Vents, Flares and Drains Petrofac

SECTION 9

VENTS, FLARES AND DRAINS

1 Introduction

2 Vents and Flares

2.1 System Function
2.2 System Equipment
2.3 Sources of Released Fluids
2.4 HP Flare System
2.5 LP Flare System
2.6 LLP Flare System
2.7 Flare Tips
2.8 Maintenance/Atmospheric Vents

3 Drains System
3.1 System Function
3.2 System Equipment

Figures

9.1 Flare System Schematic

9.2 Combined HP/LP Flare Coanda Type Flare Tip
9.3 Flare Tip Pilot and Ignition System
9.4 Open Drains System Overview
9.5 Closed Drains System Overview

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9.1 INTRODUCTION

On offshore installations there must be a provision for handling and dealing

with hydrocarbons that are not recovered or contained during various
scenarios.

Such a provision is required both during normal operations and during upset
or emergency conditions.

During upset and emergency conditions the facility must be capable of

accepting a full process plant depressurisation.

A full process plant depressurisation may well involve dumping of

hydrocarbon liquids to drains, as well as the flaring and venting of gases.

Therefore such a facility will comprise two related systems:

Vents and flares

Drains

9.2 VENTS AND FLARES

9.2.1 System Function

Refer to Figure 9. 1

The vents and flares installed on offshore installations can comprise three
separate systems operating at high pressure (HP), low pressure (LP) and
low-low pressure (LLP). The purpose of these systems is to:

Collect and safely dispose of hydrocarbons released at different

pressures from process and utility equipment during platform normal
operation, upset conditions or emergency situations

Collect and safely dispose of water, probably containing hydrocarbons

and released through pressure safety valves or rupture discs fitted on
certain heat exchangers to cater for tube rupture

Segregate, prior to liquid knockout, the collection of wet gases and

dry gases, within each HP and LP system, to avoid the possibility of
hydrate formation in pipework essential for controlled gas release

Recover separated liquids and transfer them to the platform drains for
recovery

Gases from the three systems are burnt at HP, LP and LLP flare tips located
adjacent to each other at the end of the flare boom.

The flare system is designed such that in the event of maximum flaring
conditions there is a minimal risk to personnel and equipment due to heat
radiated from the flare tip.

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9.2.2 System Equipment

By referring to the system shown in Figure 9.1 it can be seen that three
collection and disposal systems are provided:

HP system comprising the HP flare drum, condensate recovery pumps

and the HP flare tip located at the end of the flare boom

LP system comprising the flare drum and the LP) flare tip

LLP system comprising the flare drum and the LLP flare tip

A combined high pressure and low pressure flare tip is shown in Figure 9.2.

9.2.2.1 Flare Ignition

Refer to Figure 9.3

A means of igniting the flares is provided by a common system, which

incorporates pilot lights, pilot igniters and a method of ignition.

Each flare tip is equipped with three pilots which are fed by fuel gas.

Each pilot has a dedicated ignition riser in which a mixture of instrument air
and fuel gas is lit by a flame front generator located on the flare ignition
panel.

The ignited air/gas mixture or flame front is then diverted through the
appropriate ignition riser to its particular pilot, which in turn ignites the
associated flare tip.

Failure of any of the flare pilots, low purge gas flow or high fuel gas filter
differential pressure is indicated on the flare control panel.

Normally cross-ignition takes place between the flare tips, once the first tip
has been lit. However, the system must be checked to ensure that all the
flares are burning.

9.2.3 Sources of Released Fluids

Hydrocarbon gases, vapours and liquids are released to HP, LP and LLP flare
systems from blowdown valves (BDVs), pressure safety valves (PSVs),
bursting discs (pressure safety elements (PSEs)), pressure control valves
(PCVs) and vents as follows:

When equipment requires to be depressurised, as a result of an

emergency, or prior to maintenance, BDVs are opened to vent
hydrocarbons to either the HP or LP systems. BDVs are opened
automatically by the emergency shutdown (ESD) system or manually
by operator command

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As a legal requirement pressure valves and other equipment items are

protected against overpressure by PSVs and PSEs. Depending upon
system pressure and nature of materials released they will relieve to
the HP, LP or LLP system when the corresponding setpoint is exceeded

Pressure control valves will pass hydrocarbon gas unable to be handled

by system equipment to the flare systems to maintain normal
operating pressure within the platform process and utility systems

Vents pass fuel gas to the LLP flare after use by process and utility
equipment for blanketing purposes, eg on drains, vessels and so on

In general, hydrocarbons released from:

Main process equipment items are routed to the HP system

The LP/HP associated gas compressors depressurisation flows,

necessary to ensure non-failure of oil seals are routed to the LP
system

All other atmospheric pressure discharges which are not discharged

into a pressure flare system are routed to the LLP system

9.2.4 HP Flare System

Hydrocarbons that are vented to the HP flare system are routed to either
one of two HP flare headers, the wet or dry header. The purpose of the two
headers is to prevent the HP flare system becoming inoperative through
possible blockage by hydrates. As hydrate formation is dependent upon
temperature, pressure, free water and hydrocarbon gases being present
under certain conditions, the system is designed to prevent this occurring by
eliminating one or all of these conditions.

