SHANGHAI HUALI COMBUSTION EQUIPMENT CO.

LTD

Technology documents of ammonia flare

Equipment Installation Description For Ammonia Flare System

ISSUED FOR CONSTRUCTION

23,AUG.2010

FOR APPROVAL

01,JULY.2010

REV.

DESCRIPTION

DATE

DRAWN

CHECKED

APPRVD

SUPPLY:

SHANGHAI HUALI COMBUSTION EQUIPMENT CO.,LTD

CONTRACT NO .

50061-01-00-PO-1950-001

OWNER

VIETNAM NATIONAL CHEMICAL CORPORATION

MR NO.

50061-01-00-MR-1950-003

NINH BINH FINE COAL BASED UREA PLANT PROJECT

PROJECT NO.

50061

PROJECT:

DOCUMENT NO.

50061-MR-003-ST

Content
1 summary........................................................................................................................... 2
2 installation special requirement........................................................................ 2
3 storage requirement before and after installation ................................. 5
4 installation parts list on site...................................................................... 6
5 certificate and check list......................................................... 6
6 consumable parts for installation, aommissioning and
start-up ............................................................................................................................................ 7
7 ( )spare parts for installation,
aommissioning and start-up (included in material bill) .................................................................. 7
8 special tools........................................................................................................ 7
9 the equipment installation procedure ................................................................. 8
10 inatallation, leveling and welding procedure ............................ 9
11 maintence special tools list........................................................................ 9
12 recommended two years operation spare parts.............................. 9

1 summary

The major process unit of ammonia flare includes: ammonia flare tip(with velocity
seal), two pilots, ammonia flare stack and derrick support.
GB50461-2008

The installation of equipment except derrick support meets GB50461-2008code

for acceptance of construction quality of petrochemical static equipment installation
engineering
2 installation special requirement
2.1 orientation
50061-MR-003/10-01 PIPING LAYOUT AND DRAWING
OF FLARE PACKAGE 50061-MR-003/10-02 EQUIPMENT ELEVATION
LAYOUT DRAWING
The orientation of equipment installation is shown on drawings 50061-MR-003/1001 PIPING LAYOUT AND DRAWING OF FLARE PACKAGE and 50061-MR003/10-02 EQUIPMENT ELEVATION LAYOUT DRAWING. The orientation is
below:
0
0

Flare tip: 0 is north

Flare stack: 0 is north
FFG: operation place is in the east
2

Derrick support: ladder is in the west

2.2 equipment delivery status

Delivery in sections and weld on site for ammonia stack; prefabricated supply and
assembly on site for derrick support. Integrated supply for other equipment.
2.3 groups of welding on site

Flare stack is deliveried in sections which have serial number on. The sections are
welded on site according to supplier relative information.
2.4 derrick supply assembly
3300mm20.5
20.8

Derrick support is trilateral figure. Height of base elevation is 0.3m above grade. And
height of the derrick is 20.5m. Top platform is 20.8m after installation. There are rigid
section and soft segment for derrick support. prefabricated supply and assembly on site
for derrick support. Flange connection for derrick parts and components.

Mobile jib, rigid rod and rail are assembled according to serial number. When flange
connection carried out, justify the nick line on the side of flange, and then pass through
bolts.

7.815
The installation includes rigid section and soft segment installation. From the
ground to elevation 7.8m, that is from 1 to 5 section, is rigid derrick, and the other parts
are soft segment derrick.
3


(
)6

After rigid section installation completed, adjust soleplate of derrick foundation to

adjust verticality. Once the verticality reaches requirement, perform the second
grouting.(according to design drawing and technical document). After maintenance
period and acceptance, begin to install the sixth soft derrick. Regulate verticality after
each soft segment installation completed. The verticality can be adjusted by means of
adjusting brail tension rods turn buckles bolts.

