СНТ 03-519-03

RF GosGorTechNadzor Resolution dated June 10. 2003 No. 83

"On approval of regulations of the safe operation of flare systems"

GosGorTechNadzor of the Russian Federation rules:

1. Approve the Regulations of the safe operation of flare systems.

2. Send the Regulations of the safe operation of flare systems to the Ministry of Justice of the
Russian Federation for state registration.

Head of GosGorTechNadzor of the Russian Federation V.M. Kulyechev

Registered with the RF Ministry of Justice on June 19, 2003.

Registration No. 4725

Regulations

of the arrangement and safe operation of flare systems

(approved by the resolution of the RF GosGorTechNadzor of June 10. 2003, No. 83)

Regulations of the arrangement and safe operation of flare systems

These Regulations of safe operation are assigned the following code: PB 03-591-03

I. General Provisions
 1.1. 1.1. These Regulations of the arrangement and safe operation of flare systems (hereinafter
referred to as the "Regulations") specify the requirements directed at ensuring industrial safety,
prevention of accidents/occupational injuries in the course of operation of flare systems in chemical,
petrochemical, and refining industries.

1.2. These Regulations are developed in accordance with Federal Law of 21/07/97 No. 116-FZ "On
industrial safety of hazardous production facilities" (Collected Legislation of the Russian Federation,
1997, No. 30. p. 3588), Regulation on Federal Mining and Industrial Supervision of Russia approved by
the RF Government Decree of 03/12/01 No. 841 (Collected Legislation of the Russian Federation, 2001,
No. 50. p. 4742), General rules of industrial safety for the organizations operating in the field of
industrial safety of hazardous industrial facilities approved by the RF GosGorTechNadzor of 18/10/02
No. 61-A registered with the RF Ministry of Justice on 28/11/02 No. 3968 (Rossiyskaya Gazeta,
December 5, 2002, No. 231), and are intended for use by all organizations regardless of their
organizational and legal forms of ownership which operate in the field of industrial safety and
supervised by the RF GosGorTechNadzor.

1.3. These Regulations are to be applied:

а) during the design, construction, operation, expansion, reconstruction, modernization,

preservation, and elimination of flare systems in the production of oil and gas processing, chemical,
petrochemical and other hazardous industrial facilities involved in handling and storage of toxic
substances and substances that are capable of generating steam- and air-gas explosive mixtures;

b) during the flare system industrial safety examination.

II. General Requirements

2.1. Flare system is designed to discharge and subsequently flare combustion gases and vapors in
the following cases:

triggering of emergency release, pressure relief valves, hydrogates, manual outgassing, as well as
the clearing of processing units from gases and vapors in case of emergency either automatically or
with the use of remote operated valving etc.;

regular bleeding-off prescribed by the Regulations for Manufacturing Processes;

periodic discharges of gases and vapors, as well as starting, stopping and setting up of processing
facilities.

2.2. The design, construction, reconstruction, modernization and operation of flare systems are
implemented in accordance with the requirements of the regulations on industrial safety, fire safety,
arrangement rules for electrical installations, construction norms and regulations, state standards, and
these Regulations.

2.3. Organizations that operate flare systems shall:

draw up and adopt in accordance with the established procedure the instructions on the safe
operation of flare systems and their maintenance. If it becomes necessary to make additions to the
above instructions, as well as in the case of changes in the operational scheme or mode of operation of
flare systems, such instructions need to be reviewed before their expiration date;

allow the operation of flare systems only by operating personnel possessing the required
qualifications, who have been certified or whose knowledge on industrial safety has been verified in
the prescribed manner;

implement activities on localization of potential emergencies and prevention of accidents, as well

as make provisions for the emergency-response actions by the personnel.

2.4. Flare system consumers (flame monitoring devices, ignition devices, and control,
measurement, and automation equipment) are classified as Category 1 consumers in terms of security
of supply.

III. Types of discharges and corresponding requirements

3.1. During the design process, where necessary, provision should be made for block release of
equipment and pipelines from hazardous gases and vapors with a corresponding automatic pre-
programmed or a remote-controlled interceptors that cut off the flow of gases and vapors into the
emergency unit.

3.2. combustion gases and vapors, which are divided into regular, periodic and emergency, should
be discharged into the following types of flare systems for flaring or collection and subsequent use:

general flare system (subject to discharge compatibility);

separate flare system;

special flare system.

Schematic diagrams of discharge of gases and vapors are presented in Annexes No. 1 and No. 2.

