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OPERATIONS MANUAL

VOLUME 14

UNIT 37 FLARE SYSTEM

Project Name : BTIP-Onshore Facilities / Offshore Pipelines

Contract No. : E-09335

Client : Shell Petroleum Development Company of Nigeria Limited

Document No. : E-09335-10-09-6S-012

EPIC CONTRACTOR

Rev Date Description Prepared by Reviewed by Approved by

0 05 Jan 2007 Released I. Jones T. H. Lee H. D. Kim

1 15 May 2007 Updated Malcolm Arnold T. H. Lee H. D. Kim

2 30 Nov 2008 As-built Stephen Jessen C. K. Park T. H. Lee

1, Cheonha-Dong, Dong-Ku, Ulsan, Korea, 682-792, http//:www.hhi.co.kr


Tel: 82-52-230-5461/2, Fax: 82-52-230-3549, E-mail: j740hhi@hhi.co.kr

REVISION HISTORY
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 2 OF 17

EPIC CONTRACTOR SPDC

Prepared Reviewed Approved Validity Reviewed Approved


Rev Date Date
by by by Period by by

A 30 Oct 2004 K. K. Chang D. I. Park W. S. Kim

B 25 Jan 2006 K. K. Chang D. I. Park C. W. Shin

0 05 Jan 2007 I. Jones T. H. Lee H. D. Kim

15 May Malcolm
1 T. H. Lee H. D. Kim
2007 Arnold
Stephen
2 30 Nov 2008 C. K. Park T. H. Lee
Jessen
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 3 OF 17

TABLE OF CONTENTS

1.0 INTRODUCTION....................................................................................................4
1.1 General...................................................................................................................4
1.2 Unit Location and Equipment list.........................................................................5

2.0 PROCESS DESCRIPTION.....................................................................................6


2.1 General...................................................................................................................6
2.2 Flare KO Drums and Pumps.................................................................................6
2.2 Combined Enclosed Flare.....................................................................................7

3.0 OPERATIONAL PROCEDURES...........................................................................8


3.1 General...................................................................................................................8
3.2 System Purge Out.................................................................................................9
3.3 Flare Ignition..........................................................................................................9
3.4 Staging Operation...............................................................................................11
3.5 Flare K.O. Drum Pumps P-3701A/B, P-3702A/B...............................................13
3.6 Normal Shutdown Procedure.............................................................................13

4.0 OSD AND ESD ....................................................................................................15


4.1 Operational Shutdown.........................................................................................15
4.2 Emergency Shutdown.........................................................................................15

5.0 HEALTH, SAFETY AND ENVIRONMENTAL......................................................16


5.1 Area Classification...............................................................................................16
5.2 Fire and Gas system...........................................................................................16
5.3 Fire Extinguishing System..................................................................................16
5.4 Effluents and Emissions ....................................................................................17
5.5 Noise....................................................................................................................17
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 4 OF 17

1.0 INTRODUCTION
1.1 General
The information contained in this operations manual is intended as an aid to the operation
of the Bonny Oil and Gas Terminal. It is provided to guide and instruct the persons in
charge, operating supervisors and plant operators. This helps to ensure the safe operation
of the plant.

Process Flow Schemes PFS are included to show the main equipment, flow lines and
basic controls within the plant. For full details of equipment, reference should be made to
the relevant Process Engineering Flow Schemes PEFS. The actual conditions may be
different from the design conditions and may change in the course of time. The operator
must, therefore keep the manual up-to-date by adjusting for actual operating
requirements. The updated manual should be issued by BOGT management as required.

Safety

Total attention must be given to safe operating practices. Ignorance and disregard of the
safety instructions will result in serious consequences. Improper operation can be
dangerous and may result in injury or death. The operator shall observe utmost caution
and pay careful attention in operating the plant at all times. Never operate the plant or any
part thereof until the resulting effect of the operation on the behavior of the plant is fully
understood and ascertained to be safe.