Hydrocarbons vented to the wet header contain free water but, because of
process conditions ie temperature and pressure, will not create low enough
temperatures to form hydrates.

Hydrocarbons vented to the dry header do not contain free water and may
be disposed of safely from plant areas that could create low temperatures
when vented, ie if the gas process were vented from a cold gas separator
hydrates will form should water be present.

For this reason the source and nature of the hydrocarbon is taken into
account and routed accordingly.

Purge gas (refer to Figure 9.1) is continually supplied to the HP dry flare
header to blow any liquids that may be present through to the flare drum;
prevent air ingress into the system and ensure a minimum flow at the flare
tip. Likewise a minimum flow is introduced to the HP wet header.

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Collections from the HP wet and dry headers enter the HP flare drum as
separate streams. On entering the drum each stream hits a deflector
causing liquids and gases to separate. Gas exits the drum from both ends,
flows to a common header and then to the HP flare tip where the gas is
disposed of by burning. The common header is manifolded to receive gas,
from the gas export line, whenever the line is required to be depressurised.

The liquid level in the drum is automatically controlled between upper and
lower limits by the level indicating controller (LIC). At the upper limit the
HP flare condensate pump A is signalled to start and transfer separated
liquids to the pressure drain flash drum. If the level increases to a high
level, the second pump is signalled to start. When the level drops to the
lower limit both pumps are signalled to stop.

The liquid in the drum is heated by electrical immersion heaters to ensure

the liquid temperature is automatically controlled to between 8C and 25C
eliminating the possibility of liquids freezing in the event of a cold release
of hydrocarbons. They also reduce the flashpoint of the liquid to allow it to
be handled in the drains system.

9.2.5 LP Flare System

As with the HP system separate wet and dry LP flare headers segregate
collections within the system. Hydrocarbons that are vented to the LP flare
system are routed to either the wet or dry header. The purpose of the two
headers is to prevent the LP flare system becoming inoperative through
possible blockage by hydrates.

Hydrocarbons vented to the wet header contain free water, but because
of process conditions, ie temperature and pressure are not likely to form
hydrates. Hydrocarbons vented to the dry header do not contain free water
and may be disposed of safely from plant areas that could create low
temperatures when vented.

Certain process equipment can be permanently open to the LP flare wet and
dry headers.

Purge gas is continually supplied to the LP flare headers to flow liquids

through to the flare drum, prevent air ingress into the system and present a
minimum load at the flare tip.

Liquid accumulating in the LP drum flows through a level valve (LV) before
passing to the slops oil tank. Liquid level in the drum is automatically
controlled by the LIC acting on the LV.

The liquid in the drum is heated by a single electrical immersion heater to

ensure the temperature is automatically controlled to between 8C and
12C. This is to eliminate the possibility of liquids freezing in the event of a
cold release of hydrocarbons.

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9.2.6 LLP Flare System

The calculated maximum release of hydrocarbons to this system based on a

fire arising provides for emergency depressurisation of the systems such as
the glycol package and flotation units. Certain process equipment is also
permanently open to the LLP flare system.

The problem of freezing condensed or entrained water is not considered to

exist in this system and a separate wet header is not required.

Consequently, only one collection header is provided. Purge gas is

continuously supplied to the extreme end of the header preventing air
ingress into the system and providing a minimum flow of gas to the LLP flare
tip.

The single collection header routes released hydrocarbons to the LLP flare
drum which separates out liquids by gravity. Gases leave the top of the
drum and flow to the LLP flare tip for combustion. Separated liquids leaving
the base of the drum flow through a loop seal to the slops oil tank.
Elevation differences between the normal liquid level and the Slops oil tank
allow liquids to be transferred by gravity.

The transfer line maintains a minimum level by means of the liquid seal
contained in one arm of the loop. The loop is continuously vented to the LLP
flare header to prevent liquids being inadvertently syphoned out of the
drum followed by gas breakthrough. Piping downstream of the loop is self-
draining and is normally free of liquid.

9.2.7 Flare Tips

Hydrocarbon gases from each of the three flare drums are discharged to
corresponding flare tips through dedicated flare headers. The flare tips are
located at the extremity of a flare boom. The quantity of gas flared is
measured and recorded by means of flowmeters installed in each header.

Released hydrocarbon gases are burnt on discharge from the individual HP,
LP and LLP flare tips. The continuous fuel gas purge to each HP, LP and LLP
system maintains a continuous flame at the flare tips so that any additional
release to the flare systems automatically ignites at the flare tip.

