ONSHORE
and
OFFSHORE
Technical Presentation
ONSHORE and OFFSHORE
FLARE SYSTEM DESiGN
THE FLARE A KEY COMPONENT
The flare is a key component of the closed emergency
release system.
Emergency releases from various sources are routed
through a blow-down drum to separate liquids.
Flare provides safe disposal for personnel and
equipment.
Reduce environmental pollution (smoke, noise, light) by
correct flare system design.
FLARE SYSTEM DESIGN
Capacity and Sizing:
Largest vapour release or combination;
Maximum allowable back pressure on relief valves;
Consider pressure drop through system from relief valve
to flare tip;
Generally limit tip exit velocity to Mach 0.5 onshore (LP)
and Mach 1.0 offshore (HP);
For H2 or inert rich gases limit exit velocity;
FLARE SYSTEM DESiGN
Flare Location and Height:
Predominantly based on radiation;
In some cases toxic gas dispersion;
Radiation:
Limits based on personnel tolerance
500BTU/h.ft2 (1.6kW/m2) Continuous
1500BTU/h.ft2 (4.7kW/m2) Emergency
Solar to be added where appropriate.
Thailand - TOC
KSA - IBN-ZAHR
Khursaniyah SAUDI ARAMCO
OFFSHORE
ONSHORE
GBA SOLUTiONS
Statoil Snorre TLP
Sendje Ceiba FPSO
Exxon Falcon FPSO
ONSHORE
ONSHORE FLARE SYSTEMS
Refineries, Chemical Plants, Oil
Terminals, LPG Terminals,
Steelworks;
Flare System operates at low or near
atmospheric pressure;
Often release high molecular weight
gases that produce smoke;
ONSHORE
TYPiCAL ONSHORE FLARE P&ID
OFFSHORE FLARE SYSTEM
OFFSHORE
Oil and Gas Production Facilities
Platforms, FPSOs and Pipeline
Terminals
Primarily high pressure flare
systems with some associated
low pressure
Low molecular weights less
prone to smoke
OFFSHORE
TYPiCAL OFFSHORE FLARE P&ID
OFFSHORE FLARE TiPS
OFFSHORE
General Purpose low pressure streams
Pipeflare
High Pressure Sonic
Multi-Nozzle (each nozzle with annular gas exit slot
for greater efficiency)
Single Nozzle open pipe
Variable Slot multi-nozzle low radiation and
smokeless from purge to maximum
Water injection to reduce radiation
AirLock seals included in all tips
OFFSHORE
ONSHORE
TYPiCAL RADiATiON PLOTS
ONSHORE
OFFSHORE
OFFSHORE
ONSHORE
FLARE SYSTEMS
Elevated Flare
Derrick Structure
Guyed Riser
Guyed Derrick
Self Support
Ground Flare
Enclosed
Open
Burnpit
Gas and Liquids
OFFSHORE
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
OFFSHORE
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
OFFSHORE
ONSHORE
FLARE TiPS
General Purpose
Pipe flare
Smoke Suppression
Steam assist
Air assist
Gas assist
High Pressure
Sonic
FLARE TiPS
PIPE Flare
OFFSHORE
ONSHORE
PF model
Low Velocity Acid Gas
FLARE TiPS
Steam Assist - Smoke suppression
OFFSHORE
ONSHORE
GCT-C STEAM ASSiSTED model
GCT-30C
FLARE TiPS
Steam Assist - Smoke suppression
OFFSHORE
ONSHORE
GAJ-C LOW NOiSE SMOKELESS model
FLARE TiPS
Steam Assist - Smoke suppression
OFFSHORE
ONSHORE
GAJ-AJ-C HiGH CAPACiTY SMOKELESS model
GCT-AJ-54/48-C
FLARE TiPS
Air Assist - Smoke suppression
OFFSHORE
ONSHORE
CAF model
FLARE TiPS
Gas Assist - Smoke suppression
OFFSHORE
ONSHORE
PF-GA model
FLARE TiPS
High Pressure - Sonic
OFFSHORE
ONSHORE
CSF model
SONiC FLARE
OFFSHORE
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
AiR INGRESS SEALS
AiR LOCK SEAL / MOLECULAR SEAL
To prevent flash back and internal
explosion;
Air
Air Lock
Seal
Air can enter through the flare tip;
Inlet
upstream flare
tip
Outlet
Add an air ingress seal to reduce
purge;
Drain
Inlet
Hand
Hole
Molecular Seal
Purge with hydrocarbon or inert
gas;
Air Lock Seal
OFFSHORE
ONSHORE
within flare tip
AiR INGRESS SEALS
OFFSHORE
ONSHORE
AiR LOCK SEAL / MOLECULAR SEAL
Air Lock Seal
Molecular Seal
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
STRUCTURAL SUPPORTS
ONSHORE
Self-support short stacks, not economic for SS
risers
Guy wire supported riser most economic
Good for heights up to 150m
