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Flaring, Venting, and

Purging
Handbook

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CONTENTS
Introduction..............................................................................................3
General Considerations...........................................................................4
Waste Gas Handling Considerations............................................................4
Waste Gas Removal....................................................................................4
Challenge Questions..................................................................................7
Venting........................................................................................................8
Conditions That Require Venting..................................................................8
Filling a Tank.........................................................................................8
Draining a Tank.....................................................................................9
Steam Cleaning a Tank........................................................................ 10
Types of Vents.......................................................................................... 10
Safe Work Practices.................................................................................. 13
Challenge Questions................................................................................ 14
Purging..................................................................................................... 15
Materials Used for Purging........................................................................ 15
Purging Methods...................................................................................... 16
Continuous Purge Method................................................................... 16
Fixed Volume Purge Method................................................................ 16
Inerting.................................................................................................... 17
Safety...................................................................................................... 18
Operator Responsibilities......................................................................... 19
Challenge Questions................................................................................ 21
Flare System............................................................................................. 22
Safety Considerations............................................................................... 22
Components and Operation...................................................................... 22
Challenge Questions................................................................................ 26
Flare Operations, Part 1......................................................................... 27
Startup Preparations................................................................................ 27
Startup.................................................................................................... 28
Control Room Operator Responsibilities.................................................... 30
Challenge Questions................................................................................ 31
Flare Operations, Part 2......................................................................... 32
Outside Operator Responsibilities............................................................. 32
Abnormal Conditions................................................................................ 33
Loss of Flare Stack Gas Purge............................................................... 33
Loss of Pilot Flames............................................................................. 34
Abnormal Steam Flow.......................................................................... 34
Abnormal Water Seal Level.................................................................. 34
Flare Shutdown........................................................................................ 35
Challenge Questions................................................................................ 36
ANSWERS to CHALLENGE QUESTIONS.......................................................... 37
GLOSSARY................................................................................................... 40

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Introduction
Industrial process operations produce many different types of useful products. In
many cases, however, these operations also produce waste materials that must either
be recovered for reuse or safely discarded. Although waste materials may be solids,
liquids, or gases, this course focuses on waste gases. Specific attention is directed to
how waste gases are removed from process systems and safely disposed of.

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General Considerations
This section describes some general considerations for handling waste gases and
uses an example to show how a relief and flaring system can remove waste gas.

Objectives
Describe some considerations for handling waste gases.
Explain how a relief system can remove waste gas.

Waste Gas Handling Considerations

Waste gases are formed during certain types of process operations. For example,
they are often formed when materials are heated during processing. In some processes, reactions occur that give off heat and gases as by-products. The evaporation
of liquids also produces gases or vapors.
The main consideration that makes it important to handle waste gases properly is
safety. When waste gases are formed in vessels and equipment, the gases increase
the pressure inside the vessels and equipment. If the gases are not removed, the pressure can exceed the pressure rating for the vessel or piece of equipment. The result of
the overpressurization can be personal injuries, equipment damage, and, in extreme
cases, explosions and fires.
Another consideration is health protection. Although waste gases must be removed
from equipment, gases that are potentially hazardous cannot be simply released to the
atmosphere. The release of potential pollutants can cause health problems for plant
workers and for people in surrounding communities. In many cases, it is a violation of
clean air regulations to release certain types and amounts of gases or vapors to the atmosphere. Violations of federal, state, or local clean air regulations can result in fines,
plant closings, and imprisonment for some personnel.
A third consideration is cost. Since waste gases cost companies money, companies
have procedures and work practices that must be followed to minimize the creation of
waste gases. When waste gases are generated, as much as possible is recovered and
ultimately reused in processes to reduce costs.

Waste Gas Removal

Waste gases are generally removed from vessels and equipment by releasing them
through openings, or vents. This process is called venting.
In some cases, hazardous gases and other materials are removed from vessels and
equipment through vents by purging. Purging is the removal of hazardous materials
from piping and equipment with a gas or vapor to prevent the formation of explosive
mixtures.

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The basic purpose of venting is to release waste gases and purge gases, which
collectively can be called relief gases. The vents through which these gases are released are typically pipes located on top of equipment. Some vents discharge to the
atmosphere, but this is done only when the gas is relatively harmless and does not
contribute to pollution. When hazardous gases are involved, vents usually discharge
into piping.
Vents and the piping they discharge into are part of what is called a relief system.
For the purposes of this training unit, a relief system is considered to be a collection
of vessels, piping, and equipment designed to handle, recover, or dispose of gases
released from process equipment. For other applications, relief systems may also be
designed to handle liquids.
Figure 1 is an illustration of a relief system. The example system includes the vents
and piping from a units vessels and equipment, a relief header, a knockout drum with
a pump, a vapor recovery unit, and a flare.
Figure 1. Relief System

Gas that is released through the vents flows through the piping to the relief header.
The relief header is the main pipeline to the rest of the system. Its primary purpose is
to collect gases and vapors from the vents of vessels and equipment. A relief system
may include more than one header.
From the header, the waste gas flows to the knockout drum, where any liquid entrained in the gas is removed. The knockout drum represented in Figure 2 contains a
gas inlet, baffles, a liquid outlet line, a pump, and a gas outlet.

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Figure 2. Knockout Drum

Gas that enters the knockout drum strikes the baffles and changes direction. Any liquid contained in the gas is knocked out by the baffles. The pump is used to maintain a
certain level in the drum by removing liquid when necessary. In some cases, the liquid
is oily water. When the liquid is removed, it is sent elsewhere so that the oil and water
can be separated for reuse.
The waste gas flows out of the knockout drum and on to the vapor recovery unit. The
purpose of the vapor recovery unit is to recover relief gases that would otherwise be
wasted. The vapor recovery unit includes another knockout drum that removes any liquid remaining in the gas. The gas flows next to compressors, where it is compressed,
and it is then sent on for storage or reuse.
Any portion of the waste gas that exceeds the handling capacity of the vapor recovery
unit is sent to the flare Figure 3. When the flare is operated properly, it safely disposes
of combustible gases by burning them. All that remains after combustion are harmless
amounts of carbon dioxide and water vapor. If a flare is not operated properly or if a malfunction occurs, smoke, odorous gases, and excessive light and noise may be generated.
Figure 3. Flare

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Flares are generally used to handle waste gases resulting from unusual conditions
such as unit upsets or unscheduled shutdowns. During such times, more waste gas is
relieved than the vapor recovery unit can handle.

