Aker Kvaerner Powergas Pvt. LTD.: Flare System

Aker Kvaerner Powergas Pvt. Ltd.
Flare system
Satish K. Saxena Sept. 2005
Typical flow diagram

Sept,2005 Page 2
System protection
Primary protection Control system Secondary protection Hard wired trip protection
Tertiary protection
Safety valves, rupture disk

Sept,2005 Page 3
Reliving Scenarios
Fire Power failure Steam failure C.W. failure
-
Refrigeration failure Vaporisation in exchangers Overfilling Tube rupture Entrance of volatile liquid Chemical reaction (Run away reaction) Closed outlet
Inst. Air failure

Reflux failure Side reflux failure
Sept,2005
Air cooler fan failure

Control valve failure
Page 4
Liquid expansion
Reliving devices

Safety Relief valve. Rupture disk.
Emergency de-pressurisation.

Sept,2005 Page 5
i) Safety valves
Types Conventional. Balance bellows. Pilot operated.
Set pressure equals to design pressure/MAWP of equipment. Allowable Back pressure depends upon the type of safety valve. P = 3% of set pressure of safety valve.

Sept,2005 Page 6
ii) Rupture disk

Rupture Disk is most preferred, fool prove, safety device, opens instantaneously to protect the system against over pressurisation. It is designed to burst when differential pressure across the disk exceeds a predetermined value at predetermined temperature. Rupture disks are used in gas, liquid, highly corrosive, highly viscous and congealing services. It is installed in various combinations, sole safety device, with safety valve, either inlet or in parallel depending upon the criticality of system.
---Continue--

Sept,2005 Page 7
Rupture disk
APPLICATIONS:
The use of rupture disk as pressure-relieving device is preferred in the following cases: Where pressure rise is so rapid that the inertia of a safety valve would be a disadvantage. Where minute leakage of process fluid (Toxic, highly inflammable, safety valve opens to atmosphere) cannot be tolerated under operating conditions. Service conditions led to deposition, which can make safety valve inoperative. Cold ambient condition could prevent a safety valve to operate. Solid containing gas makes safety valve inoperable. Corrosive gases spoil the safety valve internals.
---Continue---

Sept,2005 Page 8
Rupture disk
Rupture disk is used as sole safety device in following cases: --Instantaneous relief is required. --As an additional safeguard for pressure relieve.
Following are the applications, where rupture disc is used in series, of safety valve at up-stream. --To protect the safety valve against corrosion. --To prevent leakage of corrosive, toxic and valuable material. --To prevent total loss of material from the system following rupturing of rupture disc. --To protect the safety valve becoming inoperable due to congealing of material.

Sept,2005 Page 9
iii) Emergency
Vapor De-pressurisation
De-pressurisation during fire minimises the risk of failure of equipment even at lower than its design pressure, due to reduction in Yield Strength of its material of construction with increase of wall temperature during fire. De-pressurisation also reduces the risk of increasing the internal pressure of equipment exceeding the Rupture pressure during external fire, thus preventing the occurrence of major leak of hazardous chemicals, which leads to safety and environment hazards. De-pressurisation helps in reducing the wall temperature thus reduces the risk of pre-mature failure of equipment.
-----Continue-Aker Kvaerner Powergas Pvt. Ltd.

Sept,2005 Page 10
Conditions for requirement of Emergency Vapor De-pressurisation
All the process equipment, as part of a system, should have atleast total cumulative inventory of 3 to 5 cubic meters of Butane or more volatile liquid under normal operating conditions, shall be provided with remotely operated depressurisation assembly. As per the API-521 (Clause 3.19.1), the release capacity should be such that the continuous vapour depressurisation should reduce the equipment pressure to 50% of its design pressure within 15 minutes. The API-521 (Clause 3.19.1), further states that when fire is controlling contingency, it may be appropriate to limit the provision of depressurisation facility only for the equipment and sections which operate 250 lbs/square inch and above, where the size and volume of a system is significant. The depressurisation is limited to 100 lbs/square inch or 50% of the design pressure, whichever is lower, within 15 minutes time (for vessels with wall thickness 1 or more, thinner vessel requires higher depressurisation rate, means lower than 15 minutes). ---ContinueAker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 11
Emergency Vapor De-pressurisation

Type of vapor de-pressurisation:
Controlled de-pressurisation.
Uncontrolled de-pressurisation.
-----Continue----