Limited by differential process temperature
maximum DT~200/300oC
Guy wire supported derrick;
Derrick
Fixed riser
Demounting risers
STRUCTURAL SUPPORTS
ONSHORE
Self-Support
STRUCTURAL SUPPORTS
ONSHORE
Guy wire supported Riser
STRUCTURAL SUPPORTS
ONSHORE
Guy wire supported Derrick
STRUCTURAL SUPPORTS
Derrick
ONSHORE
FIXED RISERS
STRUCTURAL SUPPORTS
Derrick
ONSHORE
DEMOUNTING RISERS
STRUCTURAL SUPPORTS
Derrick
ONSHORE
DEMOUNT STRUCTURE
Multiple flares in one
derrick
Individual flares can be
demounted to access
flare tip for maintenance
Highest flares in world at
204m
(3 derricks for Finaneste,
Antwerp)
STRUCTURAL SUPPORTS
Derrick
ONSHORE
INSTALLATION SERVICES
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
ONSHORE
WATER SEAL
Provide
Positive seal against air ingress
into header
Flashback prevention
Maintain flare header at positive
pressure
Horizontal or vertical
Manway
Flare Gas Inlet
Water Inlet
Sized to prevent water carryover
except in emergency
fast water make-up required.
Level Inst.
Level Inst.
WL
Level Inst.
Level Inst.
Water
Overflow
Steam In
Steam Out
Internal design critical
to prevent pulsation
Drain
DIA
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
ONSHORE
KNOCK-OUT DRUMS
Designed to
remove large liquid
droplets that
cannot be burnt by
the flare tip.
Return liquids to
the process or
drain.
Flare Gas Outlet
Flare Gas Inlet
Manway
Pressure
Gauge
Conn.
Temperature Inst.
Level Inst.
Level Inst.
Site as close as
possible to the flare
stack.
LL
Level Inst.
Level Inst.
288
Drain
DIA
No internals that
OFFSHORE
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
SMOKE EMiSSiON CONTROL
Ringelmann Index
OFFSHORE
ONSHORE
THE PROBLEM
Long smoke plume in typical light wind conditions
Ringelmann 0
SMOKE EMiSSiON CONTROL
Ringelmann Index
OFFSHORE
ONSHORE
THE PROBLEM
Ringelmann 1
Ringelmann 2
Ringelmann 3-4
Ringelmann 4-5
SMOKE EMiSSiON CONTROL
Steam Control system
OFFSHORE
ONSHORE
THE SOLUTION
Accurate control of steam will:
Minimise smoke emission;
Minimise noise emission;
Minimise steam consumption;
Avoid over steaming & possible loss of flame.
Use Infra-red monitor to
provide closed loop steam
control based on flame
condition,
rather than flow/density
measurement.
SMOKE EMiSSiON CONTROL
Air Assist system
THE SOLUTION
OFFSHORE
ONSHORE
Low pressure fans
Axial for low capacities
Centrifugal for high capacities
Air flow control
2 speed motor gives 10% and
100%
Variable speed drive (VSD)
Inlet vane control
Multiple fans 2 x 50%
Duty / standby
2 x 100% or 3 x 50%
OFFSHORE
ONSHORE
FLARE SYSTEM COMPONENTS
Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system
OFFSHORE
ONSHORE
IGNiTiON SYSTEM
Flame Front Generator [F.F.G.]
Manual
Automatic
High Energy Ignition [H.E.I.]
Automatic easy
Ballistic Spark Ignition
Pilot Monitoring
Thermocouples
Flame ionisation rod
Infra-red camera
IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system
OFFSHORE
ONSHORE
Mix gas and air in correct ratio (10:1);
Fill ignition line with gas/air mixture (allow several
minutes);
Generate spark from push button to ignite mixture
(grunt sound rather than crack);
Flame front travels along pipe to light pilots;
Monitor pilot status with thermocouple (may take a
couple of minutes to heat up);
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
Flame Front Generator (F.F.G.) system
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
Flame Front Generator (F.F.G.) system
Free standing easel;
Open to atmosphere;
Robust;
Operator interface;
Remote monitoring;
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
Flame Front Generator (F.F.G.) system
ADVANTAGES:
DISADVANTAGES:
Generally simple to operate;
Suffers from changes in fuel
gas and air conditions;
Requires operator adjustment;
Difficult to operate in automatic
mode;
Water in lines will prevent
flame front.