3.3. For each source of discharge of gases and vapors that are directed to flare systems, potential
compounds and their parameters (temperature, pressure, density, flow, duration of discharge, as well
as the parameters of maximum, mean, and minimum total discharges from the facility) should be
determined.

3.4. To prevent generation of explosive mixtures inside a flare system, purge gas - fuel or natural
gas, inert gases including gases produced by processing plants and used as inert gases - should be used.

The schematic diagram of the flow of purge gas is presented in Annex No. 3.

3.5. As a rule, the oxygen content in the purge and discharged gases and vapors, including
complex gases, should not exceed 50 pct of the minimum explosive oxygen content in the possible gas-
fuel mixture and is validated by the project developer.

3.6. When hydrogen, acetylene, ethylene, carbon monoxide, and mixtures of these quick-burning
gases are discharged, the oxygen content in them should not exceed 2 pct by volume; in every case,
this content is validated by the project developer.

3.7. Agents, the interaction of which might lead to an explosion (e.g. oxidants and reductive
agents), may never be directed against the flare system.

3.8. The gases and vapors discharged into the common and the separate flare systems should not
contain drops of liquid and solid particles. This is achieved by installation of separators inside the
process units.

The temperature of gases and vapors in the flare header and the supply pipe must be sufficient to
exclude crystallization of the discharged products.

3.9. For the flare system with the installation of the collection of hydrocarbon gases and vapors,
the temperature of discharged gases and vapors at the outlet of the process unit should not be above
200 °C or below - 30 °C; at the distance of 150 - 200 m before the gas tank entry, it should not exceed
60 °C.

3.10. The use of discharged hydrocarbon gases and vapors that contain inert gases, the volume
content of which exceeds 5 pct; hazard classes I and II substances (except benzene), the volume
content of which exceeds 1 pct; and hydrogen sulphide, the volume content of which exceeds 8 pct, as
fuel is prohibited.

The discharges, the flaring combustion products of which generate or store the hazard class I and
II harmful substances, should be directed into special containers for recycling and reprocessing.

3.11. Permanent and periodic discharges of gases and vapors into general flare systems, into
which emergency discharge is directed, is not allowed if if the combination of these discharged
substances can lead to an increase of the system pressure to the value that hinders normal operation
of safety valves and other emergency-response units.

3.12. In case of maximum discharge, the loss of pressure in the flare system may not exceed:

for the systems, into which the emergency dischage of gases and vapors is directed: 0.02 MPa for
the process unit and 0.08 MPa at the site from the unit up to the exhaust of the tip of the flare stack;

for systems with the collection installation for hydrocarbon gases and vapors: 0.05 MPa from the
unit up to the exhaust of the tip of the flare stack.

For separate and special flare systems, the pressure loss is not limited but is determined by the
safe operation conditions of the connected devices.

3.13. The combustion gases and vapors that are discharged from the process units through water
seals designed for operation under the pressures below the pressure in the flare header should be
directed to special flare systems or away from the other safety devices, emergency relief, permanent
and periodic discharges via a special flare line that is not connected to the header.

The special pipeline should be connected directly to the flare stack through a separate drip.

3.14. With good reason, mounting of stop valves after hydrogates in the tie-in section of the
general flare system (provided it cannot be accidentally shut) is permitted. At the same time, provision
is made for additional security measures, including removal of the valve wheel, sealing it open,
mounting of special covers, output of the signal of the position of valves to the control panel.

The type of stop valves is determined by the project organization.

IV. Discharges from bleeders

4.1. Discharges from bleeders are directed to the flare systems.

4.2. Discharges of gases and vapors from the bleeders that are installed on vessels and equipment
operating with non-explosive and non-hazardous media, as well as discharge of light gases are allowed
to be directed through the discharge pipe into the atmosphere.

The structure of discharge pipes and the discharge conditions should ensure efficient dispersal of
discharged gases and vapors, which excludes creation of explosive concentrations in the area of
process equipment, buildings, and constructions. The estimation of the concentration of combustion
gas in case of pipe discharge is presented in Annex No. 4. In this case, provision should be made for
devices that prevent ingress of liquid into the discharge pipe and its accumulation.

The light gases include methane, natural gas, and hydrogen-bearing gas with a maximum density
of 0.8 as compared to the air density.

In case of possible changing of the composition of the discharged gas that leads to an increase in
its density to the value exceeding 0.8 as compared to the air density, the discharge of gas into the
atmosphere is not allowed.
 In the course of organization of discharges into the atmosphere, model calculations of the
concentration of harmful substances in discharged by enterprises, as well as sanitary standards, must
be complied with.