Ensure that the equipment is not subject to any previously issued and still valid permit to
work controls/restrictions and that all required work permits and certificates for the present
activity of this instruction have been authorized and in place. Before operating any
equipment on the unit it is essential that the Vendors Equipment Operation Manual has
been read and fully understood.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 5 OF 17

1.2 Unit Location and Equipment list


Flare System Unit 37 is on the Northwest side of the new process area, which is at the
north east corner of the BOGT. The areas to be filled extend approximately between
N.0+863 and E.1+543.

The flare system consists of the following equipment:

 Gas plant flare Pit Purge Blowers K-3702A/B

 Gas plant flare KO drum V-3702

 Gas plant flare KO drum pumps P-3702A/B

 Flare KO drum Sump pump P-3703

 Flare KO drum V-3701

 Flare KO drum pumps P-3701A/B

 Combined enclosed flare A-3701

 Flare Ignition staging control system J-3701


CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 6 OF 17

2.0 PROCESS DESCRIPTION


2.1 General
Refer to PEFS E-030142-1 thru 4.

Two (2) Flare KO Drums are provided: Relief gas from NAG plant flows to Gas Plant KO
Drum (V-3702) and relief gas from Unit 11, 12, 13 and 25 flows to Flare KO Drum (V-
3701).

Relief gas from V-3702 is combined with that of Unit 11/12/13/25 and enters into V-3701.
The overhead gas from V-3701 is fed to the Combined Enclosed Flare system (A-3701)
where the relief gas is burnt and flue gas is vented to atmosphere.

Each drum has transfer pumps to return the accumulated condensate back to the Crude
FWKO. Purge gas lines are provided at the end of the headers to supply the LP fuel gas.

There are tie-in points with existing facilities as follows:

The vent line of 25PCV-111 (LP fuel gas system pressure control valve) is tied-in to the
existing Flare Pit Header.

The existing Flare Pit Header is tied-in to the flare line to V-3702.

A 10” block valve on the existing line 10-PV-2527-1143 is replaced.

2.2 Flare KO Drums and Pumps


The flare knock-out drum V-3701 will knock out any liquid from the relief gas from the
process units. The design capacity of V-3701 is 18.9 kg/s. Capacity of the flare KO drum
pumps P-3701 A/B is 43.6m3/hr 274bbl/hr @ diff. pressure of 4.27 bar of being pumped.

Gas plant flare KO drum V-3702 collects all relief valves from NAG plant and sends to the
main flare header that flows to V-3701. The design capacity of V-3702 is 4.97 kg/s.
Capacity of gas plant flare KO drum pumps P-3702 A/B is 20.1m3/hr (126.4bbl/hr) @
differential pressure of 3.06 bar.

Level/temperature instruments are provided for V-3701/V-3702 as follows:

V-3701 level indicator 37LIA-002 Temperature indicator 37TIA-006

V-3702 level indicator 37LIA-001 temperature indicator 37TIA-003

Operation of the gas plant flare KO drum pump P-3702A/B (as an example) is described
as follows:

high level switch 37LISH-001 lead pump P-3702A or B is started

high-high level switch 37LSAHH-001 the lag pump P-3702A or B is started

low level switch 37LISL-001 alerts the operator of a low level condition

low-low level switch 37LSALL-001 stops both pumps if they are running.

Operation of the flare KO drum sump pump P-3703 is intermittent and automatic based on
the level switch.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 7 OF 17

2.2 Combined Enclosed Flare


Flare header 10-B37002-11410 from Gas plant KO drum V-3702 is combined with the flare
header 24-B37003-11410 from Unit 11, 12, 13 and 25 and the combined gas enters into V-
3701 and then discharged to a combined enclosed flare A-3701.

The combined enclosed flare will be operated with a capacity of 68,050kg/hr through 5
stages of flaring. The staged flares are designed to flare smokeless or near smokeless
gas over range of flare releases given adequate gas pressure.