General ConsiderationsChallenge Questions

1. Name three considerations associated with handling waste gases.
2. ____________ is the removal of hazardous materials from piping and equipment with a gas or vapor to prevent the formation of explosive mixtures.
3. The basic purpose of venting is to:
a. Eliminate pollution
b. Increase plant efficiency
c. Release waste gases and purge gases
d. All of the above
4. Hazardous gases created during process operations are usually discharged
into a relief system.
a. True
b. False
5. Waste gases that exceed the handling capacity of a relief systems vapor
recovery unit are generally sent to a:
a. Knockout drum
b. Flare
c. Secondary relief system
d. Holding tank
Please refer to the end of the handbook for answers.

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Venting
Venting helps to prevent damage to equipment and vessels from overpressurization
or other hazards. This section describes some of the conditions that require venting,
identifies several types of vents, and describes safe work practices associated with
venting.

Objectives
Describe conditions that require venting.
Describe various types of vents.
Describe work practices that help ensure the safe venting of equipment and vessels.

Conditions That Require Venting

Several routine tasks associated with vessels and equipment require the vessels
and equipment to be vented. These tasks include filling, draining, and steam cleaning.
Venting is also necessary when conditions such as high fluid levels and excessive temperatures result in equipment or system upsets that may involve excessive pressures.
Filling a Tank
The tank represented in Figure 4 has a pump on the feed inlet and a pump on the liquid outlet. The tank also has a vent on top, which is closed. Although the tank is empty
of liquid, it contains air, because it was recently open to the atmosphere.
Figure 4. Empty Tank With Vent Closed

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When liquid is pumped into the tank, the air in the tank is displaced to make room
for the liquid. Without venting, as the level of the liquid rises, the air is compressed
at the top of the tank (Figure 5). Eventually, the compressed air will prevent liquid
from completely filling the tank. It also increases the pressure in the tank. In extreme
situations, the pressure could increase so much that the tank could be damaged from
overpressurization.
Figure 5. Tank FillingVent Closed

If the vent is open during filling (Figure 6), overpressurization does not occur. When
liquid is pumped into the tank, the displaced air is forced out of the vent. The open vent
helps equalize the pressure inside the tank with the pressure outside the tank.
Figure 6. Tank FillingVent Open

Draining a Tank
Equalizing pressure is also important when a tank is drained. If the vent is closed
(Figure 7) as the pump removes liquid from the tank, a vacuum is pulled above the liquid. This occurs because air cannot enter through the vent to equalize the pressure. If
the tank is not rated to withstand a vacuum, it could eventually collapse.

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Figure 7. Tank DrainingVent Closed

Steam Cleaning a Tank

Without venting, a tank or other vessel may collapse after it has been steam cleaned.
For example, to steam clean a distillation column Figure 8, steam is sent into the column until a certain pressure is reached. After the steam supply is shut off, the vessel
begins to cool, and the steam condenses, which causes the pressure to drop inside
the column. As the column becomes cooler, and more condensate forms, the pressure
can drop below atmospheric pressure, creating a vacuum. To prevent the creation of a
vacuum that could collapse the column, vents are normally opened after the steaming
is complete.
Figure 8. Distillation Column After Steaming

Types of Vents
One simple method of venting is through an open pipe connected to equipment. This
type of vent is always open. Because open vents release gases directly to the atmosphere, they are not generally used on equipment that handles hazardous materials.

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A variation on the open vent is a type of vent that can be called a pipeaway vent.
In a pipeaway vent, the vent line typically contains a valve to relieve pressure. If the
pressure gets too high, the valve is opened to allow vapor to leave through piping for
treatment or disposal.
Another type of vent that is commonly used on piping and equipment is a manually
operated valved vent (Figure 9). This kind of vent can be opened by hand to release gas
and vapor from a system.
Figure 9. Manually Operated Valved Vents

A valved vent may also be opened and closed by a pressure control valve. In this type
of arrangement, a controller is used to position the valve so that internal equipment
pressure does not exceed a preset value. For example, when the pressure in a vessel
exceeds an established set point, the controller detects the high pressure and opens
the valve to release gas or vapor through the vent and relieve the pressure. The controller closes the valve again when the pressure drops below the set point.
Conservation vents (Figure 10) are often used on storage tanks to reduce the evaporation of tank contents. This is done by means of a valve that is weighted to relieve
pressure at a preset value. The conservation vent reduces evaporation by allowing the
vapor to accumulate within a safe pressure range. This accumulation keeps more vapor
from forming.

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Figure 10. Conservation Vents

In some situations, such as equipment upsets that may involve sudden and excessive pressure increases, emergency venting is necessary. Emergency vents allow the
relief of relatively large amounts of material to quickly reduce pressure.
Included in (Figure 11) are hatch-type emergency vents. This type of vent typically
uses a spring or a weighted pallet to open the vent when tank pressure gets too high.
Figure 11. Hatch-Type Emergency Vents

Another type of emergency vent is commonly called a relief valve, but it may also
be called a safety valve. When pressure overcomes the force of an internal spring, this
type of valve opens and vents the gas.
A rupture disc is another type of emergency vent. There are various types of rupture
discs, but they all operate in essentially the same way. The rupture disc shown in
Figure 12 contains small cuts, or scores. When a certain pressure is reached, the disc
splits at the scores to vent the gas and relieve the pressure. After a rupture disc has
burst, it must be replaced with a new one.

