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HomeIntroductionFlareSystem:Types,Segregation,Tips,PurgeSystemandMore

FlareSystem:Types,Segregation,Tips,PurgeSystemandMore
2Comments

Tableofcontents:

1.TypesofFlare
2.SegregationofFlares
3.FlareKnockOutDrum
4.FlareKODLiquidRemoval
5.FlareKODsizingdependsontwoaspects
6.LiquidSealDrum
7.Purgereductionseals
8.FlarePurgesystem
9.Flarestack
10.FlareStructure
11.FlareTip
12.RinglemannChart

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13.Pilotburner
14.PilotIgnition
15.OtherAccessories

Flaringisdefinedasaprocessofcontrolledburningofexhaustgaseswhichgeneratesheatandnoise.Flaringisacommonpracticeinoil/gas
exploration,productionandprocessingoperations.Aflaresystemconsistsofaflarestackandpipesthatfeedgastothestack.Thetypeandamountof
gasorliquidsintheflarestackgovernsthesizing&brightnessoftheflare.

Therearemanyfunction&reasonforflaring,fewreasonsforflaringare:

1. Duringwellproductiontestingafterdrillingiscompleted
2. Forsafetyandduringemergenciesandmaintenance
3. Formanaginggasduringcompressionandprocessing
4. Flaringatwellsitestorecoveroil

1.TypesofFlare
1. ElevatedFlare
2. GroundFlare
EnclosedFlare
OpenFlare

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ElevatedFlare

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EnclosedFlare

OpenFlare

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ClicktoenlargefigureTypicalFlareSystemwithElevatedFlare

2.SegregationofFlares
1. Service
Acidgasflare
Colddryflare
Warmwetflare

2. Pressure
Atmospheric
Lowpressure
Highpressure

3.FlareKnockOutDrum
1. Objective
Separatebulkliquidfromgas
Limitliquiddropletsizeentrainedwithgastotheflare
Provideadequateresidencetimeforliquid
2. Sizingbasis
BasedonAPI521
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Separationofliquiddropletsizeof300600micronsconsideringthedesigncasefortheflare
2030minutesofliquidholduptimebasedonareliefcasethatresultsinmaximumliquid
Nointernalstofacilitateseparation
Manyorientations/optionspossible,horizontalKODsmostpreferred

FlareKODrumelevation

3. FlareKnockOutDrumElevation
KOdrumelevationdecidespiperackelevationbasedon1:500slopeofmainflareheader

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FlareKODrumelevation

KOdrumelevationdeterminedbypumpNPSHrequirement
Toreducepiperackelevationoptionsare
ReduceKODelevation(option1)
Useverticalcanpump
Locatepumpwithinpit
LocateKOdrumwithinpit
UseintermediateKOdrums(option2)

>FlareKODrumelevationarrangement(Option1)

FlareKODrumelevationarrangement(Option2)

4.FlareKODLiquidRemoval
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RemoveliquidfromflareKODafterrelieftoavoidoverfillduringfuturereliefevent

1. Options
Drainingtoevaporationpondorcloseddraindrums
LiquidremovalbyflareKODpumps
HeatertobeinstalledinKODwherefreezing,pourpointissuesexist
Rateofliquidremovaltoconsiderfrequencyandamountofliquidrelease
HighlevelinflareKODtobeconsideredforplantshutdown
2. SizingofFlareKOD

FlareKODrum

LLLLshallbesufficientlyhightoavoidanysludgedepositionimpactingLTnozzle(150mminabovefigurenotcorrect,consider300mm
minimumforserviceswhicharenotclean).
LLLLshallbeminimum700300incaseflaredrumelectricalheatersneedtobeinstalled.
LLLLLevelatwhichpumptrips.
LLLLevelatwhichbothpumpsstops
HLLLevelatwhichfirstpumpstarts
HHLLLevelatwhichsecondpumpstarts
HHHLLLevelatwhichentireplantgoesintopressurizedtrip.

5.FlareKODsizingdependsontwoaspects
LiquidHolduprequirementduringamajorliquidortwophaserelease.
SufficientdistanceshallbeavailablebetweeninletdevicebottomandHHHLL.Itispossibletohavemanuallyinitiateddepressurizationeven
afterHHHLLL.AnypossibleliquidshallbeaccommodatedaboveHHHLL.
DistancebetweenHLLandHHHLLshallbedesignedtoaccommodatemaximumliquidreleasescenario(?).Somestandardsthisdistanceis
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betweenHHLLandHHHLL.
Residencetimerequiredfordropofliquidparticlesof300600micronsize.
Liquidparticlesseparate
Whentheresidencetimeofthevapororgasisequaltoorgreaterthenthetimerequiredtotraveltheavailableverticalheightatthedropout
velocityoftheliquidparticlesand
Whenthegasvelocityissufficientlylowtopermittheliquiddropouttofall.Thisverticalheightisusuallytakenasthedistancefromthe
maximumliquidlevel.

