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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
Open 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
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
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
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
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.
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
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.
2. Use
1. Used in are gas recovery systems
2. Staged aring between enclosed are and full size emergency are
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
2. Design options
1. Buoyancy seal (molecular / density seal)
2. Velocity seal ( uidic seal)
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
2. Approximate purge ow rate can be calculated using section 7.3.3.3 of API 521.
Flare P&ID
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
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.
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Flare Tip
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
Flare Tip
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
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.
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Coanda Flare
Ringleman Chart
2 >200 to 600
3 >600 to 1050
4 >1050 to 1500
2. Pilots designed to remain lit and capable of being relit at wind speeds up to 160
km/h under dry conditions
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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
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18/1/2018 Flare System: Types, Segregation, Tips, Purge System and More
MORE READ
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
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