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Figure 12. Rupture Disc

Safe Work Practices

Operators must follow all applicable company procedures to ensure that vessels and
equipment are safely vented. In addition, operators must know the pressure ratings
of the equipment in their area. This information is often stamped on equipment nameplates or included in company procedures.
It is also important for operators to know the pressures at which pressure controlled
vent valves and emergency vent valves open. These valves are usually marked or have
tags that provide the relief pressure and other information. A rupture disc also typically
has a tag indicating the discs relief pressure.
In some cases, to make sure that open vents remain open, an operator may be required to lock valves in their open positions. This ensures that the vents are not mistakenly blocked off.
Operators may also be required to keep track of vent problems, such as sticky valves.
This type of information can be used to determine when to repair or replace a vent.

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VentingChallenge Questions
1. Which of the following tasks typically require(s) venting to avoid damaging
equipment?
a. Filling a tank
b. Steam cleaning a tank
c. Draining a tank
d. All of the above
e. Only a and c
2. Venting is sometimes needed when conditions such as high fluid levels and
excessive temperatures result in equipment or system upsets.
a. True
b. False
3. Open vents (are/are not) generally used on equipment that handles hazardous materials.
4. To help ensure that equipment is safely vented, operators should
a. Know the pressure ratings of the equipment in their area
b. Know the pressures at which pressure-controlled vent valves and
emergency vent valves operate
c. Keep track of vent problems
d. All of the above
e. Only a and b
Please refer to the end of the handbook for answers.

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Purging
Purging is the process of removing hazardous materials from equipment using a gas
or vapor. Purging is also used to remove oxygen from process equipment or to keep
oxygen from entering process equipment.
Oxygen alone is not necessarily a hazardous material. However, when it combines
with a material that is flammable, a mixture is formed that will readily ignite. Oxygen
can enter equipment any time the equipment is open to the atmosphere, such as during cleaning and repairs. Oxygen can also enter equipment through leaky components.
This section describes purging materials and purging methods. Safety concerns and
operator responsibilities associated with purging are also covered.

Objectives

Explain why nitrogen and fuel gas are used for purging.
Describe two methods used to purge vessels and equipment.
Explain what inerting is and why and how it is done.
Describe safety concerns and operator responsibilities associated with purging.

Materials Used for Purging

One material that is often used for purging is nitrogen. The main reason for using
nitrogen is that it is inert, that is, it does not react easily with other materials.
Steam may also be used to purge hazardous materials from equipment. However,
some equipment parts, such as seals and instrumentation components, cannot withstand steam temperatures, and they may be damaged.
Another material that may be used for purging is natural gas, or fuel gas. Fuel gas is
generally used for purging when it is readily available, economical to use, and compatible with the products being produced.
When fuel gas is used for purging, it must not be combined with oxygen in proportions that will allow combustion to occur. In order for combustion to occur, a certain
amount of oxygen is needed for a given amount of fuel. However, a mixture of fuel and
oxygen will not burn if there is either too little fuel or too much fuel in proportion to
the amount of oxygen. When fuel gas is used to purge equipment that contains combustible vapor, which is basically a fuel, the total amount of fuel in the equipment is
increased. As a result, if proportionately smaller amounts of oxygen mix with the fuel,
the fuel-rich mixture will not burn.

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Purging Methods
Two methods that are commonly used to purge equipment are the continuous purge,
or sweep, method and the fixed volume, or pop and purge, method.
Continuous Purge Method
Figure 13 is a simplified illustration of a mixer that contains air. The air is removed
by continuously purging the mixer with nitrogen. The nitrogen is sent into the mixer,
and the oxygen in the air is diluted and swept out of the mixer through a vent. Nitrogen
is continuously supplied until testing indicates that the atmosphere inside the mixer
is free of oxygen.
Figure 13. Continuous Purging

Fixed Volume Purge Method

When the fixed volume purge method is used to purge oxygen from a vessel such as
a mixer, the vent on the mixer is initially closed. To begin the purge, nitrogen is sent
to the mixer until a certain pressure is reached (Figure 14). The pressure is held for a
designated period of time while the nitrogen mixes with any oxygen that is present.
Figure 14. Fixed Volume Purging; Vent Closed

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The vent on the mixer is then opened (Figure 15), which releases, or pops, the
contents out of the mixer, thereby reducing the amount of oxygen in the vessel. To
prevent oxygen from entering the mixer again, the vent is closed before the pressure
in the mixer drops to atmospheric pressure.
Figure 15. Fixed Volume Purging; Vent Open

With the fixed volume method of purging, the steps required to reduce the level of
oxygen are usually repeated a number of times. With each repetition, less oxygen is
left in the vessel.

Inerting
In many cases, after equipment has been purged of undesirable materials, nitrogen
may be used to maintain an inert, or nonreactive, atmosphere in the equipment. This
process is called inerting, or blanketing.
Inerting may be done for a number of reasons. For example, the mixer represented
in Figure 16 is supplied with nitrogen to form a blanket, or pad, at the top of the mixer.
When a liquid flows into the mixer, it can build up a static charge, which could ignite
flammable materials. The nitrogen blanket makes the mixers atmosphere nonreactive, which prevents any combustion reaction from occurring.
Figure 16. Nitrogen Blanket in a Mixer

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In some cases, a nitrogen blanket is kept on a vessel while the vessel is in operation. A positive nitrogen pressure maintains a nonreactive atmosphere and prevents
air from entering the vessel and mixing with its contents. The nitrogen also prevents
combustion reactions with static charges generated by moving parts.
When a nitrogen blanket is applied to equipment, the nitrogen pressure must be
controlled. This is especially important for situations in which changes in pressure
might create an undesired vacuum in the equipment. Such pressure changes might be
caused by weather-related temperature changes, or they might be caused by process
reactions.
One way to control nitrogen pressure is to use an automatic control system. For example, Figure 16 is a simplified illustration of a tank that contains liquid and a blanket
of nitrogen. The tank has a pressure gauge; a vent that branches into a nitrogen supply,
or vacuum relief, line; and a pressure relief line. Each line contains a motor-operated
control valve.
Figure 16. Tank With Nitrogen Supply Control System

If the pressure in the tank drops below a predetermined set point, a controller sends
a signal to the nitrogen supply control valve. The valve then opens to supply nitrogen
to the tank. When the desired pressure is reached, the valve closes.
If the pressure in the tank increases above its set point, the control valve in the pressure relief line opens, and nitrogen is bled off. When the desired pressure is reached,
the valve closes.