4.3. The bleeder discharges of combustion gases or vapors that contain the hazard class I and II
substances in quantities of less than 1 pct by volume (for hydrogen sulfide, of less than 8 pct by
volume) can be directed to the general flare system.

4.4. The bleeder discharges of combustion gases or vapors that contain the hazard class I and II
substances in quantities exceeding 1 pct by volume must be subjected to cleaning and
decontamination (neutralization, absorption, decomposition, combustion etc.).Such discharges are
flared in the separate or special flare systems.

4.5. Combustion gases and vapors from the bleeders mounted on storage tanks designed for
storing liquefied petroleum gases and flammable liquids must be discharged into the separate or
special flare systems.

If technical justification is available in the project documentation, such discharges may be

directed for flaring in the general flare system stack.

V. Headers, pipelines, pumps

5.1. As regards separate and special flare systems, provision should be made for one flare header
and one flare unit.

The general flare systems should have two flare headers and two flare units to ensure non-stop
operation.

In case of discharge of gases, vapors, and their mixtures that do not cause corrosion in the
amount exceeding 0.1 mm per year into the general flare system, one flare header can be used instead
of two if technically justified in the project documentation.

5.2. In the pipeline branching sections of the general flare systems, stop valves that have been
sealed open can be mounted horizontally in order to disconnect process units, warehouses, switch
separators, collectors, and flare stacks from the flare systems.

5.3. Flare headers and piping must be a minimum length and have a minimum number of turns;
they should be laid above the ground (on poles and pipe racks).

5.4. Expansion glands may not be mounted in flare headers and pipelines.

5.5. The thermal compensation of flare headers and pipelines should be calculated taking into
account the maximum and minimum temperatures of discharged gases and vapors, the maximum
temperature of steaming vapor, as well as the heating medium temperature for a heated headers, and
the average temperature of the coldest five days.

5.6. The flare system headers and piping must be fitted with appropriate thermal insulation, and
(or) a heating cover must be mounted on them to prevent condensation and crystallization of
substances in the flare system.

5.7. For the flares that are intended for flaring combustible gases and vapors, a permanent drip
should be used.

5.8. The flare headers and piping must be installed with a minimum slant toward the drip of
0.003. If such a slope cannot be maintained, a condensate-water removing device is installed in the
flare header and pipe lowest points.The design of condensate-water receivers should exclude liquid
entrainment and provide for their thermal insulation and outer heating. The condensate-water
receivers should be emptied automatically, or - in justified cases - remotely from the operator's room.
Centrifugal pumps are used to pump the condensate water from the drip and receivers.

5.9. The shop pipelines should be tied-in into the flare header from the top in order to avoid
being filled with liquids.

5.10. In case of a low content of condensate water in the drips of the flare unit drips designed for
flaring of low-boiling liquid vapors (including propane, propylene, ammonia and ammonia-bearing
gases), the fluid from the separator can be to removed by the steam or hot water fed into the external
coil, heating drip; in this case, it is necessary to exclude the possibility of raising the vessel pressure
above the rated value. This requirement is justified in the project documentation.

5.11. If the discharged gases contain solid or tarry deposits, two parallel drips should be installed.
If the impurity content is low, the drip can be fitted with a bypass line with a system of interlocked
"close-open" gates and the quick-disconnect choke that provide a steady gas flow and allow to clean
the drip.

5.12. Depending on the installation site, it is necessary to use pumps made for accommodation
categories 1 or 2 in terms of the impact by the external environment climatic factors.

5.13. Relative to each other, the flare drip and the pump are installed on the basis of the
condition on ensuring the filling of the pump with condensate water as the latter enters the drip, and
exclusion of cavitation during the pumping operations.

5.14. The suction pipe must have a minimum length and slant toward the pump and be
stagnation-free.

The horizontal sections of the suction pipelines should be placed at the bottom (near the pumps).
The horizontal sections should not be placed immediately after the drip; this is achieved by directing
the suction pipe outlet from the bottom drip nozzle to the pump vertically downward.

5.15. The suction pipe diameter is determined by the maximum capacity of the pump accepted
according to the characteristic curve.

5.16. In order to avoid freezing in cold weather, all piplines and pump manifold fittings should be
warmed and coated in thermal insulation.

5.17. The pumps for condensate water pumping from receivers and drips should be activated and
deactivated both automatically and from the installation site (performed in accordance with the
diagram presented in Annex No. 5).

The recommended operation procedures of the pumps are listed in the above Annex.