 Maximum relieving load: 18.90kg/s (Note 1)

 Molecular weight: 39.87

Note 1: simultaneous relief loads from one (1) crude FWKO V-1102x, one (1) crude
vacuum drum V-1103x and entire depressurisation of Unit 13 equipment

The enclosure contains flame so that no flame is visible from outside and much of its heat
is directed upward rather than outward. The flare enclosure provides a barrier for outward
radiating combustion noise.

LP fuel gas is supplied to A-3701 for igniting staged burners. A pressure regulator 37PRV-
001 controls the pressure of LP fuel gas.

Flare type is a combined enclosed flare consisting of 4 stage runners and one elevated
stack. The 4 stage runners are installed in a refractory shell to shield radiation, and one
elevated stack is installed at the outside of the shell. The enclosure is open at the top, and
the bottom is partially closed with window openings. Combustion air is drawn into the
enclosure through the windows at the bottom of the flare burners. It is elevated on
multiple column legs.

Each stage runner consists of a staging valve with rupture disk and pilot burners. The
staging valves will open to the flare depending on the pressure of the flare header.

The flow rate of flared gas to the combined enclosed flare is indicated by the flow element
37FQI-005. 37PIAHH-002 is installed on the flare inlet header to the combined enclosed
flare.

The operation parameters of flows and pressures are detailed below. Staging/Destaging is
controlled according to the pressure measured by the pressure transmitter 37PT-002.
Flare Capacity Operating Pressure
Stage
Kg/h barg
Stage 1 0 → 3825 0 → 0.48

Stage 1 + 2 3825 → 11652 0.06 → 0.48

Stage 1+2+3 11652 → 24177 0.13 → 0.48

Stage 1+2+3+4 24177 → 36717 0.15 → 0.48

Stage 1+2+3+4+5 36717 → 68050 0.15 → 0.48


CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 8 OF 17

3.0 OPERATIONAL PROCEDURES


3.1 General
Prior to plant start-up:

The plant area must be cleaned; all rubbish, trip hazards, non-essential scaffolding and
other materials especially flammable or toxic must be cleaned away.

The person in charge of commissioning should check the plant condition to ensure all is
safe and correct.

Refer to the vendor manual VD-E09335-ME021-A3701-098/099/101 for the flare system.

The flare system should be commissioned prior to introduction of hydrocarbon to the plant.

The pre-start-up check shall be completed before the plant start-up (Refer to the
Operations Manual Volume 1, 4.0 Preparation for Start-up)

Before proceeding with start-up operations, the following checks must be


carried out:

(1) The system is properly boxed up with all safety valves are in place.
(2) All valves, instruments, sample points have proper access for operation and
maintenance.

(3) Drain points are located where the entire liquid can be drained.
(4) All globe valves and orifice plates have correct flow direction.

(5) Basket filters have correct inlet/outlet connections. Reverse flow connections may
damage filter elements.

(6) All electrical lockouts are identified by tags and checked.

(7) All motors, pumps and blowers are checked for correct alignment, direction of rotation.
(8) All pump strainers are installed
(9) The ESD and OSD systems are operational.
(10) All control valves have the correct air failure action Fail Open or Fail Close. Check
that other facilities which are not in a position to start-up are isolated by blinds from
this unit.

(11) The isolation valves for the safety valves will be in the locked open position. The
stand-by valves are isolated.

(12)Check that all blinds are in correct position.

(13) Check that communication system is operational within plant and from plant to
control room.

(14)Check that all necessary maintenance tools and tackles are ready for on line
maintenance.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 9 OF 17

3.2 System Purge Out


Carry out nitrogen purge of the flare system as follows:

(1) Establish a continuous nitrogen flow from end of each flare header.
(2) Open the stage 2 valve (37SDV-102) at the flare so that purge flow will be distributed
to both sides of the staging manifold.