Safety
Although nitrogen is nonflammable, there are some safety concerns associated with
its use. For example, exposure to high concentrations of nitrogen should be avoided.
Nitrogen can dilute oxygen in the air below the point at which air can support life.

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Nitrogen is often stored as a liquid in a pressurized tank. Liquid nitrogen is extremely cold, so personnel who handle it must be careful to avoid frostbite.
Operators must always follow company procedures and take the required precautions when they open equipment that has been purged or blanketed with nitrogen.

Operator Responsibilities
One important operator responsibility associated with purging is ensuring that
valves are properly lined up. Company procedures should be followed carefully to
ensure that the purge gas will be supplied to and vented from all the required points.
Operators are also responsible for making sure that equipment is properly isolated.
To do this, an operator may have to close block valves and install blinds. Blinds are
solid discs that are inserted into pipelines to block flow. When blinds are used, the
correct size blinds must be installed. Improper equipment isolation can result in overpressurizing equipment and can cause relief valves to lift.
Before lines are opened to install blinds, operators must obtain any necessary permits and notify appropriate areas of the plant, such as those downwind of the work
area. Company procedures applicable to the use of respirators and standby operators
during blinding should always be followed. Purging may be required when a line or a
piece of equipment is opened.
In some cases, operators may have to make nitrogen supply connections with temporary lines from bleeders, drains, and other parts of a process system to the relief
system. These lines must be installed according to procedures, and all connections
must be tight.
To avoid subjecting equipment to inappropriate pressures during purging, operators must know the pressure and vacuum ratings of equipment. They should also know
the lifting pressures of relief valves.
To start purging, the nitrogen supply valve is opened slowly to avoid surges of nitrogen flow and pressure, which could put unnecessary stress on the system. Pressure
gauges on the purged equipment and lines are checked to make sure that the equipment pressure stays within a safe range.
Equipment is often checked for leaks during purging. After equipment is pressurized with nitrogen, any large leaks can be heard or felt by operators. Small leaks are
detected by squirting a leak-detecting liquid solution onto likely areas, such as around
flanges or valve packing. If leaks are present, the solution will bubble.

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When steam is used to leak-test equipment, operators can see the sources of any
leaks. When a leak is found, it should be reported so that it can be repaired.
After all detected leaks have been repaired, the equipment can be pressurized
again. While this is being done, the pressure on the equipment must be monitored. If
there is any drop in pressure, additional leaks may be present. Those leaks must then
be found and repaired.
Leaks can also be a problem when nitrogen is used for blanketing. In some applications, nitrogen is supplied to equipment for blanketing and then turned off. If the pressure starts to drop in the blanketed equipment, a possible cause is nitrogen leaking by
the isolation valves.
When a vessel or a piece of equipment containing flammable material is under a gas
purge or a blanket, an interruption of the gas flow can pose an immediate danger. If
this happens, the equipment must be blocked in to trap the purge gas inside. Blocking
in the equipment also keeps air from entering and mixing with the flammable material
until the problem can be corrected.
Finally, to make sure that equipment has been properly purged, operators may use
a portable gas analyzer to test the atmosphere inside the equipment.

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PurgingChallenge Questions
1. Nitrogen is often used for purging because it is what?
a. Inert
b. Highly reactive
2. Name two methods that are commonly used to purge equipment.
3. ___________ is the process of maintaining a nonreactive atmosphere inside
equipment after the equipment has been purged of undesirable materials.
4. Which of the following is NOT a safety concern related to the use of nitrogen
for purging?
a. Potential for frostbite from liquid nitrogen
b. Dilution of oxygen below the point necessary to support life
c. Danger of explosion
d. Both a and c
5. Operator responsibilities associated with purging typically include:
a. Installing blinds
b. Performing valve lineups
c. Checking for leaks
d. All of the above
e. Only b and c
Please refer to the end of the handbook for answers.

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Flare System
Relief gases that cannot be processed by a relief systems vapor recovery unit are often sent to a flare to be safely burned off. This section identifies safety considerations
associated with flaring and describes the basic operation of a flare.

Objectives
Describe safety considerations associated with flaring.
Describe the main components and the basic operation of a flare.

Safety Considerations
The function of a flare is to dispose of combustible gases by safely burning them.
Safety is particularly important when a flare is operating because two of the elements
required for combustion are always present: fuel, in the form of combustible gases,
and an ignition source, in the form of flames. The only element that is needed to start
a fire or an explosion is oxygen.
Pressure fluctuations in the system that feeds relief gas to the flare can cause pressure in the flare to become less than atmospheric. This condition can result in air being
drawn back down into the flare and the relief header, which can lead to fire and explosion hazards. Extreme care must be taken to ensure that the flare and the rest of the
relief system are protected from air entry.

Components and Operation

Figure 17 is a simplified illustration of a flare. The flares main components are a
flare stack, or riser; a stack inlet; a stack seal, or molecular seal; a water seal at the
base of the stack; and a flare tip.
Figure 17. Flare Components

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The function of the stack is to route gases entering through the inlet to the flare tip,
where they can be burned. Because it is critical to keep air from backflowing into the
flare stack, the flare has a number of safeguards. These safeguards include the stack
seal, the water seal, and purge gas.
The function of the stack seal is to keep air from backflowing down the stack. The
stack seal contains a complex network of baffles (Figure 18) that make it difficult for
oxygen to penetrate.
Figure 18. Baffles in Stack Seal

The water seal is the next line of defense against the backflow of air. If a mixture of
flammable gases and air is ignited in the stack, the water seal is designed to quench
the flame. In this way, the water seal protects the relief system and plant equipment
from flashback fires or explosions by stopping the flame before it can leave the stack.
A typical water seal is represented in Figure 19. Basically, the water seal is a reservoir that contains water. The example water seal has a makeup water line, an overflow
line, and a distributor, which is basically a plate with holes submerged in the water.
Figure 19. Water Seal

