This document is a specification for a flare tip and burner ignition system. It outlines the scope, applicable standards, service conditions, technical requirements, instrumentation and control, testing, packing/marking/documentation, and spare parts requirements. The system must be suitable for continuous operation in desert conditions with high heat and humidity, and sometimes corrosive/H2S environments. It must safely and reliably flare over a wide range of flow conditions and wind speeds.
This document is a specification for a flare tip and burner ignition system. It outlines the scope, applicable standards, service conditions, technical requirements, instrumentation and control, testing, packing/marking/documentation, and spare parts requirements. The system must be suitable for continuous operation in desert conditions with high heat and humidity, and sometimes corrosive/H2S environments. It must safely and reliably flare over a wide range of flow conditions and wind speeds.
This document is a specification for a flare tip and burner ignition system. It outlines the scope, applicable standards, service conditions, technical requirements, instrumentation and control, testing, packing/marking/documentation, and spare parts requirements. The system must be suitable for continuous operation in desert conditions with high heat and humidity, and sometimes corrosive/H2S environments. It must safely and reliably flare over a wide range of flow conditions and wind speeds.
This document is a specification for a flare tip and burner ignition system. It outlines the scope, applicable standards, service conditions, technical requirements, instrumentation and control, testing, packing/marking/documentation, and spare parts requirements. The system must be suitable for continuous operation in desert conditions with high heat and humidity, and sometimes corrosive/H2S environments. It must safely and reliably flare over a wide range of flow conditions and wind speeds.
PACKING. MARKING AND DOCUMENTATION .................... 8
SPARE PARTS AND MAINTENANCE REQUIREMENTS .............. 8
1.0 SCOPE
1.1 This specification covers the design, manufacture, inspection, testing and supply of the Flare Tip and Burner Ignition System for installation at the Facility in Kuwait.
1.2 The Flare System shall fully comply with all relevant contractual requirements specified in the Scope of Work and Technical Specification of the Contract.
1.3 This specification complements the data sheets for the flare systems in which the operating conditions and other requirements are listed in detail.
2.0 STANDARD SPECIFICATIONS
2.1 The Flare System shall conform in design, materials and performance, except where otherwise specified, with the current issue of the following standards prevailing on the effective date of the Contract:
2.1.1 International Standards
API RP 520 Sizing, Selection and Installation of Pressure
Relieving Devices in Refineries.
API RP 521 Guide to Pressure-Relieving and Depressurising
Systems
API PUB 931 Disposal of Refinery Wastes Atmospheric
Manual One Emissions, Chapter 15, "Flares"
ASME 816.5 Pipe Flanges and Flange Fittings
ASME 831.3 Chemical Plant and Petroleum Refinery Piping
2.1.2 Engineering Group Specifications
All equipment and accessories covered by this specification shall
comply with all relevant Engineering Group specifications of which the following are specifically referenced in this specification:
015-AH-1001 Basic Design Criteria
015-AH-1002 International Codes and Standards
01 5-JH-1911 Standard Auxiliary Control Room Cabinets
015-JH-1903 General Instrument Specification
Specification Number Rev Date Sheet E47Jf-m Gnwp SpediktWn 01 5-FH-1002 1 05-07-94 4 of 8
Instrumentation Requirements for Package
Equipment
Spare Parts and Maintenance Requirements
Air Blower
Standard Burn Pit Details
Noise Control Requirements
Thermal and Acoustic Insulation
Induction Motors
Packing, Marking and Documentation
Shop and Field Painting
2.2 Compliance with this specification shall not relieve the Contractor of its responsibility to supply equipment suited to meet the specified service conditions and applicable regulations.
2.3 Where conflicts exist between this specification and other Drawings, standards, codes or specifications, the most stringent shall apply.
3.0 SERVICE CONDITIONS
3.1 The Flare Tip and Burner Ignition System shall be suitable for continuous operation at a desert location under high ambient temperatures and humidity. The atmosphere at the Facility is generally dusty and corrosive and may contain traces of hydrogen sulphide.
3.2 The Flare Tip and Burner Ignition Systems shall in all respects be suitable for continuous operation in the service conditions stated in the Engineering Group Specification entitled "Basic Design Criteria" (Number 01 5-AH-1001 1.