Sept,2005 Page 12
Emergency Vapor De-pressurisation
Q MAX., UNCONTROLLED DEPRESSURISATION
SM 3 /hr DEPRESSURISATION FLOW RATE, Q
UN
CO NT RO LL ED
FLARE CAPACITY, Q MAX., CONTROLLED DEPRESSURISATION CONTROLLED ALLOWABLE TIME
TIME, MINUTES
FIG.3
DEPRESSURISATION TIME
(AREA UNDER BOTH THE CURVES WITHIN THE STIPULATED TIME ARE SAME, MEANS VOLUME HANDLED ARE SAME)

Sept,2005 Page 13
Controlled de-pressurisation
FLARE HEADER
FB LO
SCRUBBER
PROGRAMMED LOGIC CONTROL THE OPENING OF "CV" MAINTAINS CONSTANT FLOW AT ALL UPSTREAM PRESSURE
FC CV XY S ZO ZSO PIC ZC ZSC SDV IA XV PY
PSV
PSV
FUEL GAS
FC
CW
XV
CONDENSER
LIC IA XV S ZO IA ZSO ZC SDV ZSC LY
LIMIT SWITCH
ZO ZSO ZC ZSC
SDV
ACCUMULATOR
FEED,
FC LY
LP STEAM
FC
CONDENSATE
EXCHANGER
LG
LIC
LAH LAL XV S
ZO ZSO ZC ZSC SDV
IA
LIC
TRIP LOGIC CLOSES ALL THE INCOMING/OUTGOING STREAMS.
WATER
FC
FLASH VESSEL
FIG. 2
PUMP
CONTROLLED DEPRESSURISATION

Sept,2005 Page 14
Uncontrolled de-pressurisation
FLARE HEADER
FB LO RO ZC ZO
ZSC
ZSO XV S ZO IA PSV ZSO S
XV
PY
IA
FO PSV SDV
PIC ZC ZSC SDV
FUEL GAS
FC
CW
XV
CONDENSER
LIC IA XV S ZO IA ZSO ZC SDV ZSC LY
LIMIT SWITCH
ZO ZSO ZC ZSC
SDV
ACCUMULATOR
FEED,
FC LY
LP STEAM
FC
CONDENSATE
EXCHANGER
LG
LIC
LAH LAL XV S
ZO ZSO ZC ZSC SDV
IA
LIC
TRIP LOGIC CLOSES ALL THE INCOMING/OUTGOING STREAMS BUT OPENS THE BLOW DOWN "SDV" VALVE FOR DEPRESSURISATION
WATER
FC
FLASH VESSEL
FIG. 1
PUMP
UNCONTROLLED DEPRESSURISATION

Sept,2005 Page 15
Flare load summary

Flare load summary : 1) Normal 2) Emergency
C.W. FAILURE FIRE PROCESS UPSET Depressurisation Unit no. T/HR MW TEMP T/HR MW TEMP T/HR MW TEMP T/HR MW TEMP 1 UNIT A 2 UNIT B 3 UNIT C
* IT IS NOT NECESSARY THAT IF MASS FLOW IS HIGHER, THE FLARE LOAD WILL BE GOVERNING.

Sept,2005 Page 16
Streams requiring disposal
Vapor and liquid relief from safety valve and rupture disk.
De-pressurised vapors.
Any operational inflammable waste stream does not have suitable outlet.
Venting Vs. Flaring

Sept,2005 Page 17
Venting considered only, otherwise flaring
Release occurs only in extreme emergency conditions. Release vapor / gas is lighter than Air (< 0.9 times the air). No risk and consequences of accidental flame ignition. Concentration of toxic / corrosive components in dispersed clouds do not reach in harmful level. Condensation of corrosive vapor should not occur. Stream should be free of liquid. Hot gas venting should not ignite.

Sept,2005 Page 18
Flaring Vs. Venting

Considerations are to be made, based on the followings, whether to vent or flare the disposed streams.

Impact of environment. Safety and integrity of disposal system (Products are not
combustible).
Local regulations. Economic evaluations.

Sept,2005 Page 19
Common Vs. segregated flare systems

Segregated flare system may be required in following cases:
Release at various pressure levels, economic reasons to reduce the size of flare headers, sub-headers and stack. Widely differing potentials for liquid release. Corrosive and non-corrosive streams. Meet plant layouts / economics. Cold dry gas with wet gas. Contents of one stream may react with contents of other stream led to chemical reactions, producing heat.