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Water is sent in through the makeup water line to replace seal water that is evaporated by the relatively hot relief gases that pass through it. To control the water seal
level, water is continuously added through the makeup water line, and excess water
leaves through the overflow line.
When relief gas enters the stack, it passes through the distributor. The holes in the
distributor spread out the gas, which bubbles up through the water and then flows up
the stack.
Purge gas is also sent in through the stack inlet to the flare tip. The purge gas helps
maintain a positive pressure at the flare tip to prevent the backflow of air into the stack.
Purge gas used in this way may be called a gas seal.
The purge gas used in a flare may be fuel gas that is introduced near the relief
headers point of origin, so that the entire relief system is swept with purge gas. In
addition to preventing air from entering the stack, fuel gas used as purge gas also
performs other functions. It maintains a fuel-rich mixture that prevents air from producing a combustible or explosive mixture within the stack. It also helps maintain the
flare flame during periods of low relief gas flow, when there is not enough relief gas to
support combustion.
The function of the flare tip is to mix air with the relief gas in order to promote complete and smokeless gas burning. The flare tip represented in Figure 20 includes an
opening for the relief gas; pilot gas burners, or pilots; steam nozzles; a steam line; a
pilot gas line; and ignitor lines. (Only one ignitor line is represented in Figure 20.)
Figure 20. Flare Tip

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During operation, a mixture of natural gas and air is constantly supplied to the pilots. A flame is sent to the pilots to ignite the gas mixture. The pilot flames are kept on
as long as the flare is in operation.
As the relief gas flows through the flare tip, air is drawn into the relief gas. When the
air mixes with the gas, the flames from the pilots ignite the mixture and burn it.
During normal operation, the relief gas should burn cleanly and completely. In some
cases, however, because of factors such as the kinds of gases being burned and unit
upsets, combustion may be incomplete. One sign of incomplete combustion is smoke.
Smoke indicates that unburned hydrocarbons are being released to the atmosphere.
In order to achieve the smokeless burning expected of a flare, steam is injected from
the steam nozzles into the flame (Figure 21). The steam reduces smoking by creating
turbulence and pulling in air to mix with the relief gas. The thorough mixing of relief gas
and air helps to produce complete combustion. When complete combustion occurs,
the only emissions from the flare tip are water vapor and carbon dioxide.
Figure 21. Steam Injected into Flame

In some cases, a steam flow control system is used to automatically adjust the
amount of steam needed to prevent the flare from smoking. Various types of steam
control systems may be used, and they all work similarly. One type of steam control
system uses an infrared monitor that is pointed at the flare. The monitor senses the
infrared radiation of the unburned carbon at the flare tip and generates a corresponding signal.
The signal from the infrared monitor is sent to a steam flow converter that converts
the signal into a steam flow set point for a controller. The controller is connected to a
valve in the steam supply line. As the amount of unburned carbon changes, the controller sends a signal that adjusts the valve until the steam flow rate equals the set point
established by the converter.

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Flare SystemChallenge Questions

1. In general, the backflow of combustible gases into a flare or a relief header
is not a problem.
a. True
b. False
2. A __________________ is basically a reservoir of water that quenches any
flame that may result from the ignition of a mixture of flammable gases and
air in a flare stack.
a. Flare stack
b. Water seal
c. Stack seal
d. Flare inlet
3. Which of the following statements is FALSE regarding fuel gas used as the
purge gas in a flare system?
a. Promotes the backflow of air into the stack
b. Maintains a fuel-rich mixture that reduces combustion hazards
c. Helps to maintain the flare flame during periods of low relief gas flow
4. The function of the ___________ is to mix air with the relief gas in order to
promote complete and smokeless gas burning.
a. Flame jet
b. Flare tip
5. When relief gas is burned cleanly and completely at a flare, the only emissions from the flare tip are water vapor and smoke.
a. True
b. False
Please refer to the end of the handbook for answers.

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Flare Operations, Part 1

Operators who work with flares must know how flares work and how they should be
operated. This section describes some basic operator responsibilities related to the
startup and normal operation of flares.

Objectives
Describe typical operator responsibilities associated with a flare system startup.
Describe some typical control room operator responsibilities associated with
normal flare operation.

Startup Preparations
Flares are generally kept in operation most of the time. Even when there is little or
no relief gas being sent to them, the pilots usually remain lit. However, there are occasions when a flare is shut down for repairs and must then be returned to service.
The preparations for a flare startup begin upstream of the flare. The first major step
in preparing for the startup is purging a portion of the relief header and the knockout
drum. Purging is typically done first with steam and then with gas, but in some cases,
only a gas is used.
In the online course, the operator began by lining up valves to purge the relief
header, the knockout drum, and the lines between them with steam. The steam purge
would clean lines and equipment, and enable the operator to check for leaks. The
steam would also help to purge oxygen from the system.
After the appropriate equipment was properly isolated, the operator opened the
necessary drains, bleeders, and vents to prevent pulling a vacuum on the knockout
drum and other parts of the relief system. The operator then connected steam supply
lines at various points between the relief header and the knockout drum. This helps
minimize condensation and the time needed to heat up and/or dry out the system.
Finally, he opened steam line valves to start the steam purge.
During the purge, the operator checked bleeders for constant steam flow (Figure 22)
to ensure that steam was reaching everywhere it should. When the steam becomes dry,
it means that most of the air has been removed and any condensate from the steam
has been blown out. A constant flow of dry steam indicates that the purge is complete.

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Figure 22. Checking a Bleeder for Steam Flow

When the operator was satisfied that the steam purge was complete, he closed
vents, bleeders, and drains to pressurize the system for leak testing. As the pressure
built up, the operator watched a pressure gauge on the knockout drum to make sure
that the pressure did not get too high. He then checked the knockout drum for visible
or audible signs of leaks. All flanges in the relief system that was under purge were
also checked for leaks.
Next, a nitrogen purge was started at the relief header to completely remove any air
left in the system and keep it out. After connecting nitrogen supply lines to bleeders,
the operator gradually opened valves to start the nitrogen purge. When a nitrogen supply line had been connected at all the necessary locations in the system, the operator
shut off the steam purge. These steps prevented a vacuum from being created by condensing steam. Then the steam line was disconnected.
Next, the operator lined up valves to send the nitrogen purge gas from the knockout
drum to the flare. While the relief system was under the nitrogen purge, the operator
made sure that the knockout drum pump was ready for operation, so that it could be
started when needed to remove liquid from the drum to maintain the proper level.
The operator also checked the relief system at several locations with a gas analyzer to
make sure that the oxygen content was at a safe level.

