open Flare Or reach me on aj@piping-
engineering.com
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Elevated Flare
Enclosed Flare
Open Flare
Click to enlarge gure Typical Flare System with Elevated Flare
2. Segregation of Flares
1. Service
1. Acid gas are
2. Cold dry are
3. Warm wet are
2. Pressure
1. Atmospheric
2. Low pressure
3. High pressure
3. Flare Knock-Out Drum

1. Objective
1. Separate bulk liquid from gas
2. Limit liquid droplet size entrained with gas to the are
3. Provide adequate residence time for liquid
2. Sizing basis
1. Based on API 521
2. Separation of liquid droplet size of 300-600 microns considering the design case
for the are
3. 20-30 minutes of liquid hold-up time based on a relief case that results in
maximum liquid
4. No internals to facilitate separation
5. Many orientations / options possible, horizontal KODs most preferred
Flare KO Drum elevation
3. Flare Knock-Out Drum Elevation

1. KO drum elevation decides pipe rack elevation based on 1:500 slope of main are
header
Flare KO Drum elevation
2. KO drum elevation determined by pump NPSH requirement

3. To reduce pipe rack elevation options are
4. Reduce KOD elevation (option 1)
1. Use vertical can pump
2. Locate pump within pit
3. Locate KO drum within pit
5. Use intermediate KO drums (option 2)
>Flare KO Drum elevation arrangement (Option 1)
Flare KO Drum elevation arrangement (Option 2)
4. Flare KOD Liquid Removal

Remove liquid from are KOD after relief to avoid over ll during future relief event
1. Options
1. Draining to evaporation pond or closed drain drums
2. Liquid removal by are KOD pumps
3. Heater to be installed in KOD where freezing, pour point issues exist
4. Rate of liquid removal to consider frequency and amount of liquid release
5. High level in are KOD to be considered for plant shutdown
2. Sizing of Flare KOD
Flare KO Drum
1. LLLL shall be su ciently high to avoid any sludge deposition impacting LT nozzle
(150 mm in above gure not correct, consider 300 mm minimum for services
which are not clean).
2. LLLL shall be minimum 700-300 in case are drum electrical heaters need to be
installed.
3. LLLL Level at which pump trips.
4. LLL Level at which both pumps stops
5. HLL Level at which rst pump starts
6. HHLL Level at which second pump starts
7. HHHLL Level at which entire plant goes into pressurized trip.
5. Flare KOD sizing depends on two aspects

Liquid Hold up requirement during a major liquid or two phase release.
Su cient distance shall be available between inlet device bottom and HHHLL. It is
possible to have manually initiated depressurization even after HHHLLL. Any
possible liquid shall be accommodated above HHHLL.
Distance between HLL and HHHLL shall be designed to accommodate maximum
liquid release scenario(?). Some standards this distance is between HHLL and
HHHLL.
Residence time required for drop of liquid particles of 300-600 micron size.
Liquid particles separate
When the residence time of the vapor or gas is equal to or greater then the time
required to travel the available vertical height at the dropout velocity of the liquid
particles and
When the gas velocity is su ciently low to permit the liquid dropout to fall. This
vertical height is usually taken as the distance from the maximum liquid level.
6. Liquid Seal Drum

1. Objective
1. Prevent ashback from are tip back to are headers
2. Avoid air ingress into are system during sudden temperature changes leading to
condensation and maintain positive system pressure
2. Use
1. Used in are gas recovery systems
2. Staged aring between enclosed are and full size emergency are
3. Design speci cations

1. Water as liquid sealing uid not recommended for extremely cold releases; water-
glycol mixtures of su cient concentration used instead
Liquid Seal Drum
7. Purge reduction seals

1. Objective
1. Prevent air in ltration into are system at low ow rates
2. Reduce amount of continuous purge gas injection into are stack
2. Design options
1. Buoyancy seal (molecular / density seal)

2. Velocity seal ( uidic seal)
Purge Reduction Seal
8. Flare Purge system

1. Objective
1. Prevent air in ltration into are system at low ow rates
2. Prevent vacuum formation in are headers and system following steaming or
large relief event
2. Design speci cation

