The document discusses flare systems, including their purpose of safely combusting flammable gases from industrial facilities. It describes typical components of flare systems such as collection headers, knockout drums, stacks, flare tips, and integrated pilot systems. It also discusses limitations of operating flare systems, such as maintaining a stable flame, potential hazards like flashback, and proper maintenance requirements.
The document discusses flare systems, including their purpose of safely combusting flammable gases from industrial facilities. It describes typical components of flare systems such as collection headers, knockout drums, stacks, flare tips, and integrated pilot systems. It also discusses limitations of operating flare systems, such as maintaining a stable flame, potential hazards like flashback, and proper maintenance requirements.
The document discusses flare systems, including their purpose of safely combusting flammable gases from industrial facilities. It describes typical components of flare systems such as collection headers, knockout drums, stacks, flare tips, and integrated pilot systems. It also discusses limitations of operating flare systems, such as maintaining a stable flame, potential hazards like flashback, and proper maintenance requirements.
The document discusses flare systems, including their purpose of safely combusting flammable gases from industrial facilities. It describes typical components of flare systems such as collection headers, knockout drums, stacks, flare tips, and integrated pilot systems. It also discusses limitations of operating flare systems, such as maintaining a stable flame, potential hazards like flashback, and proper maintenance requirements.
Describe the components of a typical flare system Discuss the limitations and hazards associated with operating flare systems Discuss maintenance requirements of flare systems
Flares What are they?
Why do we need them? The primary function of a flare is to use combustion to convert flammable, toxic or corrosive vapors to less objectionable compounds. (API 521 paragraph 6.4.1) Safely during both emergency and routine operations.
Flare Systems - Purpose
A system of Process Safety Management (PSM) critical
mechanical equipment that gathers and safely burns hydrocarbons from pressure-relieving and vapordepressurizing systems Must be continuously available Must be reliable for years Capable of performing through all operating-plant emergency conditions, including a site-wide general power failure or a weather event including a hurricane Difficult to add equipment or modify because they are very infrequently out of service as they serve many units that are infrequently out of service. (API 537 paragraph 4.1) 4
Typical Flows to Flare Systems
Emergency Pressure relief flows Emergency depressurization Episodic Venting required for maintenance Venting required for regeneration Shutdown/Start-up operations (de-inventorying) Continuous 99+% of Typical Operation Sweep gas through the flare system piping Process venting (continuous analyzer flows, gas seals, certain types of pressure control) Pressure Relief Valve leakage 5
Typical Flare System
Flare System Major Components
Every flare system is unique and different
Every flare system contains differential components Series of collection headers from sources Knockout drum Stack Flare Tip Liquid seal Purge reduction device (stack seal) Integrated pilot system Monitoring and operation instrumentation Flare hydrocarbon recovery systems
Typical Flare Header System
PRV 2
PRV 1
Legend: PRV Pressure Relief Valve FIC Flow Control Valve Tailpipe
Process Unit Header
Purge Gas
FIC
PRV 3
Purge Gas
PRV 4
PRV 5
Process Unit Header FIC
Main Flare Header Purge Gas
FIC
To Flare Liquid Knock Out Drum 8
Hydraulic Design
Flare header is sized to limit the back pressure of each
pressure relief device during various emergency events.
The hydraulic design is a line sizing / rating problem
Design minimizes the differential pressure to ensure
each pressure relief device functions properly
Design is based on specific line size, line length and
maximum expected relief load for each relief event
Hydraulic Issues
Hydraulic issues specific to flare header design:
Different relief events govern the size of various
sections of the collection header
A variety of materials discharge to the flare system
Potential pressure discontinuities where pipe flows meet
Volume expansion throughout header piping
High velocity and significant acceleration effects
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Knock-Out Drum
Pressure Vessels
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Knock-Out Drum
Separates liquid from gas (2 phase separation)
Prevents liquids from being discharged to atmosphere
Prevents or reduces smoke because of reduced liquid
in the flame
Increases flare tip life
Allows draining of liquid prior to flare
For reprocessing
For disposal 12
Typical Knock-Out Drum
Light Liquid (oil)
Heavy Liquid (water) Heavy Liquid (Outlet)
Light Liquid (Outlet)
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Liquid Seal
Courtesy: John Zink Company
Flashback prevention Prevent air infiltration Helps maintain positive header pressure Staging device Some systems include an additional flame arrestor
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Flare System Purge Requirements
Purge gas composition
Non-condensing typically natural gas or nitrogen Non-corrosive Non-reactive to other gasses in the system Purge gas locations Upstream or downstream of a liquid seal End of major header or branch Purge must be continuous and measurable Purge gas sweeps the header of O2, corrosive, reactive, or inert components
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Purge Requirements
System Requirements (manufacturer specified)
Type of stack seal for air intrusion Flame stability Flare System Cooling Offset pressure reduction after a hot release Protect system until liquid seal can be re-established
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Purge Reduction Devices
(Stack Seal)
Velocity Seal Courtesy: John Zink Company
Density Seal 17