Startup
A typical flare startup procedure includes establishing the water seal, establishing
steam flow, purging the flare stack, and lighting the pilots.
To establish the water seal, the operator in the online course lined up valves to fill
the seal until the water level neared the overflow pipe.
To begin establishing steam flow, the operator opened drain valves in the steam
supply for the flare tip to make sure that there was no water or condensate present.
Condensate that collects in the steam lines to the flare can interfere with the flow of
steam. If the condensate is not removed, the steam will not reach the flare tip.

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Steam traps are used to remove the condensate without losing steam. As part of the
startup procedure, the operator checked the steam traps to make sure that they were
functioning properly. After the flare is in service, the traps are checked periodically.
Steam flow to the flare tip was established by opening block valves upstream and
downstream of the two steam control valves.
After testing showed that the flare stack was free of oxygen, the operator positioned
valves to start continuous purging of the relief system, including the flare, with fuel
gas. Once the continuous purge was started, the nitrogen supply was blocked in.
In the online course example, the flare stack was purged with a separate source of
natural gas. This additional purge gas was used so that the flare would not have to be
shut down if the relief system had to be isolated from the flare.
With the purge gas flow is established, the next step in a typical flare startup is
lighting the pilots. In the example, the pilots were lit using a flame front generator,
or ignitor station. Basically, an ignitor station consists of air and gas supply lines and
an air/gas mixer fitted with a spark plug, or ignitor, that provides a source of ignition.
Lines called ignitor lines connect the air/gas mixer to the pilots.
Before the pilots are actually lit, several additional preparations are needed. First, at
the base of the flare, the operator drained the ignitor lines of any condensate. This is
important because condensate can snuff out a flame in an ignitor line before the flame
reaches the pilot. Next, the operator opened valves to supply natural gas to the pilots.
At the ignitor station, the operator opened valves to blow down the air and gas lines
to make sure that they were free of moisture. To make sure that the ignitor was working
properly, the operator pressed the ignitor button and checked a sight glass to verify
that the ignitor produced a spark.
To begin lighting the pilots, the operator opened a valve on a mixer line to supply the
first pilot with an air/gas mixture.
Then he set the air pressure and the gas pressure. The correct settings send the
proper amounts of air and gas to the mixer.
Next, the operator pressed the ignitor button to produce a spark, which ignited the
air/gas mixture and produced a flame. The flame left the mixer and traveled through
the ignitor line to the first pilot.
The lighting of the pilots is verified by checking the pilot temperatures in the control
room. After the first pilot is lit, valves are lined up to mix air and gas and direct a flame
to another pilot. The steps are repeated to light the remaining pilots. After all the pilots
are lit, the air and gas valves to the ignitor are closed, and the flare is ready to receive
relief gases.

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Control Room Operator Responsibilities

Once the gases are flowing to the flare, there are a number of duties that operators
have to perform to ensure that the flare operates safely. For example, several variables
must be monitored. Some of these variables may be monitored only in the control
room, while others may be monitored both inside and outside of the control room.
One variable that must be monitored is the flare flame. It is especially important for
control room operators to observe the flame during unit shutdowns and emergency
situations, when flare activity is greatest. During such times, operators need to know
that the steam control system is reacting properly to continue to provide smokeless
burning.
The flow rate of steam to the steam nozzles is also monitored, so that any problems
with steam flow can be detected. In addition, the temperature of the flare tip is checked
to make sure that it does not get too hot. In some systems, if the flare tip gets too hot,
steam can be supplied to a ring inside the flare tip, or throat, to cool it.
The temperatures of the pilots are also monitored. If the temperature of a pilot is too
low, it can mean that the pilot has gone out and must be relit. Control room operators
also monitor the flow rates of relief gas from various locations. Any unusual flow could
indicate problems. For instance, an abnormal increase in relief gas flow could mean
that a relief valve is leaking by.
During periods of unusually high relief gas flow, samples of the relief gas may be
taken at the flare stack and analyzed in a lab. The lab tests determine the makeup of
the gas that is being burned, which can affect the environment.
Information about the purge gas is also available in the control room. An operator
can check on which kind of purge gas is used in the flare stack, and he can check the
purge gas flow rate and the water seal flow rate and level over a 24-hour period to see
if there are any unusual trends.

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Flare Operations, Part 1Challenge Questions

1. Why is steam likely to be used to purge a flare before startup?
a. To clean lines and equipment
b. To establish a water seal
c. To enable personnel to check for system leaks
d. Both a and c
e. Both b and c
2. When both steam and nitrogen are used to purge a flare system before
startup, the ___________ purge is performed last.
a. Nitrogen
b. Steam
3. Which of the following is NOT a step in a typical flare startup procedure?
a. Pulling a vacuum
b. Establishing the water seal
c. Establishing steam flow
d. Lighting the pilots
4. Basically, an ____________ consists of air and gas supply lines and an air/
gas mixer fitted with a spark plug that provides a source of ignition.
5. After a flare is started, operators typically monitor:
a. The flare flame
b. The flow rate of steam to the steam nozzles
c. The flow rates of relief gas from various locations
d. The temperature of the flare tip
e. All of the above
Please refer to the end of the handbook for answers.

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Flare Operations, Part 2

In addition to knowing how to start a flare and monitor normal flare operations, operators must also know how to handle abnormal flare conditions and how to shut down
a flare, if necessary. This section describes typical operator duties that are performed
outside of the control room, abnormal flare conditions and how to handle them, and
basic operator responsibilities associated with a flare shutdown.