5.18. The general flare system capacity is estimated on the basis of the following flow rates of
gases and vapors:

during constant and periodic discharges: for the total periodic (with the coefficient of 0.2) and
constant discharges from all connected process units, but not less than the total permanent discharges
and the maximum periodic discharges (with the coefficient of 1.2) from the unit with the greater value
of such discharge;

during emergency discharges: for the total emergency discharges (with the coefficient of 0.25)
from all connected systems, but not less than the total emergency discharges (with a factor of 1.5)
from the installation with the greater value of such discharge.

The capacity can be calculated for the total emergency discharges from all connected process
units; in case of emergency, permanent and periodic discharges, for the total of all types of discharges
to be calculated in the manner prescribed by this paragraph.

5.19. The capacity of the separate and special flare systems should be calculated for the total
permanent discharges from all connected process units, and emergency discharge from a single unit
with the greater value of such discharge.

5.20. The flow area section for emergency discharge valves with manual or remote drive
activation should match the capacity of the flare header at the exit from the installation.

5.21. On the pipelines of discharged gases and vapors, the flanged connections are only mounted
in places of connection of fittings, instruments; for the field joints, in places where welding is
impossible.

Each weld of the flare header (pipeline) and flare stack is tested with non-destructive method that
provides effective quality control of the weld.

5.22. Either the header before the flare stack or the flare stack should have a flange connector for
installation of the plug in tests of strength.

5.23. To purge the process units and shop flare pipelines with nitrogen or air at the launch or stop
for repairs, a bleeder valve with an emission stack is installed in the output of the process unit subject
to justification.

5.24. In order to avoid an explosive mixture, provision should be made for a continuous supply of
purge (fuel or inert) gas into the beginning of the flare header. If the fuel gas supply is interrupted,
provision should be made for automatic supply of inert gas. The volume of purge gas is determined in
accordance paragraph 11.2 hereunder.

VI. flare unit

6.1. In the course of operation of the flare unit, provision should be made for a stable combustion
over a wide range of gas and vapor, smokeless burning of permanent and periodic discharges, as well
as safe heat flow density and prevention of the ingress of air through the upper section of the flare
stack.

6.2. The flare design should include a flare stack equipped with a flat top and a gas gate, control
and automation equipment, remote electric primer, supply lines of fuel gas, and combustible mixtures,
igniter-equipped pilot burners.

If necessary, the flare system is also equipped with a drip, a hydrogate, a flame arrester (in case of
acetylene discharge), pumps, and a condensate water removal device.

In justified cases, combustion of gases and vapors cane use special ground flares without a flare
stack (set by the project developer).

If the discharged gases and vapors contain solid and tarry substances that, when deposited,
reduce the flow section area of the gas seal, the latter is not installed (to be justified in the project
documentation).

6.3. The diameter of the upper edge of the flare tip to ensure a stable (no-breakdown)
combustion should be calculated at the maximum rate of gases and vapors, which should not exceed
0.5 of the speed of sound in the discharged gas. The combustion of gases and vapors with the density
of more than 0.8 as compared to the air density, the rate of discharge should not exceed 120 m / sec.

6.4. For completeness of combustion of the discharged hydrocarbon gases and vapors (except for
natural and sootless gases), provision should be made for supply of steam, air, or water. The amount of
steam is determined by calculation based on the conditions for ensuring smokeless combustion of
permanent discharges.
 No steam supply is not required if the ratio of the discharge rate to the speed of sound exceeds
0.2.

6.5. Igniter-equipped pilot burners should be mounted on the flare tip. The number of burners is
determined depending on the flare tip diameter in accordance with the data presented below.

Flare tip diameter, 10-250 300-550 600-1000 1100-1600 Over 1600

mm

Number of burners, 1 and more Not less than 2 Not less than 3 Not less than 4 Not less than 5
pcs

6.6. The flare stack should be provided with a supply of fuel gas for pilot burners; the flame
igniter, of fuel gas and air for the preparation of the igniting charge. In order to eliminate the
condensate of steam and its freezing in the pipes during the cold seasons, the fuel gas must be
dehydrated or supplied via heated pipelines. Fuel gas shall not contain mechanical impurities.

6.7. The flare stack height is determined by calculating the heat flux. The calculation is presented
in Annex No. 6.

6.8. In determining the flare stack height, the possible contamination of the surrounding area
with harmful combustion products should also be considered in additioon to the heat flux, in
accordance with the requirements of regulatory and technical documents.

6.9. In order to prevent air suction into the flare header (pipeline), a water seal gate with
permanent flow of the sealing fluid should be mounted before the flare stack.