Flare Types
Single point With or without smoke suppression Vertical, elevated discharge point, but may be horizontal (pit) May stage two single point flares for better control
Multi-point Improved burning through multiple burning points Smokeless Divided into stages to facilitate better burning Must operate with high back pressure
Enclosed Conceals flame from direct view Reduction in noise level Minimization of radiation 18
Flare Tip Design
Provides safe and efficient burning of flare gases over
wide flow conditions
Steam or air injection provided for smokeless operation
for most operating scenarios
Smokeless operation a function of flow
Smokeless operation a function of gas composition
Maintain flame stability
May require multiple flares and types
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Single Point Flare
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Air Flare
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Staged Flare
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Multi-Point Flare
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Enclosed Ground Flare
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Integrated Pilot System
Pilots Premix burner Pilot igniters Direct spark Flame Front Generator (FFG) Pilot monitors Heat: Thermocouples Light: Infrared camera Sound: Acoustic monitoring Flame ionization
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Pilot Assembly
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Pilot Assembly
Flame front tube
Direct spark
Fuel gas
Dual Thermocouples
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Flare System Operational Controls
Steam or air flow to flare tip
Cooling (minimum flow)
Protection for metal
Eliminate internal burning (center steam)
Smoke control Upper steam Steam Air tube steam (larger tip size only) Center steam Keep steam hot (minimize condensate) Water seal level Flow and temperature control Staging control Knock-out drum liquid flow Assist gas flow Collection header purge Oxygen level in flare header Pilot ignition
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Flare System Monitoring Instrumentation
Flare system operation monitoring
Video camera Pilot gas flow and temperature Relief gas flow, pressure, temperature and composition Knock-out drum level Water seal level, pressure, and temperature Steam flow to flare Collection header purge gas flow Flare gas recovery Control and monitoring equipment may not be available for maintenance with flare system in service Each flare system monitoring requirement is unique and can be different 29
Recovered Flare Hydrocarbon Gas to Processing Unit Recovered Liquids
Main Flare Header
Liquid KO Drum
Flare Seal Drum
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Flare Recovery System
Gas collection for routine operations limited in outlets when
pressure is low Low pressure streams generally have 1 of 4 outlets Lower pressure system (often not available) Eduction to higher pressure system Compressor to increase pressure Flare Eduction has some, but limited, applicability Pressure of eduction must be considered Acceptability of stream being educted High H2S in stream is often a factor Compressor can be a viable option Wet Gas compressor for FCCs is an example of viable option If no compressor nearby, cost of new compressor often is prohibitive 31
Flare Recovery System
Flare hydrocarbon gas recovery systems
More common in refineries Less common in chemical plants Flaring generally last preferred destination Any gases sent to flare are lost product for company Flaring has regulatory, environmental and community impacts that companies prefer to not have
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Other Flaring Reduction Best Practices
Leak source monitoring and control
Acoustic monitoring Temperature monitoring Flare gas analysis Start-up/shut-down planning Flare minimization best practices Load shed plans, routine operating practices Root cause analysis of flaring events
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Flare Operation
Maintain stable flame - EPA 40 CFR 60.18 defines
requirements for stable flame: Have a continuous pilot with monitoring Limits minimum heat content of flare gas: 200 BTU/scf for non-assist flare 300 BTU/scf for assist flare Maximum exit velocity based on heat content of flare gas (60 400 FPS) Flame may not always be visible Hydrogen Low BTU gas - e.g. CO 34
Operation - Weather Effects
Wind Alter flame shape Sheer unburned hydrocarbons Extinguish pilot flame Physical damage to equipment Rain Extinguish pilot flame Extreme conditions (i.e. hurricane) Loss of steam Loss of power Extinguish pilot & main flame 35
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Operational Flow Control
Emergency Maximum Hydraulic Flow
May not be able to control smoking Able to maintain destruction efficiency Episodic Medium Flow Mostly able to control smoking Able to maintain destruction efficiency Continuous Extreme Turn-Down Condition Able to control smoking May not be able to control destruction efficiency Cooling steam to hydrocarbon ratio Weather effects 37
Factors that can Affect
Flame Stability Flame stability
Fuel exit velocity
LHV of fuel Pilot(s) Weather
Operation Maintenance Steam Control Air Control
flare Courtesy: John Zink Company
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Operating Hazards and Limitations
Loss of flame/pilot Liquid carry-over Flashback - air intrusion Loss or insufficient purge Steam control under/over Freezing condensate in cold climates Inconsistent composition, pressure, and temperature Brittle fracture of material for cold relief Blockage Soot Freezing condensate in cold climates Mechanical failure Noise Light Thermal radiation Limited ability to perform maintenance while in service 39
Flare Maintenance
Most major maintenance has to occur during a turnaround
Consideration for T/A inspection, PM, repair or replacement Pre T/A survey e.g.. drone technology Pilots Thermocouples Clean/check fuel and FFG piping for leaks and pluggage Critical instrumentation Stack riser Guy wire connections at stack Water seal KO drum Aviation lights 40