6.LiquidSealDrum
1. Objective
Preventflashbackfromflaretipbacktoflareheaders
Avoidairingressintoflaresystemduringsuddentemperaturechangesleadingtocondensationandmaintainpositivesystempressure
2. Use
Usedinflaregasrecoverysystems
Stagedflaringbetweenenclosedflareandfullsizeemergencyflare
3. Designspecifications
Waterasliquidsealingfluidnotrecommendedforextremelycoldreleaseswaterglycolmixturesofsufficientconcentrationusedinstead

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LiquidSealDrum

7.Purgereductionseals
1. Objective
Preventairinfiltrationintoflaresystematlowflowrates
Reduceamountofcontinuouspurgegasinjectionintoflarestack
2. Designoptions
Buoyancyseal(molecular/densityseal)
Velocityseal(fluidicseal)

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PurgeReductionSeal

8.FlarePurgesystem
1. Objective
Preventairinfiltrationintoflaresystematlowflowrates
Preventvacuumformationinflareheadersandsystemfollowingsteamingorlargereliefevent
2. Designspecification
Continuouspurgeratewithvelocityinstack
15fps:withoutmolecularseal
01:withmolecularseal
020.04:withvelocityseal
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Approximatepurgeflowratecanbecalculatedusingsection7.3.3.3ofAPI521.

PurgeReductionSeal

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FlareP&ID
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9.Flarestack
1. Objective
Combustionofreliefgasesatelevationtominimizeradiationexposuretopersonnel/equipment/structure
Ensureadequatedispersionofunburnthydrocarbonsandtoxiccomponents

Flareprotection

2. Designconsiderations
Radiation:Limitradiation,eithercontinuousandpeak,onoffsitepropertiesandpersons,equipment,buildingsandpersonnelonthe
installation.Applicabletoimpactedarea,restrictedareaandequipmentlayout.
Flammablegas:Avoidignitionofaflammablegascloudreleasedfromacoldventorincaseofflareflameout.
Toxichazards:(MainlyforH2SandSO2,butnotlimitedto)limittheriskofatoxicgascloudtoreachoffsitepopulation,providemeans
ofalarmandadequateprotectiontopersonnelpresentintherestrictedarea.
Noise:Limitbothcontinuousandpeaknoise
StackheightisdeterminedbyHSEgroupbasedonpermissibleradiationlevelasperprojectphilosophyorAPI521.
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Tallerstackwillresultinsmallersterilezone.
Locateprocessplantupwindofflare.

10.FlareStructure
Selfsupportedflarestack
Guywiredsupportedflarestack
Derricksupportedflarestack
Morethanoneflaremaybesupportedonthesamestructure

FlareStackSupport

11.FlareTip
Producedesireddestruction/combustionefficiencyofmaximumspecifiedreliefgas
Establishandmaintainproperignition
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Pilotgas/Pilotburners/Ignitionsystem
Ensurestablecombustion
Windshield
Retentionrings
Resultinsmokelessoperationatnormalcontinuousflowsorat100%flows
Steam
Air(highpressureorlowpressure)
Highpressurewater
Noexternalmedium,maintainhighpressureattipbystaging

FlareTip

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FlareTip

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FlareTip:VelocitySeal(topview)