In order to prevent freezing of the sealing fluid, the water seal gate should be equipped with a
heating device or placed in a heated room.

Provided technical justification, the project allows for absence of the water seal if:

the temperature of discharged gases and vapors is close to the sealing fluid freezing or the boiling
point;

the depression at the base of the flare stack does not exceed 500 Pa.

6.10. The ladders and platforms should provide comfort and safety during installation and repair
of the flare tip and other equipment located at different heights of the flare stack.

6.11. The material of the flare tip, pilot burners, manifold pipelines, as well as fasteners should be
selected taking into account the possible temperature of their heating by thermal radiation of the flare.
 Manifold pipelines in the flare tip area should be made of seamless pipes.

6.12. The flare stack, drips, and hydraulic gates must be equipped with samplers.

6.13. The drip installed in front of flare stack should be heated externally and be equipped with
continuous condensate water removal, which excludes the possibility of ingress of discharged gas into
the condensate water receiver and ingress of condensate water into the flare header.

6.14. Pilot burners that serve as pilot lights of the operating flare system are mounted on the flare
stack; in case of flare system cut-off, light fencing on the top part of the flare stack with portable lamps
should be provided in accordance with the requirements for labeling and light fencing of high
obstacles.

VII. Collector of hydrocarbon gases and vapors

7.1. In case of appropriate justification, the flare system can contain special installations for
collection, short-term storage, and return for further use of the disposed hydrocarbon gases and
vapors.

7.2. The following requirements should be considered during the collection of hydrocarbon gases
and vapors:

the gas tanks of variable or constant volume should ensure reception of discharged gases and
vapors within 5 - 10 minutes in an amount determined in accordance with paragraphs 5.18, 5.19;

the lifting speed of the gas-holder bell (of the variable-volume gas tank) should comply with the
requirements for safe operation, maintenance of wet gas tanks designed for flammable gases;

the gas condensate that is collected in the upper part of the wet gas tank reception basin should
be diverted to the condensate drip;

the water from condensate drips should be diverted to the appropriate industrial wastewater
system of the enterprise for further purification;

the drip in the bottom part should be heated externally and thermally insulated;

the collectors of hydrocarbon gases and vapors should have backup equipment to ensure stable
and uninterrupted operation.

VIII. Territory and buildings

 8.1. The flare should be placed taking into account the wind diagram, the minimum length of the
flare headers (pipelines), mainly in the areas that border on the fence of the enterprise. Separate or
special flares can be installed on the territory of the process unit if the requirements of the paragraph
5.7 hereunder are complied with.

8.2. The distance between the flare stack and the warehouses, the buildings, the transformer
stations and other process unit facilities should be determined taking into account the allowed heat
flux and fire regulations. The distance between these objects and the flare stack - if it is installed
directly on the territory of the process unit - should be calculated only on the basis of the allowed heat
flux.

8.3. In order to ensure safety of repair or maintenance of the flare tip, the distance between flare
stacks should be such that the heat flux from the working flare on the repaired flare tip does not
exceed the allowed value.

8.4. In order to reduce the thermal impact on the personnel, the flare stack ladder should be
located on the side opposite to the adjacent flare stacks.

8.5. The equipment and the facilities located in the thermal impact area should be made of
fireproof materials.

8.6. The area around the flare stack, as well as the area around buildings, installations, and
equipment, which is part of the flare system should be designed; roads for vehicles and pedestrians
must be laid on this territory.

8.7. The area around the flare stack, except where it is located on the territory of the process
plant, is fenced out and indicated with warning signs. The fencing should provide passageways for the
personnel and gates for the passage of vehicles.

8.8. The number of passages in the fence should be equal to the number of flare stacks; besides,
the path to each stack should be as short as possible.

8.9. Installation of pumps and stand-alone drips in the flare stack fencing area, except for the
drips combined with the flare stack, is prohibited.

IX. Instrumentation and automated control systems

9.1. Supervision and remote control of flare systems should be implemented:

for the general flare systems: from the proper control premises (operator room, central control
panel) or from the control room of one of the process units that discharged gas into the flare system;

for the separate and special flare systems: from the control room of one of the process units that
discharged gas into the flare system.

9.2. The flare systems must be equipped with technical equipment that provides permanent
record (with the output of the values to the control room) of the following data:

flow of purge gas in the flare header and the gas valve;

liquid level in the drips, condensate receivers;

liquid level in the flare water seal;

amount of discharged gases and vapors, and condensate that are returned from the collector of
hydrocarbon gases and vapors;

temperature of the gases and vapors that enter the gas tanks;

temperature of the liquid on the flare water seal.