Sept,2005 Page 20
Disposal of H2S rich gas

Gas stream rich in H2S should not be combined with gas streams free of H2S.
Because off:
H2S spread in entire flare network, shall call for NACE materials for entire system. H2S attack on the CS will make Pyrophoric substance that can lead to fire hazard in presence of explosive mixture (Auto ignition temperature is very low for Pyrophoric substance).

Sept,2005 Page 21
Disposal of Oxygen rich gas

Stream rich in oxygen should not be put into the common flare header.
Oxygen forms explosive mixture with hydrocarbons, leads to explosion, if fire source is available.
Oxygen converts H2S in elemental sulfur that plugs, obstruct free flow of gas. As well,H2S produces Pyrophoric substance by reacting with pipe material. If Oxygen laden H/C gas ,already in explosive range, pass can create fire hazards either due to pyrophoric substance or by Static electricity.
Sept,2005 Page 22
Conventional flare system

FLARE SYSTEM
PILOT FLARE TIP
PSV PSV
PILOT IGNITION LINE
DRY SEAL F.G PURGE

PSV PSV
1:200 B.L
1:200
F.G PURGE
WATER
H/C
K.O DRUM
PUMP LIQUID SEAL DRUM

WATER WATER
FLARE STACK
PLANT AIR FLAME FRONT GENERATOR
FUEL GAS

Sept,2005 Page 23
Component of Flare network

Flare tip with pilots. Dry gas seal.
Flare stack.
Liquid seal. Flame front generator.
Knock-out drum.
Flare header and sub-headers.

Sept,2005 Page 24
Problem encounter in flare system
Glaring: Causes inconvenience to the surrounding population and feeling of unnecessary waste of resources. Noise: Causes inconvenience to the surrounding population and prolonged exposure to excessive noise may cause mental irritation, fatigue and even deafness.
Radiation: Effects the surrounding population, properties and vegetation, also effects the working of operating staff in near vicinity.
Ground level concentration (GLC) : Long term effects of toxic, combustion products on population, structures and plant and animals. Smoke: Causes considerable amount of environmental pollution.
Sept,2005 Page 25
Daily noise exposure limit

Daily exposure, hrs OSHA Noise regulation NIOSH Noise regulation
dBA
8 90
dBA
85
4
2 1 0.5 0.25
95
100 105 110 115
90
95 100 105 110
OSHA Occupational Safety and Health Administration. NIOSH National Institute of Occupational Safety and Health.
Sept,2005 Page 26
Recommended flare radiation levels

Permissible radiation level, BTU/Hrxft2,
(Including solar radiation)
Conditions/exposure times as per API-RP-521(1) Continuous exposure of personnel Emergency action lasting for several minutes without proper clothes Bruzutowski & sommer 2 hrs.
500
1500
Less than two hrs.
2000
Emergency action Less than 20 Sec. lasting up to 1 minute.

Sept,2005 Page 27
Recommended GLC levels

Pollutants
CO
Period of measurement
8 hrs average 1 hr average
Max. permissible level, PPM.

9.0 35.0 0.03 0.14 75 g/m3 260 g/m3 0.03 0.05 0.24
SO2 Particulate matter
Annual arithmetic avg. mean 24 hrs. avg. Annual geometric mean 24 hrs avg.
H2S NO2 Hydrocarbon
1hr avg. Annual arithmetic mean 3 hrs avg.
These levels of pollutants are as per OSHA standards

Sept,2005 Page 28
Types of flare system (Tip controls efficient burning)
Conventional : Conventional
flare consists of pipe stack with flare tip and pilot at top. The kinetic energy of the gas does not aid to air mixing for improving the burning efficiency.
Coanda effect flare:- High pressure gas
injected from a narrow slot follows a profile of curved surface. The tulip of coanda profile aids in formation of hollow cylinder of gas entrains air up to 20 times of gas volume helps in efficient burning. This creates both turbulence and sucking of air.
Jet Mix flare :- These are multiple nozzles and arms. The flare gas is
spread out to the ambient air at high velocity promoted rapid turbulence mixing with air and thus produces efficient burning.
Air Assisted flare:- These are provided with special mixing heads. Air
is blow into the stack through a concentric pipe results in turbulence mixing of air, ensuring efficient burning. --Continue--Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 29
Flare tips
BURNER
AIR
AIR
HP GAS FLARE GAS LP GAS
EXTERBNAL COANDA TIP (KALDAIR)
CONVENTIONAL TIP