4.0 TECHNICAL REQUIREMENTS
4.1 The Elevated Flare System shall be designed and constructed as a package which shall consist of, but not be limited to, the following:
4.1.1 Flare stack with flare tip, seal, pilot burners and ignition system.
4.1.2 Flame front generator.
4.1.3 Monitoring panel.
Specification Number Rev Date Sheet
QKOC E n g i m n g Gnwp Spdihubn 015-FH-1002 1 05-07-94 5 of 8
The ground Flare System shall be designed and constructed as a unit which shall consist of, but not be limited to the following:
4.2.1 Burn pit suitably lined with refractory, surrounded by a protective
dike.
4.2.2 Horizontal flare tip, seal, pilot burners and ignition system.
4.2.3 Flame front generator.
4.2.4 Monitoring panel.
The Flare System shall operate satisfactorily over the full range of operating conditions from purge to maximum flow, including instantaneous flow changes, with a sustained wind velocity from zero up to maximum values as specified in the Engineering Group specification entitled "Basic Design Criteria" (Number 01 5-AH-1001).
The maximum permissible radiation levels are as follows:
At grade 18370 W/m2 Perimeter of sterile area 5680 W/m2 Facility Fence 2360 W/m2
(All the above, including solar radiation 950 W/m2.)
When more than one elevated flare system and/or ground flare system is located in a common flare area, the maximum permissible radiation levels specified above are applicable to the combined radiation from ad flare systems in the area. However, if standby flares are provided, only one of two mutually replaceable units shall be taken into account for determination of the combined radiation levels.
Valves and other equipment on the flare line shall be located at a safe distance from the flare such that routine maintenance can be carried out.
The sizing and location of flares in a common flare area shall ensure possibility of maintenance of standby units when other units are .operating. The radiation level at maintenance points shall not exceed 4730 W/m2, including solar radiation of 950 W/m2.
Where stated on the data sheets, the Flare System shall be provided with additional combustion air by means of an electric motor-driven air blower. The blower and motor shall be in accordance with the Engineering Group Specifications entitled "Air Blowers" (Number 015-KH-1006) and "Induction Motors" (Number 015-PH-1908): respectively. Flares installed with the Speclflcation Number Rev Date Sheet Ettgln9811ng Orwp 1 05-07-94 6 of 8 s.oeC#hM 0 15-FH-1002
facility of an air blower shall be capable of burning flare gas with or without the blower in operation. With the blower in operation, the flare tip shall produce a non-luminous, smokeless flame for waste gas all flow rates from maximum down t o 15% of maximum. Trip of the blower shall not cause flame-out.
The maximum allowable outlet velocity at the flare tip is 0.5 Mach.
The flare tip assembly shall be structurally designed using the design wind velocities defined in the Engineering Group Specification entitled "Basic Design Criteria" (Number 015-AH-1001 ).
The flare tip shall be designed to minimise flame impingement on the outside of the tip and on any part of the support structure regardless of gas flow rate, wind speed or wind direction.
The material of the flare tip shall be heat-corrosion resistant, e.g., AlSl 31OS, or Company-approved equivalent. All ancillaries connected to this part of the flare shall be of the same material.
For maintenance purposes, a facility shall be provided for access to and
lowering of the flare tip of elevated flares. Access shall also be provided to flare tip of ground flares and manholes of elevated flares.
For flare tips up to 16 in., a minimum of two pilot burners shall be provided. Three pilot burners shall be provided for flare tips of 16 in. and greater. Each of these burners shall be ignited by means of an individual ignition from a flame-front generator at ground level.
The ignition lines to the pilot burners shall be stainless steel (AISI 31 6). The top 4 m shall be AlSl 310, or Company-approved equivalent.
Each pilot shall be provided with two thermocouples. Each thermocouple
shall be dual-element type. One element of each thermocouple shall be used, with the other terminated at the grade junction box and available as a spare. One stainless steel fuel gas supply line along the elevated flare stack is required for each pilot burner. A filter shall be installed between the carbon steel fuel gas supply line to the flare and stainless steel fuel gas supply lines to pilots.