9.3. The flare systems must be equipped with alarm devices (with output of signals to the control
room) triggered when the following parameter values are reached:

the minimum allowed flow rate of purge gas into the drip and the gas valve;

the minimum allowed pressure or flow rate of fuel gas directed toward the pilot burners;

the pilot burner flame failure;

creation of vacuum at the base of the trunk flare that is equal to or more than 1,000 Pa;

the minimum and the maximum allowed liquid levels in the drips, condensate receivers;

the minimum allowed liquid level in the flare water seals;

the maximum allowed temperature of gases that enter the gas tank;

the minimum allowed temperature in the flare water seals;

activation of condensate pumps;

activation of compressors;

presence of combustion gases and vapors in an amount of 20% of the lower concentration limit of
flame propagation in the compressor presimes, water seal with overlapping of sound and light signals
and placement of this alarm equipment above the front door, as well as in the outdoor installations in
locations of gas tanks, drips, pumps.
 The vacuum alarm devices are not required if the product of multiplication of the density
difference of air (kg/m3) and the purge gas by the flare stack height (m) does not exceed 100.

9.4. Duplicate equipment should be installed in situ to control the pressure of fuel gas and the air
in the ignition system and lines to the control valves or valve units, the vapor pressure, the liquid level,
and the temperature in the drips and condensate receivers.

9.5. The design of the flare unit should provide for automatic control of the pressure of the fuel
gas that is fed to the pilot burners, as well as of the amount of purge gas supplied to the top of the flare
header.

9.6. The flare systems must be equipped with locks (taking into account the instrumentation and
automation control system pickup response and the time required to open the motorized valve) that
provide:

supply of inert gases into the gas valve in case of vacuum in the flare header that is equal to or
more than 1,000 Pa;

supply of inert gases into the drip in the beginning of the flare header if the supply of purge (fuel)
gases is interrupted (the option of a constant supply of nitrogen is allowed subject to obligatory
justification in the project documentation);

removal of condensate from the drips and condensate receivers, except the ones equipped with a
constant discharge through the water seal, upon reaching the maximum levels;

opening of the motorized valve of the line of gas discharge into the flare when the gas tank is 85
pct full, with a simultaneous shutting of the motorized valve of the gas supply line to the gas tank;

opening of the motorized valve of the line of gas discharge into the flare when the gas tank is 70
pct full, with a subsequent shutting of the motorized valve of the gas and vapor supply line to the flare
stack;

deactivation of the compressor with a decrease in the gas volume in the gas tank to the level of
10 pct;

activagtion of the compressor, the control circuit of which allows automated implementation of
this operation, or alarming, which allows manual activation if the gas tank is at least 25 pct full.

9.7. The pumps for flammable liquids should be equipped with interlocks to ensure safe and
trouble-free operation, as well as alarming devices that signal the violation of operating parameters
that could affect safety of operation.

9.8. Subject to justification, the flare system control premises of the storage facilities of liquid
ammonia for agricultural purposes that are located at considerable distances from the inhabited areas
should be equipped with remote monitoring devices and alarm systems that atre triggered when the
following parameter values are reached:

the minimum pressure of inert or fuel gas fed to the gas valve;

the maximum and the minimum allowed pumped-out liquid levels in the drip;

the minimum liquid level in the water seal and the maximum allowed level in the condensate
receiver;

creation of vacuum at the base of the trunk flare that is equal to or more than 1,000 Pa;

In addition, the pressure control is provided in situ:

fuel gas and air: in the ignition system and in the lines to control valves or valve units;

purge gas, steam, and air: in the pipelines that reach the flare.

9.9. The alarm systems and recording devices for gas discharge by process units (sections) should
be installed in the flare system control rooms of oil refineries and petrochemical enterprises.

X. Specific flare system requirements

Yellow phosphorus production

10.1. No drips, water seals, or gas valves should be installed on the flare stack. Steam (water)
supply into the flare unit is prohibited.

10.2. The necessity and the procedure for nitrogen supply into the flare stack without discharge is
determined according to the special instruction produced in compliance with the technical design
decisions and approved by the technical director of the organization.

10.3. The flare units of ore-thermal furnaces can be used without ignition devices and pilot
burners.

Production of acetylene by natural gas oxidative pyrolysis

10.4. The discharged mixtures should be directed to the separate flare systems after the natural
gas oxidative pyrolysis reactors. The oxygen content in the mixture in the start-up period should be
within the limit values established by the process requirements of the specific production. The volume
content of oxygen is controlled by automatic gas analyzers.