Sept,2005 Page 30
Types of flare system (Tip controls efficient burning)
Steam assisted flare :-
This flare achieves the smokeless capability by mixing steam with the effluent. The steam is introduced at various points to suck secondary air and turbulence to improve mixing. The steam also reduces flame temperature by dilution and thus reduces the thermal radiation.
Reaction takes place ;
CnH2n+2
+2nH2O ==== nCO2 + (6n+2) H2

Sept,2005 Page 31
Flare tips
STEAM NOZZLE WIND SHIELD JET-MIX NOZZLE
STEAM
H.P. GAS STEAM FLARE GAS
L.P. GAS
STEAM ASSIST/GLASS-ASSIST TIP (JOHN ZINK)
LRGO TIP TIP (JOHN ZINK)
JET-MIX TIP (NATIONAL AIR OIL)
COANDA PROFILE
SLOT
STEAM
STEAM
FLARE GAS
COANDA STEAM-SSIST (KALDAIR)

Sept,2005 Page 32
INDUCED TANK
Dry gas seal

Dry gas seal controls the Oxygen ingress in the flare system and also reduces the quantity of gas required for the purging. There are basically four types of Dry gas seals.

Labyrinth seal. Arrestor seal. Fluidic seal @. Molecular seal @.

Sept,2005 Page 33
Dry gas seals

OUTLET FLARE TIP
AIR DRAIN AIR
DRAIN PURGE GAS
INLET
LABYRINTH SEAL
AIRRESTOR SEAL

Sept,2005 Page 34
Dry gas seals

OUTLET
AIR
SEAL
DRAIN
PURGE GAS
FLUIDIC SEAL
INLET DRAIN
MOLECULAR SEAL

Sept,2005 Page 35
Flare header sizing

Sub headers are sized for 0.9 mach number, main flare header for 0.7 to 0.8 mach number, stack is sized for 0.5 mach at peak flaring and 0.2 Mach for normal flaring. Most of times main flare header/sub-headers sizes are controlled by allowable back pressure rather than maximum allowable velocity as stated above. ** All connections to main flare header are from the top in order to avoid back flow of condensate.

Sept,2005 Page 36
Liquid seal drum

Prevents the flash back from travelling up-stream. Dry gas seal cannot prevent flash back.
Protect system against air ingress during vacuum pulling. Provides positive sealing. Avoids pulsation in flame flare tip.
Protect system against explosion.

Sept,2005 Page 37
Liquid seal drum design

( Normally vertical)
API RP-521 recommends sizing should be based on gas flow area 3 Times inlet pipe cross sectional area.
4
DdSept,2005 Page 38
( D d ) 3.
2 2
Drum diameter, M Inlet pipe diameter, M

--- Continue---
Disengaging height 2 to 3 Times the diameter. Minimum seal height: 4 w.c. Pipe height = 10 feet. Slotted / V-Notches dip tube controls surging flow. Seal height : 1.75 Times the back pressure. Design pressure = 7.0 kg/cm2g, Design temperature = As per header design.
Minimum water flow = 1.25 dm3/sec.

Sept,2005 Page 39
Knock-out drum
Liquid from the flare gas is required to be separated out before it is routed for flaring because: Liquid particles 90 burn in flare unnoticed except marginally change in flame colour.
Liquid particles 90 to 400 burning droplet visible in day light.

Liquid particles 400 gives fire balls, Therefore, liquid requires separation before it enters flare stack for burning.

Sept,2005 Page 40
Knock- out drum design

Normally Horizontal.
- Diameter : i) Single flow
D2
W 360 (dL dV ). M .P / T
- Diameter : ii) Double flow 0.7 times diameter calculated above.

---- Continue----

Sept,2005 Page 41
Length : ---Decided on liquid hold up basis. ---Normally 10 minutes Hold-up for liquid, removed by pump, on/off operations. Design pressure : 7.0 kg/cm2g, withstanding internal explosion. Design temperature :
20oC above the maximum temperature of any release.