Basedonvelocityofgasexitfromtip,flaretipsareconsideredassonicandsubsonic(pipeflare)type.Thisisthetermusedbyprocessdesigner
forhighpressureflaresandlowpressureflares.
Generalstackpressuredropsareasgivenbelow.
Sonicflare2to4bar
Subsonicflare0.20.5bar
OpenPipeflaretips:Theseareusedforcombustionofgasesthatdonotproducesmoke,gaseswithalowheatingvalue,orforinstallationswhere
smokelesscombustionofheavyhydrocarbonsisnotrequired.Theseflaretipsareoneofthelowercapitalcostoptionsforsafedisposalofwaste
gases.Ingeneralthesekindofflareshavetipswithverylowpressuredrop.
Openpipeflaretipswithsteaminjection:Steaminjectionisprovidedreducethesmokeformation.
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Openpipeflaretipwithhighpressuregasinjection:Thiswillincreasetheturbulenceatflaretipandreducethesmokeformation.Fuelgas
canbegenerallyusedasassistgas.Fuelgasinjectioncanbeeithercontinuousorinitiatedmanuallybasedonmonitoringofflaretip.
Airassistedflaretip:Whensmokelessflaringisdesiredandneithersteamnorassistgasisavailable,blowerscanbeusedtoinjectcombustionair
directlyintothewastegasstreamasitexitstheflaretip.Combustionefficiencyofflaredgasisincreasedbyinstallingairblowerwhichwill
reducesmokeformation.
Multiplenozzletypeflares:Theyareusedwherehighflaregaspressuresareavailable(1bargandup)andwhereitispreferredtohavesome
smokelessburningcapabilityandalsolowerradiationlevels.ThesekindsofflaresareusedforHPflareapplication.Theyhavegoodcombustion
efficiencyandlesschancesofsmokeformation.
Coandaflaretip:TheCoandaeffectisagasadhesionprinciplethatdramaticallyenhancesthecombustionprocess,resultinginmaximum
destructionofwastegases.CoandaEffectoccurswhengasispassedoverandadherestoacarefullyprofiled,curvedsurface,creatinganear
vacuumthatpullsinsubstantialamountsofair.Theairturbulentlymixeswiththegasflow,resultinginhighefficiencycombustion.

OpenPipeFlare

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MultiNozzleFlare

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CoandaFlare

12.RinglemannChart
Aseriesofcharts,numbered0to5,thatsimulatevarioussmokedensitiesbypresentingdifferentpercentagesofblack.
RingelmannNo.0isclearsmoke
RingelmannNo.5is100percentblack.
RingelmannNo.1isequivalentto20percentblack

RinglemanChart

13.PilotBurner
1. Objective
Provideflameforreliableignitionofmainflaregasatalltimes
2. Designspecifications
PilotsystemtocomplywithAPI537
Minimumnumberofpilots Flareburnerouterdiameter,DN

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1(2fortoxicgas) Upto200
2 >200to600
3 >600to1050
4 >1050to1500
Tobeagreedwithpurchaser >1500

Pilotsdesignedtoremainlitandcapableofbeingrelitatwindspeedsupto160km/hunderdryconditions

Pilotgasline

14.PilotIgnition
1. HighEnergyIgnition(HEI)
Electrodecapableofhighenergyorhighvoltagedischargenearpilottip
DoesnotrequirepropagationofaflamefrontasinFFGsystem
Doesnotrequirecompressedair,selfaspiratingpilots
Simpleandeasytouseandautomate,requirelittletrainingormaintenance.Reignitiontakesfewseconds
Shutdownofflaresystemrequiredformaintenance
BackupFFGignition(whenusingHEI)maybeconsideredfor
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Verytallflaresthataredifficulttoaccess
Flaresystemsthatcanbeofflineonlyonceinmorethan35years
Offshoreplatformsincorrosiveandsaltenvironments

ElectricalIgnitionPanel

2. FlameFrontGenerator(FFG)
Ignitionlinefrompaneltoflarepilotfilledwithflammablefuelgasairmixtureandsparkintroduced.Mixturesignitedandflamefront
travelsthroughpipingtoignitepilotatflaretip
FFGpanellocatedatgrade
Paneloperatedmanuallyorautomatedtoreigniteofpilotflameoutdetection.Reignitioncantakeseveralminutes
Moistureaccumulationcanleadtocorrosion,flameextinguishmentIgnitionlinestobeheattraced

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FFGPanel

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FFGSystem

15.OtherAccessories
Flowmeasurement
Monitoringreliefdevicesleaksduringnormaloperation
Assessflaringofgasesduetopressurecontroloperations
Notereliefflowsforassessingflaresystemadequacychecksandpotentialforflaregasrecovery
Nonintrusiveultrasonicflowmeterswithwiderangeandnopressuredropispreferred
Smokelessflaring:mediumcontrol
Propersteamoraircontrolisrequired
Bymeasuringgasbeingflaredandadjustingsteamrate/blowercapacity
Detectionsmokeusinginfraredanalyzers
AircraftWarningLights
Requiredwhenflareheightsexceed61morwhensiteisclosetoairport
Typeandnumberbasedonregulations

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2comments

1.
Abhijit
August30,2016at4:37am

Processplanshouldbedownwindtoflaretoavoidflammablegasesgettingtotheflair.

Reply

2.
YAK
October26,2016at12:49pm

Thankyou,thisisreallyusefuldataforme!

Reply

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