2-1
2-1
Before adjusting verticality for each section, all nuts should not be too screwed. (the
tightening torque see table 2-1 first screwed moment), after the verticality adjusted well,
screw the nuts. (the tightening torque see table 2-1 final screwed moment)

Bolts and nuts for derrick flange should use strictly according to derrick drawing.
Wrong connection influences overall strength.
2-1
Table 2-1 bolts for derrick screwed moment
bolt size

Nm first Nm final

screwed moment

screwed moment

M42A3

1000

3600

M368.8 grade

630

2100

M308.8 grade

360

1220

M248.8 grade

230

780

M208.8 grade

160

540

M168.8 grade

100

340

50061-MR-003-ST/02
4

2.5 connection type for equipment and foundation

Ammonia flare stack: anchor bolts connection

FFG: weld connection

Derrick support: anchor bolts connection

3 storage requirement before and after installation
3.1 package type for equipment

Ammonia flare tip: wooden case packing

Ammonia flare stack: nude packing

Derrick support: nude packing

3.2 storage requirement before installation
1

Material of ammonia flare tip is stainless steel. The tip can be placed outside, but should
be on the board, and be covered by tarpaulin. Take care carefully.
2
The other nude equipment and material should be stored in dry indoor.
3

All equipment and material in wooden case should put in dry environment, and avoid
strenuous vibration during transfer.

4 installation parts list on site

name

size

O.

material

mass
kg

quantit

remarks

310SS+304

1010

Huali

SA333-6

1540

Huali

15500

Huali

150

Huali

static equipment

DN250/1200

flare tip (with

H=4000mm

velocity seal)
2

flare stack

DN250
H=21000mm

derrick

Q345steel

support

pipe

20.5
trilateral figure
Side length=5m
H=20.5m
4

CS/304

flame front generator

5 certificate and check list

5.1

After the equipment is deliveried to site, perform checking and accepting. The equipment
must meet design requirement, and include certificate of merchandise.
5.2

Check equipment name, model, size, outside measurement, nozzle orientation, surface
failure, size and quantity. Fill check list.
5.3 100%
JB4730.2-2005

Butt welding for flare stack. The welding joint should perform 100% RT to meet
grade in JB4730.2-2005.
6 consumable parts for installation,
aommissioning and start-up

N/A
7 ()spare parts for installation,
aommissioning and start-up (included in material bill)

name

item

unit

20
stainless

10

m
piece

1
1

piece

quantity

matrial

DN25 pipe

DN25 pipe

steel
3

DN50 pipe

20

DN25 gate valve

DN25 gasket

A105
stainless

DN25 gasket

steel
CS

piece

DN50 gasket

CS

piece

DN250 gasket

CS

piece

M14X80 /

CS

set

10

bolts/nuts
M14X80 /

stainless

set

11

bolts/nuts
M16X105 /

steel
CS

set

bolts/nuts

8 special tools

N/A

9 the equipment installation procedure

9.1 flare stack
SA333-6
Ammonia flare stack is connected with ground by anchor bolts. The material of stack is
SA333-6
9.2.1 orientation
(50061-MR-003-20/0200
0 degree of ammonia flare stack on equipment drawing (document NO: 50061-MR-00320/02) match battery limit 0 degree.
9.2.2 butt welding on site
22

Flare stack is deliveried by two-section. And then welded on site. The serial number one
and two is marked on stack. Butt welding from top to bottom.
9.2 flare stack

310SS
Flare tip is on the top of flare stack, the bottom flange is connected to ammonia flare
stack. The main material of ammonia flare tip is 310SS.
9.2.1 orientation
(50061-MR-003-20/01-000
0 degree of ammonia flare tip on equipment drawing (document NO: 50061-MR-00320/01-0) match battery limit 0 degree.
9.2.2 connection with flare stack
50061-MR-003-20/01-0a
50061-MR-003-20/02b
HG/T20634-2009M27175 35CrMoA16HG/T20634-2009
M2732HG/T20631-2009 D250-300 1
8

Nozzle A on flare tip (drawing NO: 50061-MR-003-20/01-0) is connected to Nozzle B

on flare stack (drawing NO: 50061-MR-003-20/02). The fastenings are 16 pieces
M27175 bolts (HG/T20634-2009), 32 pieces M27 nuts(HG/T20634-2009) and gaskets
D250-300 (HG/T20631-2009)
flame front generator

The bottom of FFG is welded to steel plate on foundation directly.

9.3.1 orientation
1203180
Nozzle one and two is placed to 0 degree, and nozzle three is placed to 180 degree.
10 inatallation, leveling and welding procedure
GB 50461-2008
See GB 50461-2008code for acceptance of construction quality of petrochemical static
equipment installation engineering
11 maintence special tools list

N/A
12 recommended two years operation spare parts

name

item
instrument

unit

quantity

material
shell

thermocouple
stainless

set

Y-100BF

piece

G20

piece

Inconel 600 10m

pressure gauge
3

Cable gland

Stainless steel
9