Sept,2005 Page 42
Pilot ignition System

For pilot ignitions various devices are available, most common are:

Flame front generator Piezometer
Ballistic spark ignition

Sept,2005 Page 43
Flame front generator

FLAME FRONT GENERATOR
IGNITION FAILURE
PURGE FAILURE PURGE GAS R G
PILOT ON/OFF, GREEN/RED R R
IGNITION AUTO/MANUAL
ON PB OFF POWER
CONROL PANEL
IGNITION PG
PURGE
FLARE GAS 1/2"

PG
1/2"
1" TO PILOTS WINDOW
PLANT AIR

Sept,2005 Page 44
Flare gas purging system
All the dead ends of flare sub-headers / main header requires gas purging. The dry gas seal also requires continuous purging to avoid air ingress in the flare header due to chimney effect and during vacuum pulling. Normally gas for purging should be heavier than the air. The rate of purge flow should be sufficient to overcome any tendency of Flash back (1.0 fps min with H/C and up to 10.0 fps for hydrogen. Higher purge is required for the hydrogen because it has highest Flame propagation velocity). ----- Continue--Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 45
Flare gas purging system
In order to control the purge rate, a sample point is provided below the dry gas seal to monitor the oxygen content. As per API-521, oxygen should be less than 6%V. Any increase in oxygen content calls for increase in purging rate. Purge gas lighter than air is more effective than heavier gas. In case of heavier than air purge gas, there is no buoyancy mechanism causing air entry into the stack, and there is thus no incentive to include a dry gas seal.

Sept,2005 Page 46
Zero Flaring/ flare gas recovery Concept

Local environmental regulations Substantial reduction of CO2 and NOx emissions
Reduction in CO2 Taxes (in some countries)

Increase flare tip lifetime No loss in fuel gas purging
No need of pilot gas

Increased profit due to the sales value of flare gas Less noise and light disturbances
Achieving status of clean environment.

Sept,2005 Page 47
Instantaneous Ignition System

Requirement of an instantaneous ignition system, otherwise the pilot burner needs to be kept on.
Ballistic spark ignition technology
Continuous sparking ignition system

Sept,2005 Page 48
PPA possible option
PSH
0.8 MMSCFD
Flash Gas Recovery Comp. 29 psig 1st Stage FGC
PSH
2nd Stage FGC
LP 1 MMSCFD
0.05 MMSCFD 0.2 MMSCFD
HP
ATM VENT A ATM VENT B

Sept,2005 Page 49
Tapti possible option
PSH
?? MMSCFD
To suction of Booster Compressor
LP ?? MMSCFD
1st stage Recovery Comp.
2nd stage Recovery Comp

PSH
?? MMSCFD
HP
Waste gas to pilot

Sept,2005 Page 50
Concept of Box flare

Concept of box flare has been derived for the plants (Refinery and gas processing units) where substantial quantity of gas is required to be flared for quite some time. The concept of Box flare attends all the problems normally encountered with conventional flare. In Box flare, controlled combustion of flare gas is carried out inside the enclosed chamber and during peak flaring there is auto diversion of flare gas to conventional elevated flare stack.
Glaring: Controlled combustion inside the enclosed chamber, invisible from outside.
--Continue--

Sept,2005 Page 51
Concept of Box flare
Noise: - Enclosed chamber is provided with noise insulation from outside, which arrests noise emission from the burning. Radiation :-Enclosed chamber provided with refractory inside, acts as the barrier, does not allow heat radiation at outside working area. Ground Level Concentration:- Chimney at the top of box flare and controlled complete combustion helps in controlling the GLC rising above the dangerous level. Smoke :- Combustion is controlled by stages to ensure that gas should burn completely. Besides, there is check to divert the excess gas above its capacity towards elevated flare, thus ensures no smoke to emit from box flare.
Sept,2005 Page 52
Box flare
BOX FLARE
FLARE TIP
DRY SEAL 1:200 B.L 1:200
ELEVATED STACK
WATER
K.O DRUM
SEAL DRUM
WATER
ELEVATED FLARE
PIC
WATER
PIC
PIC
CLOSED CHAMBER
SEAL DRUM (FOR BOX FLARE)
BOX (ENCLOSED BURNING)

Sept,2005 Page 53
THANK YOU

Sept,2005 Page 54

Aker Kvaerner Powergas Pvt. LTD.: Flare System

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Aker Kvaerner Powergas Pvt. Ltd.

Typical flow diagram