Flare Systems

Typical Relief System

Vent Header

R.V.

RE/U&O Flares-2

Purpose of Flare

Define Loadings to be Handled

Calculate loadings for all

contingencies
Geographic location of each
source
Calculate maximum load
(power failure,fire case)

Fire case limited to a

ground area of 230 - 460
square meters

Calculate maximum back

pressure

Major Factors Influencing Flare Design

Gas Composition
Flow Rate
Gas Pressure Available
Initial Investment
Operating Costs
Gas Temperature
Energy Availability
Environmental
Requirements
Safety Requirements
Social Requirements

Main Flare Standards and

Recommended Practices

API RP 520: Part I Sizing Selection and Installation

of Pressure-Relieving Devices in Refineries Part I
Sizing and Selection
API RP 520: Part II Sizing Selection and Installation
of Pressure-Relieving Devices in Refineries Part II
API RP 521: Guide for Pressure-Relieving and
Depressurizing Systems
API Standard 537: First Edition September 2003:
Flare Details for General Refinery and Petrochemical
Services
RE/U&O Flares-5

US EPA Requirements 40CFR60.18

Sizing must also comply with Federal Register (40 CFR 60.18) for
maximum velocity of steam-assisted, elevated flares:
Net Heating Value of Vent Stream
Bv (Btu/scf)
300
300-1000
> 1000

Maximum Velocity
Vmax (ft/sec)
60
log10(Vmax) = (Bv + 1214)852
400

It is standard practice to size the flare so that the design velocity of flow
rate Qtot, is 80 percent of Vmax:
Dmin (in) = 12*[((4/PI)(Qtot/60sec/min))/(0.8*Vmax)]^0.5
Dmin (in) = 1.95 * (Qtot/Vmax)^0.5
Where:
Qtot = Q + F (measured at stream temperature and pressure)
Dmin should be rounded up to the next largest available commercial size
Btu/scf * 0.0373 = MJ/scm and ft/sec * 0.305 = m/s

Auxiliary Fuel Requirement

Amount of fuel required (F) is calculated based on

maintaining the vent gas stream net heating value
at the minimum of 300 Btu/scf (11.2 MJ/SCF)
required as described in the United States Federal
Register:
(Q * Bv) + (F * Bf) = (Q + F)* (300 Btu/scf)
Where:
Q = vent stream flow rate, scfm
Bv = Btu/scf of the vent stream
Bf = Btu/scf of the fuel stream
Therefore,
F (scfm) = Q * (300-Bv)/(Bf-300)
The annual auxiliary fuel requirement (Fa) is:
Fa (Msfm/yr) = (F scfm) * (60 min/hr) * (8760 hr/yr)
Fa (Mscfm/yr) = 526 * F

Elevated Flare System

Flare Tip
Steam Ring
Dry
Seal
Knockout Drum
Pumpout Pump

Flare Knockout Drum

Flare
Stack

PI
TI
Instrument
Air
Vent
Emergency
Gas Purge

Switch

LIAH

LGR

Solenoid
Valve
(With Manual
Reset)

RO RO

Purge Gas

Gas To
Pilot

PI

TAH

Grade

Pilot Ignition
Systems Locate
At Flare Knockout Drum

Normal
Gas Purge
Steam

Pressure Relief
From Process Units

Slop To
Slop Tank

PI

PC

Fuel
Gas

Plant
Air

Ground Flare
System

Flare Knockout Drum

Knockout Drum
Pumpout Pump

PI
TI

LGR

LIAH

Switch

PI

Instrument
Air
Vent

Emergency
Gas Purge

Solenoid
Valve
(With Manual
Reset)

Ground Flare
Retention Dike
Burners
Grade

Stage
Header

PO PO
Normal
Gas Purge

Purge Gas

Main
Header PC

Pressure Relief
From Process Units

Slop To
Slop Tank

Gas To
Pilot

PI

Pilot Ignition
Systems Locate At
Flare Knockout Drum
PC

Fuel
Gas

Plant
Air

Two Stage Flare System

(Elevated/Ground)
Flare
Tip

Seal
Flare
Stack
Flare Knockout Drum

Knockout Drum
Pumpout Pump

PI
TI

LGR

LIAH

Switch

PI

Instrument
Air
Vent

Water
Seal

Solenoid
Valve
(With Manual
Reset)

Enclosed
Ground
Plane

Gas To
Pilot

Pilot Ignition
Systems Locate At
Flare Knockout Drum

Emergency
Gas Purge RO RO

PI
Normal
Gas Purge

Purge Gas

Pressure Relief
From Process Units

PC

Slop To
Slop Tank

Water

Fuel
Gas

Plant
Air

Grade

Flare Stack

Structure
Self
Supporting
Guy
Supported
Derrick Type

Demountable Derrick Single-Section Riser

Normal Position
is A then can
be lowered for
work on the tip
to position C
Allows for easy
replacement of
tip

RE/U&O Flares-12

Demountable Derrick-Multiple Section Riser

Riser assembled in
sections
Designed to
accommodate
multiple risers
Designed so that one
flare can be taken
out of service while
others are still in
operation

RE/U&O Flares-13

Conventional
Pressure Relief Valve

RE/U&O Flares-14

Balanced-Bellows
Pressure Relief Valve

RE/U&O Flares-15

Pop-Action Pilot-Operated Valve

(Flowing Type)

RE/U&O Flares-16

Radiation Theory

6
5

Exposure Times Necessary

to Reach the Pain Threshold

4
Threshold of Pain

3
2

Safe Limit

440 Btu/(hr) (ft)2

1
0

10

550
740
920
1500
2200
3000
3700
6300

30

40

Exposure Time, Sec.