Economic;
Mechanically robust.
IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system
NATURAL DRAFT
OFFSHORE
ONSHORE
Uses fuel gas pressure to inspirate its own air;
Fuel gas ejected from jet of venturi inspirator;
Action of gas through centre causes drop in static
pressure;
Drop in pressure causes air to be drawn in to form
correct gas/air mixture;
Ignition line 2 to 3 due to low pressure;
Has a high tolerance to set pressure;
Used over shorter distances < 200m;
IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system
OFFSHORE
ONSHORE
NATURAL DRAFT
IGNiTiON SYSTEM
High Energy Ignition (H.E.I.) system
OFFSHORE
ONSHORE
Direct electric spark ignition in flare pilot;
High Energy = rapid discharge of large capacitors at
relatively low voltage;
Powerful spark not prevented by dirt, water or oil build
up;
High temperature cable rated to 600oC;
Transmission at 2.5kV - standard cable;
Ignitor unit in control panel up to 300m from pilot;
Fully automatic control using thermocouple or flame
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
High Energy Ignition (H.E.I.) system
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
High Energy Ignition (H.E.I.) system
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
High Energy Ignition (H.E.I.) system
Stainless Steel NEMA 4X Purged
Stainless Steel EExde IIC T3
IGNiTiON SYSTEM
High Energy Ignition (H.E.I.) system
OFFSHORE
ONSHORE
HIGH TEMPERATURE
CABLE
Typically 12m long
Max Temp 600oC
Simple screw connector to
ignitor rod
SS braid over SS flexible
hose
LOW TEMPERATURE CABLE
400m maximum
- 45o C to 200oC
Wire armoure
PVC or silicone rubber sheath
1 cable per pilot
IGNiTiON SYSTEM
OFFSHORE
ONSHORE
Ballistic Spark Ignition
ABB GAS TECHNOLOGY,
NORWAY
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
THERMOCOUPLES
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
THERMOCOUPLES
ADVANTAGES
DISADVANTAGES
Simple
Economic
Easy to replace
Generally >90 sec. response
time
Prone to failure
Cannot be replaced without
shutdown
IGNiTiON SYSTEM
Pilot Monitoring
FLAME IONISATION ROD
OFFSHORE
ONSHORE
Monitors for presence of flame in the pilot nozzle;
DC potential applied to ionization rod and ground;
Weak current passes through ionised gases of the
flame;
Electronic detection remotely located;
Instantaneous detection;
Ionization rod made of high temperature alloy for long
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
FLAME IONISATION ROD
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
FLAME IONISATION ROD
ADVANTAGES
DISADVANTAGES
Instantaneous detection
Control system at ground
level accessible
Relatively resistant to
thermal damage
Relatively expensive
Prone to dirt/carbon build-up
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
INFRA-RED CAMERAS
Continuous monitoring
of pilot flames;
Senses unique
frequency of pre-mix
flame;
Infra-red detector up to
400m away, will monitor
regardless of flame
movement, varying
luminosity, most climatic
conditions;
IGNiTiON SYSTEM
Pilot Monitoring
INFRA-RED CAMERAS
OFFSHORE
ONSHORE
Principle of Operation
All objects above absolute zero emit I/R energy;
Amount of energy emitted is proportional to body
temperature;
Monitor collects energy via focusing optical system;
Energy concentrated onto a sensitive I/R detector;
Specialised amplification circuitry converts signal into DC to
activate relay and mA outputs for signal indications;
IGNiTiON SYSTEM
Pilot Monitoring
OFFSHORE
ONSHORE
INFRA-RED CAMERAS
ADVANTAGES
DISADVANTAGES
Visual detection of pilots
Located at ground level
accessible
Does not suffer thermal
damage
Quick response time
Expensive
Optics require frequent
cleaning
Standard temp range 4 to 52oC
Can add heater and cooler
added utilities
ANCiLLARY FLARE EQUIPMENT
OFFSHORE
ONSHORE
Propane Racks, Snuffing Systems,
Monitoring Equipment, Aircraft Warning Lights
Aircraft Warning Light Control
System
CO2 Snuffing System