1. Continuous purge rate with velocity in stack
1. 1-5 fps : without molecular seal
2. 01 : with molecular seal
3. 02-0.04: with velocity seal
2. Approximate purge ow rate can be calculated using section 7.3.3.3 of API 521.
Purge Reduction Seal
Flare P&ID
9. Flare stack
1. Objective
1. Combustion of relief gases at elevation to minimize radiation exposure to
personnel/ equipment/ structure
2. Ensure adequate dispersion of un-burnt hydrocarbons and toxic components
Flare protection
2. Design considerations
1. Radiation: Limit radiation, either continuous and peak, on o -site properties and
persons, equipment, buildings and personnel on the installation. Applicable to
impacted area, restricted area and equipment lay-out.
2. Flammable gas: Avoid ignition of a ammable gas cloud released from a cold vent
or in case of are ame out.
3. Toxic hazards: (Mainly for H2S and SO2, but not limited to) limit the risk of a toxic
gas cloud to reach o -site population, provide means of alarm and adequate
protection to personnel present in the restricted area.
4. Noise: Limit both continuous and peak noise
5. Stack height is determined by HSE group based on permissible radiation level as
per project philosophy or API 521.
6. Taller stack will result in smaller sterile zone.
7. Locate process plant upwind of are.
10. Flare Structure

Self supported are stack
Guy wired supported are stack
Derrick supported are stack
More than one are may be supported on the same structure
Flare Stack Support
11. Flare Tip

Produce desired destruction/combustion e ciency of maximum speci ed relief gas
Establish and maintain proper ignition
Pilot gas /Pilot burners/ Ignition system
Ensure stable combustion

Windshield
Retention rings
Result in smokeless operation at normal continuous ows or at100% ows

Steam
Air (high pressure or low pressure)
High pressure water
No external medium, maintain high pressure at tip by staging
Flare Tip
Flare Tip
Flare Tip: Velocity Seal (top view)
Based on velocity of gas exit from tip, are tips are considered as sonic and subsonic
(pipe are) type. This is the term used by process designer for high pressure ares
and low pressure ares.
General stack pressure drops are as given below.
Sonic are 2 to 4 bar
Subsonic are 0.2-0.5 bar
Open Pipe are tips: These are used for combustion of gases that do not produce
smoke, gases with a low heating value, or for installations where smokeless
combustion of heavy hydrocarbons is not required. These are tips are one of the
lower capital cost options for safe disposal of waste gases. In general these kind of
ares have tips with very low pressure drop.
Open pipe are tips with steam injection: Steam injection is provided reduce the
smoke formation.
Open pipe are tip with high pressure gas injection: This will increase the
turbulence at are tip and reduce the smoke formation. Fuel gas can be generally
used as assist gas. Fuel gas injection can be either continuous or initiated
manually based on monitoring of are tip.
Air assisted are tip: When smokeless aring is desired and neither steam nor assist
gas is available, blowers can be used to inject combustion air directly into the waste
gas stream as it exits the are tip. Combustion e ciency of ared gas is increased by
installing air blower which will reduce smoke formation.
Multiple nozzle type ares: They are used where high are gas pressures are
available (1 barg and up) and where it is preferred to have some smokeless burning
capability and also lower radiation levels. These kinds of ares are used for HP are
application. They have good combustion e ciency and less chances of smoke
formation.
Coanda are tip: The Coanda e ect is a gas-adhesion principle that dramatically
enhances the combustion process, resulting in maximum destruction of waste
gases. Coanda E ect occurs when gas is passed over and adheres to a carefully
pro led, curved surface, creating a near vacuum that pulls in substantial amounts of
air. The air turbulently mixes with the gas ow, resulting in high-e ciency
combustion.
Open Pipe Flare
Multi Nozzle Flare
Coanda Flare
12. Ringlemann Chart

A series of charts, numbered 0 to 5, that simulate various smoke densities by
presenting di erent percentages of black.
Ringelmann No. 0 is clear smoke
Ringelmann No. 5 is 100 percent black.
Ringelmann No. 1 is equivalent to 20 percent black
Ringleman Chart
Ringleman Chart
13. Pilot Burner