Radiation Intensity
Btu/hr-ft2

20

Kilowatts per M2

Times to Pain Threshold

(Seconds)

1.74
2.33
2.90
4.73
6.94
9.46
11.67
19.87

60
40
30
16
9
6
4
2

50

60

Contours of Radiant Heat Intensity

Safe Boundary
(440 Btu/Hr/Sq.Ft.)
Boundary
for Radiant
Heat Intensity
(1500 Btu/Hr/Sq.Ft.)
- Normally Fenced in with
Warning Signal
Protection
Required for
Equipment

Protection
Required for
Personnel
Boundary for
Radiant Heat Intensity
(3000 Btu Hr/Sq.Ft.)

Environmentally
acceptable
combustion
Tips normally
proprietary in
design
Flame stability
Ignition reliability
Exit velocity 1 to
600 ft/s (.3 to 183
m/s)
Exit velocity at
50% of sonic
velocity
Multiple pilot
burners
Surrounding
windshield

Flare
Tip

Flare Tip Design

Flare Tip Design

Considerations
Design for maximum
flow rates
Design for maximum
temperatures
Design for wind
conditions
Design for minimum
flow rates

Pilot and Ignition Systems

Continuously burning pilots

Flame front generator

Fuel gas and air admitted to

the ignition pipe in a
combustible ratio
Gas is ignited by an electric
spark
Flame travels through the
pipe

Flame Front Generator

Ignition System

Air

A To Pilot #1

H
J
Gas

To Pilot #2
To Pilot #3

E
C

Gas To Pilots

Pilot Burners

Automatic systems
may be activated by:
Thermocouples
Infrared Sensor
Ultraviolet Sensor
(ground flare
application)

Installation of Thermocouples
Correct Installation

Incorrect Installation

Pilot Windshield

Allows pilot to operate

at wind speeds greater
than 100 mph
Should always be
specified
Prevents misreading of
the thermocouples

Pilot Gas Requirement

The average pilot gas consumption based on an

energy-efficient model is 70 scf/hr. The annual
pilot gas consumption (Fp) is calculated by:

Fp (Mscf/yr) = (70 scf/hr)*(N)*(8,760 hr/yr)

Fp (Mscf/yr) = 613*N

N can be calculated from the following table:

Flare Tip Diameter (IN)

1-10
12-24
30-60
>60

Number of Pilot Burners (N)

1
2
3
4

Multiple Pilots

Multiple pilots
allow one pilot
to fail

Most flares
have two to
four pilots

Equally
spaced around
the flare

Troubleshooting Pilots
Problem Possible Cause

Corrective Action

Plugged
Pilot Tip

Start-up debris left in system

Remove debris manually

or by high pressure
blowing

Plugged
Pilot Tip

Unsaturated Fuel
Hydrocarbons

Remove manually or by
high pressure blowing
then return to fuel gas

Damage
Pilot Tip

Pilot tip has increased in size;

Pressure drop in pilot
decreased; Fuel/Air mixture
more lean

Replace pilot tip

Incorrect
Fuel

This can be determined by

fuel sample; if hydrogen
concentration has increased
significantly then flashbacks
may be audible and visible

Return to design fuel gas;

Pilot modifications may
include: replace pilot
orifice; adjust air door;
replace pilot entirely
RE/U&O Flares-28

Purging

Flare purge gas

Any gas which cannot go to

dew point under any
condition of operation

Fuel Gas
Inert Gas
Nitrogen

Purge Rate

Flare Stack
Linear velocity 1FPS to
5FPS (.3 to 1.5 m/s)
Flare stack with molecular
seal
0.10 FPS to 0.20 FPS
(.03 to 0.06 m/s)

Purge Gas Requirements

Prevents flashback problems

Flare operates at positive pressure
Purge all subheaders (upstream)
.04 feet per second to 1 feet per second
(.01 meters per second to 0.33 meters per second)

F (Mscf/yr) = (0.04 ft/sec)*((PI*D^2/4)/144 ft2))*(3600 sec/hr)*(8,760 hr/yr)

F (Mscf/yr) = 6.88*D^2

Dry Seals

Molecular Seals

Double Seals

Fluidic Seals

Airrestors

Molecular Seal

Flare
Assembly

Molecular
Seal
Liquid
Drain

Prevents explosions
Prevents entry of air
Reduces purge gas
Performs silently with
small pressure drop