10.5. The water seal is not installed if the flare stack is mounted on the device or on the cover of
the industrial construction (stack).

10.6. For acetylene discharges, fire barriers equipped with a heating device should be installed
before the entry to the flare stack.

XI. Start-up and operation

11.1. Before each start-up, the flare system must be purged with nitrogen until the oxygen
content at the base of the flare stack no longer exceeds 50 pct of the minimum explosive value.

For hydrogen, acetylene, ethylene, and carbon monoxide discharge, the oxygen volume content
should not exceed 2 pct.

To prevent air ingression into the flare system during purging of process units with nitrogen, the
purge gas should be discharged through the gas emission stack into the atmosphere.

In case of simultaneous nitrogen purge of all process units that are connected to the flare system,
discharge of purge gases into the flare stack with extinguished burners to remove the air is allowed.
The frequency of testing is determined by process requirements.

Purge gases discharge into the general flare system is not permitted.

11.2. In order to prevent ingress of air into the flare system, the purge gas flow with an intensity
that provides the following flow rate per sub-tip flare stack cross-section is required:

not less than 0.05 m/sec - with a gas gate;

not less than 0.9 m/sec - without a gas gate at the density of the purge (fuel) gas of 0.7 kg/m3 or
more;

not less than 0.7 m/sec - without a gas gate, with inert purge gases (nitrogen).

In the flare systems that are not equipped with gas gates, the fuel gas with the density of less
than 0.7 kg/m3 should not be used as purge gas.

11.3. Before terminating the discharge of combustion gases and vapors that have been preheated
to high temperatures, it is necessary to provide additional supply of purge gas to prevent vacuum
creation in the flare system during cooling or condensation.
 11.4. Before implementing repairs, the flare system should be disconnected from process units
with standard plugs and purged with nitrogen (steamed, if necessary) until the complete removal of
combustion materials followed by purging with air until the oxygen volume content is, at least, 18 pct,
and the content of the harmful substances does not exceed the MAC.

Specific activities to ensure the safety of repair work should be developed in accordance with the
guidance.

11.5. The flare tips repair operations in the common fencing area of several flare stacks should be
conducted in a thermal suit.

11.6. During the thunderstorm, it is prohibited to be on the flare unit platform and touch metal
parts and pipes.

11.7. The persons that are not involved in the operation of flare systems are prohibited from
being in the flare fencing area.

11.8. The flare units should be provided with primary fire extinguishing equipment in accordance
with applicable regulations.

Annex No. 1

Schematic diagram of the gas (vapor) discharge

from bleeders into the flare system

Annex No. 2

Schematic diagram of the gas (vapor) discharge into the flare system

with constant condensate removal from the drip through the water seal

Annex No. 3
 Schematic diagram of the purge gas supply into the flare header

Annex No. 4

Calculation

of combustion gas concentrations during discharge from the bleeder through the discharge pipe

The calculation was performed for the conditions where the discharge is carried out horizontally
for an extended time period in the worst weather conditions (no-wind conditions), and the maximum
surface gas concentrations do not exceed 50% of the lower flame propagation (inflammation) limit. It is
recommended to direct the discharge stub upward to reduce the surface concentrations.

1. The value of surface gas concentrations at various distances from the bleeder is calculated
using the following formula:

-1 0.5 -0.5(10h/Х)

C = 6 x M x d(VX) (pо/pо ) e , g/m3,

in

wherein М - the amount of discharged gas, g/sec;

d - discharge stub diameter, m;

V - volume rate of flow at normal pressure,

m3/sec;

X - horizontal distance from the bleeder to the location

of the concentration calculation, m;

ро, ро - density of discharged gas and ambient air, kg/m3;

 in

h - discharge stub height, m.

2. The value of the maximum surface gas concentration is calculated using the following formula:

-1 0.5

С = 0.35 x М x d(Vh) (ро/pо ) , g/m3.

m in

3. The distance, at which the maximum surface concentration is observed:

X = 10h, m.

4. The minimum discharge height is calculated using the following formula:

-1 0.5

h = 0.7 x М x d(VC ) (ро/pо ) , m,

min lel in

wherein C - concentration of the flame propagation lower limit, g/m3.

lel

Notes:

1. The advised rate of gas discharge from the discharge stub equals 80 m/sec.
 2. The hazardous area is confined to a circle of radius H m.

Annex No. 5

The completion scheme of hydrocarbon pump-out units with pipelines,

instrumentation and automated control systems

Pump operation description

Situation 1

Hydrocarbon gases should not be discharged into the flare system. The flare system is filled with
fuel or inert gas. The flare drip and pumps are not filled with liquid . The valves (Annex No. 6 - pos. 13
and 14) and valve units (pos. 3 and 10) are opened. The valved (pos. 4 and 9) are shut.