1. Objective
1. Provide ame for reliable ignition of main are gas at all times
2. Design speci cations

1. Pilot system to comply with API 537
Minimum number of pilots Flare burner outer diameter, DN
1 (2 for toxic gas) Up to 200
2 >200 to 600
3 >600 to 1050
4 >1050 to 1500
To be agreed with purchaser >1500
2. Pilots designed to remain lit and capable of being relit at wind speeds up to 160
km/h under dry conditions
Pilot gas line
14. Pilot Ignition

1. High Energy Ignition (HEI)
1. Electrode capable of high energy or high voltage discharge near pilot tip
2. Does not require propagation of a ame front as in FFG system
3. Does not require compressed air, self aspirating pilots
4. Simple and easy to use and automate, require little training or maintenance. Re-
ignition takes few seconds
5. Shutdown of are system required for maintenance
6. Back up FFG ignition (when using HEI) may be considered for
1. Very tall ares that are di cult to access
2. Flare systems that can be o line only once in more than 3-5 years
3. O shore platforms in corrosive and salt environments
Electrical Ignition Panel
2. Flame Front Generator (FFG)

1. Ignition line from panel to are pilot lled with ammable fuel gas- air mixture
and spark introduced. Mixtures ignited and ame front travels through piping to
ignite pilot at are tip
2. FFG panel located at grade
3. Panel operated manually or automated to reignite of pilot ame out detection.
Re-ignition can take several minutes
4. Moisture accumulation can lead to corrosion, ame extinguishment Ignition lines
to be heat traced
FFG Panel
FFG System
15. Other Accessories

Flow measurement
Monitoring relief devices leaks during normal operation
Assess aring of gases due to pressure control operations
Note relief ows for assessing are system adequacy checks and potential for
are gas recovery
Non-intrusive ultrasonic ow meters with wide range and no pressure drop is
preferred
Smokeless aring : medium control

Proper steam or air control is required
By measuring gas being ared and adjusting steam rate / blower capacity
Detection smoke using infra-red analyzers
Aircraft Warning Lights

Required when are heights exceed 61m or when site is close to airport
Type and number based on regulations
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2 COMMENTS
Abhijit
August 30, 2016 at 4:37 am
Process plan should be downwind to are to avoid ammable gases getting to the
air.
Reply
YAK
October 26, 2016 at 12:49 pm
Thank you, this is really useful data for me!

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7/26/2017 Flare System: Types, Segregation, Tips, Purge System and More

to search type and hit enter

Flare System: Types, Segregation, Tips, Purge FOLLOW US ON GOOGLE+

System and More

Table of contents: Flaring is de ned as a process of + 682

7 Excel Functions You Must

Click to enlarge gure Typical Flare System with Elevated Flare

3. Flare Knock-Out Drum

Flare KO Drum elevation

3. Flare Knock-Out Drum Elevation

Flare KO Drum elevation

2. KO drum elevation determined by pump NPSH requirement

5. Use intermediate KO drums (option 2)

>Flare KO Drum elevation arrangement (Option 1)

Flare KO Drum elevation arrangement (Option 2)

4. Flare KOD Liquid Removal

2. Sizing of Flare KOD

5. Flare KOD sizing depends on two aspects

6. Liquid Seal Drum

3. Design speci cations

Liquid Seal Drum

7. Purge reduction seals

1. Buoyancy seal (molecular / density seal)

Purge Reduction Seal

8. Flare Purge system

2. Design speci cation

Purge Reduction Seal

10. Flare Structure

Flare Stack Support

11. Flare Tip

Ensure stable combustion

Result in smokeless operation at normal continuous ows or at100% ows

Flare Tip: Velocity Seal (top view)

Open Pipe Flare

Multi Nozzle Flare

12. Ringlemann Chart

13. Pilot Burner

2. Design speci cations

1 (2 for toxic gas) Up to 200

To be agreed with purchaser >1500

Pilot gas line

14. Pilot Ignition

Electrical Ignition Panel

2. Flame Front Generator (FFG)

15. Other Accessories

Smokeless aring : medium control

Aircraft Warning Lights

Share this on WhatsApp

Hazardous Area Di erent Steam Trap Piping Stress Critical

Thank you, this is really useful data for me!

Check here to Subscribe to noti cations for new

Con rm you are NOT a spammer

copyright Piping-engineering 2017 All Rights Reserved. Privacy Policy | About Us

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