The pilot and igniter lines shall be piped separately in accordance with ANSI B 31.3 between the flame front generator and the flare tips. All pipes shall be flanged at the flame front generator and at the bottom of the tip assembly to facilitate flare tip removal.
All necessary controls shall be provided to ensure that the required flow of fuel gas passes to each pilot and that each pilot can be ignited individually. Specification Number Rev Date Sheet Engindng Grwp 01 5-FH-1002 1 05-07-94 7 of 8 S m # I
A flame-front generator shall be provided for each flare. Each package shall contain all the necessary control valves, isolating valves, pressure gauges, ignition chambers and piping to provide the correct gas-air mixtures for remote ignition of the pilots.
The flare ignition control panel and components shall be suitable for operation in hazardous or safe area, as specified in the flare data sheets.
All fuel gas and air pipework, valves and fittings comprising the flare ignition package shall be provided terminating at flanged connections to ANSI B 16.5.
Inspection shall be carried out in accordance with a program specified by the
Contractor and approved by the Company.
The Contractor or the designated Representative shall inspect all Flare
System components and their assembled units to ensure that materials and workmanship are in accordance with applicable standards, specifications, codes and Drawings.
5.0 INSTRUMENTATION AND CONTROL
5.1 The Flare System shall be started and shut down locally.
5.2 A local flame-front generator panel shall be provided. This panel shall contain all necessary equipment and repeat indications to enable a field startup of the system.
5.3 Thermocouple indication alarms shall be activated from each of the following conditions:
5.3.1 The loss of each thermocouple signal.
5.3.2 Both thermocouple signals lost from pilot.
5.3.3 All thermocouple signals lost (i.e., all pilots are lost).
5.4 The flame-front generator panel shall be mounted at grade at a position
determined to be safe for exposure of the operator during operation of the flare. The flame-front generator provides a moving column of ignited gas-air mixture which can be directed by means of hand valves to any of the pilots on a flare.
5.5 A Flare System monitoring panel shall be provided and shall be mounted in the un-manned auxiliary control room, which has a safe controlled environment. The panel shall have a data communication link to the DCS. The cabinet shall be of the same type, Approved Manufacturer and colour as the other cabinets in the system, as referenced in the Engineering Group Specification entitled "Standard Auxiliary Control Room Cabinets (Number 015-JH-1911).
The monitoring panel shall contain as a minimum all electronic devices for control, logic and condition monitoring, which are affected by high temperatures. The monitoring panel may be "blind" with no indicating devices included.
All instrumentation and controls shall terminate at segregated junction boxes
as detailed in the Engineering Group Specification entitled "lnstrumentation for Packaged Equipment" (Number 015-JH-1909).
The prime operator interface shall be the main DCS. Dedicated page(s) shall be allocated to display the equipment status, alarms, etc.
The alarm and trip inputs shall be integrated into the DCS and main Emergency Shutdown System (ESD) system first-up sequences.
The selection of instruments, hazardous area execution and installation
techniques shall all be in accordance with the Engineering Group Specifications entitled "General Instruments" (Number 015-JH-1903) and "lnstrumentation for Packaged Equipment" (Number 01 5-JH-1909).
Stainless steel tubing double-ferrule fittings and pneumatic connections shall
be used throughout. The burner thermocouple shall be sheathed in lnconel for the full height of the flare.
All instrumentation shall be fully mounted and piped. An air supply header shall be provided and all users connected in accordance with the specifications. All electronic instruments shall be wired down to skid- mounted junction boxes, with signal segregation in accordance with the specifications. Junction boxes at the flare base shall be protected by a radiation shield.
6.0 TESTING
As a minimum, the Approved Manufacturer shall carry out a functional test on all instrumentation and flame-front generator prior to leaving the Works. The testing procedure shall be approved by the Company.
7.0 PACKING, MARKING AND DOCUMENTATION
For all relevant requirements, refer to the Engineering Group Specification entitled "Packing, Marking and Documentation" (Number 01 5-UH-1001).
8.0 SPARE PARTS AND MAINTENANCE REQUIREMENTS
For all relevant requirements, refer to the Engineering Group Specification entitled "Spare Parts and Maintenance Requirements" (Number 01 5-KH-1902).