Objectives
Describe typical outside operator responsibilities associated with normal flare
operation.
Identify some abnormal flare operating conditions and describe typical operator
responsibilities for handling them.
Describe basic operator responsibilities associated with a flare shutdown.

Outside Operator Responsibilities

During normal flare operation, outside operators routinely check the relief system
purge gas flow rate. This flow rate is typically indicated on a flow meter at the relief
header. If the proper flow rate is not maintained, air could leak into the system. In addition to the purge gas flow rate, the flow rate of natural gas to the pilots should also
be checked.
The level and pressure in the knockout drum should also be checked during flare
operation. These checks are especially important when a unit is upset and when equipment is washed or steamed, which increases the amount of liquid sent to the knockout
drum. If the knockout drum pressure or level gets too high, liquid will remain entrained
in the relief gases and be carried over to the water seal. This would add liquid that may
contain oil and other contaminants to the water seal.
Operators should check the lubricating oil level for the knockout drum pump, and
they should check the pump for abnormal conditions such as leaks and for unusual
noises and vibration.
Another check that operators must make is at the water seal. A sight glass is typically
used to check the seal level. A normal operating level will ensure that air will not enter
the relief system.
In the online course, the operator double-checked the operation of the level instrumentation by touching the stack where the appropriate water level should be. The
stack should be relatively cool up to the water seal level. Above the water level, it will
be relatively warmer. The physical location of the water level can then be compared
to the sight glass reading. A flow meter at the water seal may be checked to see if the
makeup water flow is at the proper rate. If there is not enough makeup water, the seal

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level will drop, and its effectiveness will be reduced. A level that is too low will not
quench a flame. Too much makeup water generates excess water that is usually contaminated by relief gases and must be treated.
Accumulations of scale, other solids, and liquid hydrocarbons in the water seal
can also obstruct various lines, such as connections for level instrumentation and the
overflow line. To prevent this problem, the water seal lines are periodically steamed to
remove any accumulations.
The operator in the online course was able to look into a bulls-eye to observe
signs of water contamination. At the seal outlet, the water may be sampled (Figure 23)
and tested periodically to determine the degree of contamination it contains.
Figure 23. Sampling the Water Seal

If testing indicates too much seal water contamination, an operator may be able to
correct the problem by increasing the fresh water flow to the seal. When this is done,
the seal is allowed to overflow until the fresh water displaces the contaminated water.
The buildup of solids and oil can also be a problem for the stack seal. Such accumulations can interfere with the flow of gas to the flare tip. In some cases, the stack seal
is steamed regularly to keep it clean.

Abnormal Conditions
Most of an operators responsibilities are routine ones. In some cases, however,
unusual conditions require actions that are not routine. Operators must be prepared
to deal with these unanticipated occurrences quickly and safely.
Loss of Flare Stack Gas Purge
One abnormal condition that may occur is the loss of the flare stack gas purge. Usually, nitrogen and natural gas are both available to purge the stack. As soon as the
purge loss is detected, valves must be lined up to switch to another available purge
gas. The failed purge gas line should be blocked in, and the problem should be found
and corrected as soon as possible.

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Loss of Pilot Flames

The loss of pilot flames is another problem that demands immediate attention. Several conditions can cause a pilot flame to go out. For example, if the pilot gas flow is
too high, the pilot flames can lift off of the pilot tips and blowout. If the gas flow to the
pilots is too low, the flames can burn down inside the pilot tips, where they would be
extinguished.
If all of the pilots go out during operation, the units venting to the flare must be
notified, and environmental personnel must be contacted. An emergency alarm may
have to be sounded to notify other plant personnel, depending on factors such as the
amount of material that can leave the flare unburned, the speed with which the affected unit can stop venting, and how quickly the pilots can be relit.
In general, chances are good that if one or more pilots go out, quickly troubleshooting the cause of the problem will avoid an emergency situation. The pilot gas pressure
and flow rate should be checked, and it may also be necessary to check the pressure
and flow rate of the natural gas used to purge the flare stack.
Abnormal Steam Flow
Abnormal steam flow to the flare can also create problems. If too little steam is sent
to the flare, unburned materials can be released into the atmosphere. Too much steam
can put out the pilots, with the same results.
An interruption in steam flow could indicate problems with the steam supply, such
as a down or malfunctioning boiler. If the steam supply is normal, then the positions of
the steam line block valves and the operation of the control valves should be checked.
Steam traps may also be checked for proper operation. If the problem is not found, appropriate personnel may have to clean the steam flow monitor lens and adjust or align
the steam control system.
Abnormal Water Seal Level
At the flare, another abnormal condition that may be encountered is an abnormally
high or low water seal level. A low level can easily be corrected by simply increasing
the makeup water rate.
A high water seal level may be caused by a blocked outlet line or by excessive liquid
carryover from the knockout drum. The high level can cause excessive backpressure
in the relief system and create resistance to gas flow through the system. In extreme
circumstances, the water level can eventually reach the flare tip. If the water contains
hydrocarbons, it can be ignited and then spew from the flare tip.
If the water seal level is too high, the makeup water flow rate should be verified.
If necessary, the flow rate should be reduced or shut off. Valves can be positioned to
supply steam to the outlet line to remove any blockages.

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Flare Shutdown
To handle certain abnormal conditions or to allow for repairs to be made, operators may be required to shut down a flare. In some cases, the unit relief systems that
use the flare can be rerouted to a second flare that is isolated from the first one, and
then the first flare can be shut down. If a second flare is not available or rerouting is
not possible, the units whose relief systems use the flare have to be shut down and
depressurized before the flare is shut down.
After the flare has been isolated from the relief systems and the knockout drum,
the natural gas pilots must be isolated. The purge gas at the base of the flare must be
stopped, the water to the water seal must be isolated, and the steam to the flare tip
must be isolated. Additional cleanup steps may be necessary to complete the shutdown according to company procedures.