Situation 2

Hydrocarbon gases are discharged into the flare system. Condensate appears in the drip and flows
into both pumps via the suction pipe and fills them. The gas phase is extracted from the injection pump
lines into the drip via the pipeline of nominal bore 25 through the orifice plate with a hole of 10 mm.

Situation 3

The flare drip continues to accumulate liquid. The liquid reaches the pump-out level (1/4 of the
drip height). The working pump is automatically activation. The discharge valve is opened (Annex No. 6
- pos. 4). If the level continues to rise and reaches the a maximum level (1/2 of the drip height), the
backup pump is activated via a special command, and the discharge valve (position 9) of pump is
opened.

Situation 4

As a result of pumping, the drip liquid level is reduced to the minimum value, which is
determined by the time the pumping stops. When this level is reached, the pump(s) is (are)
automatically turned off, and the discharge valves, closed.

Annex No. 6

Calculation

of the heat flux from the flame, the minimum distance, and the flare stack height

1. Notation and definitions.

C , C - components heat capacity, J / (mol * K);;

pi vi

D - flare pipe diameter, m;

k - ratio of specific heats, k = Sum N /C / Sum N /C ;

i pi i vi

М - molecular weight, kg / (kg / kg / mol);

N - mole fraction of the i-th component in the mixture;

Т - gas temperature, K;

V - discharged gas rate, m/ sec;

V - wind speed at the center of the flame, m/sec

in

V = V [0.9 + 0.01(H + Z)] at H + Z < 60.

in m

V = V [1.34 + 0.002(H + Z)] at 60 < H + Z < 200;

in m
V - maximum wind speed m/sec,

V - sound speed in discharged gas, m/sec:

snd

V = 91.5 sq. root (kT/M);

snd

μ - the ratio of the exhaust velocity to the sound speed in discharged gas,

μ = V/V .

snd

In this case, it is recommended to accept the following values:

for constant discharges, μ <=0.2;

for periodic and emergency discharges, μ <= 0.5;

X - distance from the flare stack, m;

X - the minimum distance from the flare stack to the object, m;

min

q - the heat flux density in the reference point, kW/m2;

q=q +q,

f s

q - the heat flux density from the flame, kW/m2;

q - the maximum allowed heat flux density, kW/m2;

ma

q =q -q,

mad ma s

q - the maximum allowed heat flux density from the flame,

mad kW/m2;

q - the direct solar radiation, kW/m2, is determined for 11 - 12 o'clock;

Q - amount of heat emitted by the flame, kW;

h - height of the object, m;

Н - height of the flare stack, m; the minumum recommended value is 35D;

Z - distance from the flame radiation center to the top of the stack, m;

for μ < 0.2, the recommended value of Z = 5D,

for μ >= 0.2, the value is calculated using the following ratios:

H/D....... 20 30 35 40 60 80 100

Z/D....... 32 37 39 40 44 47 48

α - the flame deviation angle (the angle between the vertical axis and the flame)

degrees, tqα = V_in/V;

ε- the flame emissivity to be adopted according to reference

data.

The recommended value of q_ma kW/m2 is:

at the base of the flare stack - 9.4;

 subject to personnel evacuation within 30 seconds - 4.8;

on the flare unit fencing and subject to

pesonnel evacuation within 3 min - 2.8;

unlimited personnel sojourn - 1,4.

The estimation vairant of the discharge is determined by the maximum heat flux density.

2. Calculation formulas.

2.1. The heat flux density q_d is checked at the selected flare stack height H and at the pre-set
distance X. The minimum distance between the flare stack and the object is determined for the pre-set
flare stack height. The flare stack height is determined for the given distance between the flare stack
and the object.

2.2. For μ < 0.2

εQ

q = ————————————————————;

d 2 2

4π [(X - Z sin α) + (H - h + Z cos α) ]

εQ 2

X = sq. root (————————— - (H - h + Zcos α) ) + Z sin α;

min 4π q

mad

εQ 2

H = sq. root (———————— - (X - Z sin α) ) + h - Z cos α;

 4π q

mad

2.3. For μ > 0.2

εQ

q = ————————————;

d 2 2

4π [X + (H - h + Z) ]

εQ 2

X = sq. root (————————— - (H - h + Z) );

min 4π q

mad

εQ 2

H = sq. root (————————— - X ) + h - Z.

4πq

mad