As a further safeguard against possible extinguishment of the flare,

continuously burning pilots are provided at each tip. A supply from the fuel
gas system maintains the flame at each pilot. Should a pilot extinguish, a
locally mounted temperature sensor relays a signal to the flare ignition
panel which monitors all pilots. Re-ignition of any of the pilots is initiated
manually.

Typical flare tips have tulip type profiles (refer to Figure 9.3). Gas burns on
the outside of the tulip and a protective layer of unburned gas between the
flame and tulip bowl prevents the flame impinging on the bowl. The tips are
designed for smokeless combustion and are capable of burning up to 25%
weight/weight of crude oil or condensate without liquid fall-out and little
smoke production.

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The LLP flare tip is normally a conventional open pipe flame with the flame
burning just outside the gas exit point. Combustion characteristics are
dependent on gas flowrate and composition.

The LLP flare is not designed to deal with appreciable quantities of liquid
carryover, which if sufficient will cause burning liquids to fall away from the
flare (flaming rain) presenting an extremely hazardous situation.

2.8 Maintenance/Atmospheric Vents

The atmospheric vent system receives hydrocarbon releases from systems

which have too low an operating pressure to allow connection into the flare
system.

These releases are manifolded together and piped to the atmosphere

through a flame arrestor. The vent typically terminates at approximately
75% of the height of the flare stack or flare boom.

In order to prevent the ingress of air into the pipework the system header is
continually purged with fuel gas or nitrogen during startup and shutdown
situations.

Low points of the system headers are fitted with liquid knockout drain pots
in order to remove any liquids formed in the system.

Overpressurisation of the systems, for example as a result of partial

blockage of the flame arrestor, is catered for by installing pressure alarms
throughout the system, typically alarming at a setpoint of 0.1barg (1.5psig).
As well as affording a facility for final depressurising of the various process
vessels and tanks which are connected to the system, the vent header
collects hydrocarbon and other gases from various sources such as:

Hazardous drains tanks

Compressor secondary seals

Analyser vent

Dehydration storage/vent systems

Drilling mud sumps

Produced water flotation unit vents

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9.3 DRAINS SYSTEM

9.3.1 System Function

The drains system is installed in order to:

Contain oil and hazardous chemical spillages, process equipment

drainings and washdown water

Recycle recovered oil back to the main process stream

Safely dispose of any gases liberated in the separation process to the

flare system or vent as appropriate

Segregate hazardous and non-hazardous drainings

Dump excess quantities of rain and deluge water directly overboard

Allow large spillages of non-hazardous chemicals from storage bunds

to be discharged safely to the sea

9.3.2 System Equipment

Refer to Figures 9.4 and 9.5

Non-hazardous and hazardous liquid wastes are segregated in order to

prevent cross-contamination and hazardous situations arising.

Innocuous non-hazardous liquids from non-hazardous area washdowns, drip

trays, tundishes etc are collected in unclassified open drains and disposed of
directly through the oily water disposal caisson to the sea.

Potentially hazardous liquids from hazardous area washdowns, drip trays,

tundishes etc are collected in classified open drains and directed to the
classified open drains tank.

Closed drains generally collect only hazardous liquids from process vessels
or pipe manifolds and are hard piped from the drain point, ie the drain
line is flanged or welded directly to the vessel or pipe. Once collected the
fluids are directed to the pressure drains flash drum.

Typically, a drains system installed for the segregation, collection,

separation of hydrocarbons and disposal of liquid is divided into the
following subsystems:

(1) The open drains system (atmosphere skid draining, washdown, deluge
and rain water draining). This is further subdivided into:

(a) The classified drains system (hazardous)

(b) The unclassified drains system (non-hazardous)

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(2) The closed drains system comprising pressure drains.

Closed drain manifolds are sometimes segregated into warm and cold
headers to reduce the potential for hydrate formation within the
system.

Any flash gas from the liquids in the closed drains vessel is vented
directly to the LP flare whilst recovered oil, including that recovered
in the hazardous drains caisson, is pumped back to the separators for
reprocessing.

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 Petrofac

Training Services Petrofac 2010

SECTION 9

VENTS, FLARES AND DRAINS

Figures

9.1 Flare System Schematic

9.2 Coanda Type Flare Tip
9.3 Flare Tip Pilot and Ignition System
9.4 Open Drains System Overview
9.5 Closed Drains System Overview
 Production Fundamentals Awareness
Vents Flares and Drains

9.1 Flare System Schematic

Petrofac Training Services / June 2010

 Production Fundamentals Awareness
Vents Flares and Drains

9.2 Coanda Type Flare Tip

Petrofac Training Services / June 2010

9.3 Flare Tip Pilot and Ignition System
9.4 Open Drains System Overview
9.5 Closed Drains System Overview