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Flare Operations, Part 2Challenge Questions

1. Typical outside operator responsibilities during normal flare operation include checking:
a. The relief system purge gas flow rate
b. The knockout drum level and pressure
c. The knockout drum pump lubricating oil level
d. The water seal
e. All of the above
2. If all of the pilot flames go out during flare operation:
a. The units venting to the flare must be notified
b. Environmental personnel must be contacted
c. An emergency alarm may have to be sounded to notify other plant
personnel
d. All of the above
3. If too little steam is sent to a flare, unburned materials can be released into
the atmosphere.
a. True
b. False
4. An abnormally low water seal level can be corrected by increasing the
____________ flow rate.
5. Which of the following steps is typically NOT part of a flare shutdown procedure?
a. Rerouting systems that vent to the affected flare
b. Establishing a water seal
c. Isolating the flare from the relief systems and the knockout drum
d. Isolating the natural gas pilots
e. Stopping the purge gas at the base of the flare
f. Isolating the steam to the flare tip
Please refer to the end of the handbook for answers.

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ANSWERS TO CHALLENGE QUESTIONS

General Considerations
1. Three considerations associated with handling waste gases are safety, health
protection, and cost.
2. Purging is the removal of hazardous materials from piping and equipment with
a gas or vapor to prevent the formation of explosive mixtures.
3. c
The basic purpose of venting is to release waste gases and purge gases.
4. a (True)
5. b
Waste gases that exceed the handling capacity of a relief systems vapor recovery unit are generally sent to a flare.

Venting
1. d
Tasks that typically require venting to avoid damaging equipment include filling
a tank, steam cleaning a tank, and draining a tank
2. a (True)
3. Open vents are not generally used on equipment that handles hazardous materials.
4. d
To help ensure that equipment is safely vented, operators should know the
pressure ratings of the equipment in their area, know the pressures at which
pressure-controlled vent valves and emergency vent valves operate, and keep
track of vent problems.

Purging
1. a
Nitrogen is often used for purging because it is inert.
2. Two methods that are commonly used to purge equipment are the continuous
purge (sweep) method and the fixed volume (pop and purge) method.

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3. Inerting, or blanketing, is the process of maintaining a nonreactive atmosphere

inside equipment after the equipment has been purged of undesirable materials.
4. c
Danger of explosion is not a safety concern related to the use of nitrogen for
purging.
5. d
Operator responsibilities associated with purging typically include installing
blinds, performing valve lineups, and checking for leaks.

Flare System
1. b (False)
2. b
A water seal is basically a reservoir of water that quenches any flame that may
result from the ignition of a mixture of flammable gases and air in a flare stack.
3. a
When fuel gas is used as the purge gas in a flare system, it maintains a fuel-rich
mixture that reduces combustion hazards and helps to maintain the flare flame
during periods of low relief gas flow. It does not promote the backflow of air into
the stack.
4. b
The function of the flare tip is to mix air with the relief gas in order to promote
complete and smokeless gas burning.
5. b (False)

Flare Operations, Part 1

1. d
Steam is likely to be used to purge a flare before startup to clean lines and equipment and to enable personnel to check for system leaks.
2. a
When both steam and nitrogen are used to purge a flare system before startup,
the nitrogen purge is performed last.
3. a
Pulling a vacuum is NOT a step in a typical flare startup procedure.
4. Basically, an ignitor station consists of air and gas supply lines and an air/gas
mixer fitted with a spark plug that provides a source of ignition.

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5. d
After a flare is started, operators typically monitor the flare flame, flow rate of
steam to the steam nozzles, flow rates of relief gas from various locations, and
temperature of the flare tip

Flare Operations, Part 2

1. e
Typical outside operator responsibilities during normal flare operation include
checking the relief system purge gas flow rate, knockout drum level and pressure, knockout drum pump lubricating oil level, and water seal.
2. d
If all of the pilot flames go out during flare operation, the units venting to the
flare must be notified, environmental personnel must be contacted, and an
emergency alarm may have to be sounded to notify other plant personnel.
3. a (True)
4. An abnormally low water seal level can be corrected by increasing the makeup
water flow rate.
5. b
Establishing a water seal is typically NOT part of a flare shutdown procedure.

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GLOSSARY
This glossary contains terms pertinent to the study of flaring, venting, and purging.
The meanings of the terms are given in that context.
Blanketing See Inerting.
Conservation vent A valved vent that is weighted to relieve pressure at a preset
value after allowing vapor to accumulate within a safe pressure range.
Continuous purge method A purging method in which the purging material is
continuously supplied to a piece of equipment until testing indicates that the
equipments atmosphere is free of undesirable materials. Also called the sweep
method.
Fixed volume method A purging method in which the purging material is sent to a
piece of equipment until a certain pressure is reached. After the pressure is held
for a designated period of time, a vent on the equipment is opened to release,
or pop, the contents out of the equipment. The vent is closed before pressure in
the equipment drops to atmospheric pressure. The steps are repeated until the
amount of undesirable material in the equipment has been reduced to a safe
level. Also called the pop and purge method.
Flame front generator See Ignitor station.
Flare A flame that, when operated properly, will safely dispose of combustible
gases by burning them.
Flaring The process of disposing of combustible gases by burning them.
Hatch-type emergency vent A type of vent that typically uses a spring or a weighted pallet to open the vent when the pressure in a tank gets too high.
Ignitor station A device used to light the pilots for a flare.
Inerting The process of using nitrogen or another inert gas to maintain a nonreactive atmosphere in a piece of equipment after purging. Also called blanketing.
Knockout drum A piece of equipment that removes liquid entrained in gas.
Pipeaway vent A type of vent that opens to allow vapor to leave through piping for
treatment or disposal.

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Pop and purge method See Fixed volume method.

Purging The removal of hazardous materials from piping and equipment with a gas
or vapor to prevent the formation of explosive mixtures.
Relief system A collection of vessels, piping, and equipment designed to handle,
recover, or dispose of gas released from process equipment.
Relief valve A type of emergency vent valve that opens when pressure overcomes
the force of an internal spring.
Rupture disc A type of emergency vent that bursts open to vent gas and relieve
excess pressure.
Sweep method See Continuous purge method
Venting The process of removing waste gases from vessels and equipment by releasing them through openings, or vents.

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