Smokeless Flare Operation

Smokeless Operation

Smoking

US EPA allows smoking for

Only 5 minutes per hour

Steam Requirements and Smoke

Suppression Methods

In general, the following equation can be used:

Wsteam (lb/hr) = Whc (lb/hr) * [0.68-(10.8/MW)]

Smoke Suppression Methods

Steam injection
High pressure gas injection
Low pressure air
Internal energized flare

Automatic Steam Control

Field Of View
Steam Nozzles

Steam Control
Valve

Monitor
Flux Density
Signal
Controller
Control Scheme

Automatic Steam Control

Minimizes steam
consumption

Controlled by the
flame appearance

Calibrated to a
particular
frequency in the
infrared spectrum

Knockout Drums

Principle Features

Complete removal of either slugs or mists of liquid

(300 microns to 600 microns)
Recovers valuable condensed hydrocarbons
Ends maintenance difficulty caused by Wet gases
Used as the base for the flare riser
Ends Wet Gas control problems

The allowable vertical velocity

in the drum may be based on
the necessity to separate
droplets from 300-600 microns
in diameter.

Truck Loading Vapor Control Flare

Achieve high destruction

efficiencies through the
loading cycle

Systems range in size

from 100 BPH to 25,000
BPH

Enclosed burners can be

easily tested for
emissions

Troubleshooting Enclosed Flares

Problem

Cause

Action

High Frequency
Noise

Most likely
associated with
steam injection

Check steam quality and properties

Combustion Roar
(low frequency)

Intense
combustion

Check flare gas pressure and steam

quality

Visible flame

Excess flow

Check diverting water seal or valve

Smoke

Air starvation

Check wind fence for blockage or is

wind condition unusual

Smoke

Low gas
pressure

Check bypass relief devices and

staging valves

Smoke

Steam/support
air shortages

Check steam supply or blowers

RE/U&O Flares-39

Coupled Effects of Temperature and

Time on Rate of Pollutant Oxidation
Pollutant Destruction, %

100
80
60
40

1 sec
1.0 sec
0.01 sec

0.001 sec

Increasing
Residence
Time

20
0
600

800

1000 1200 1400 1600 1800 2000

Increasing Temperature, F

Residence time of gases in combustion chamber calculated from: t = V/Q

t = Residence Time (s)
v = Chamber Volume (ft3)
Q = Gas volumetric flow rate at combustion conditions (ft3/s)

Schematic of a Thermal Incinerator

Fume

Fuel

Exhaust

Combustion
Air
(Fume)

Typical Marine Vessel Loading System

Product
Loading Arm
Product from
Storage Tanks
Vapor
Arm

Natural Gas/
Inerting Gas
Enriching
Gas
Detonation
Analyzer
Arrestor

Vapor
Mover

Hydrocarbon Vapor
to Control Device

Knockout
Drum(s)
Discharged
Vapors
Sump
Pump

Ship
or Barge
Dock Facilities

Condensate
to Tanks

Shoreside Facilities

Flare Gas Recovery Compressor

Flare gas
recovery
compressor
designed to
capture flare
gases and
compress to
fuel gas
pressure
Reduce natural
gas purchases
RE/U&O Flares-43

Flare Gas Recovery Compressor

Difficult service for a

compressor
Wide range in Volumetric
flow and MW
Dirty Service - water, rust,
H2S, CO2 and HCl
Corrosion and Fouling

RE/U&O Flares-44

Liquid Ring Compressor Type

Operates on the rotary liquid
piston principle
The shaft and the impellers
being the only moving parts
Shaft and impeller assembly
is mounted eccentrically
relative to the pump casing
As the impeller rotates the
water (which is continually
supplied to the pump), is
forced outwards by
centrifugal force to form a
liquid ring revolving
concentric to the pump casing

RE/U&O Flares-45

Source Reduction Program

Locate relief valve leaks

Carryout repairs to
reduce amount of gas
going to flare
Check each relief valve
every 3 to 6 months
Leakage could occur
through normal wear and
tear on the valve
Leakage could occur due
to incomplete closure
RE/U&O Flares-46

Source Reduction Program

Potential Saving of
$1,000,000 per year have
been recorded
Relates acoustic signal level
to gas losses for various
valve types of different valve
sizes and working pressure
range

Device extremely portable

Can approximate flowrates

and associated dollar values

RE/U&O Flares-47

Flare Flow Meters: Ultrasonic Time of

Flight Technology

Panametrics of Waltham Massachusetts

Proprietary algorithm to determine
instantaneously the molecular weight
and mass flow rate of the flare gas

Meter is used to conserve energy and

reduce product loss by identifying
sources of leaks into the flare systems

Reduces energy usage by accurately

controlling the amount of steam fed to
the flare tip
RE/U&O Flares-48

The End

Next: Good buy!

Questions ?

RE/U&O Flares-49