(3) It is important, prior to start-up, to purge the entire flare system with nitrogen until
there is 2.5 vol. % or less oxygen measured at the drain connection in the flare
manifold.

(4) After the completion of the cold start-up purge, close the Stage 2 staging valve.
3.3 Flare Ignition
Pilot ignition system can be operated in one of two modes:

 Manual mode from the local control panel manual.

 Automatic mode from the local control panel automatic.

The operation of the ignition system in both modes is described in detail below.

The ignition system continuously monitors the operation of the flare pilots. If the system is
operating in “automatic” mode the pilots will be re-lit with no operator interface required. If
the system is not in “automatic” mode, the system will give an alarm indicating that
operator interface is required to re-light the pilots.

Manual Mode from Local Control Panel

(1) Supply instrument air to the staging skid instruments.


(2) Initiate the panel purge with instrument air and regulate it as per vendor instructions.
(3) Power up the local control panel by turning the power switch to the ON position and
the alarm lamps should light up. The alarm lamps coming on in this start position
verifies the operation of the flame detection system in the cold, or flame out, condition.

(4) Purge the flare with nitrogen. Purge until there is 2.5 vol. % or less oxygen measured
at the flare manifold.

(5) Maintain a continuous purge through stage 1 of the enclosed flare with the pilot light
off. A continuous purge must be flowing through stage 1 before proceeding.

(6) Close all fuel valves on the control rack. Turn all ignition toggle switches to OFF
positions.

(7) Fully open all hand valves to each flare pilot.

(8) Open the hand valves in the fuel line on the rack supplying fuel to the pilots. Adjust the
fuel gas regulator to 1.03 barg (15 psig) using the pressure gauge on that line.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 10 OF 17

(9) Select which pilot is to be lit and move its toggle switch from OFF to the MAN position
it is possible to ignite all pilots at once. The switch is a spring return type and must be
held in the manual position to ignite the pilots in this mode. While the switch is held
the system sparks the pilot approximately once every 20 seconds. (See the Automatic
Mode for ignition)

(10) This spark ignites the pilot resulting in a standing pilot flame. The pilot must be
continuously lit when the flare is in operation with a continuous supply of regulated
fuel gas. The pilot in turn will light the flare gas.

(11) After the pilot is lit, the pilot thermocouples detect the flame heat. The temperature
switch in control panel will then extinguish the Flame Out lamp. When the Flame Out
is extinguished the operator should then return the pilot toggle switch to the OFF or
AUTO position.

(12) Repeat the two previous steps until all the pilots are established. Once all pilots are lit
the flare is operating normally and ready to receive flare gas.

(13) Switch the pilot ignition system to the automatic ignition mode after a manual start-
up.

Automatic Mode from Local Control Panel

(1) Ensure that Steps 1) to 8) of Manual Mode for Flare Ignition have been taken as
described above.

(2) Select which pilot is to be lit and move its toggle switch from OFF to the AUTO
position it is possible to ignite all pilots at once. Ignition will commence automatically.
All pilots determined to be unlit will receive a signal to spark once every 20 seconds.

(3) This spark ignites the pilot resulting in a standing pilot flame. The pilot can be
operated continuously standing point when the flare is in operation and therefore
should have a continuous supply of regulated fuel gas. The pilot in turn will light the
flare gas.

(4) After the pilot is lit, the pilot thermocouple will detect heat. The temperature switch in
the control panel will then extinguish the Flame Out lamp and the igniter will stop
sparking.

Fuel gas purge flows to the flare header

(1) Start the LP fuel gas purge from each end of the header via 37PRV-003, 37-PRV-004
and 27-PRV-005. The quantity of continuous purge gas shall be maintained to avoid
entry of air into the flare system while the flare is in operation and the pilots are
burning.

(2) To prevent the migration of air into the flare, the minimum purge rate of 8.04 Nm3/hr to
stage 1 is recommended. This minimum rate must be maintained at all times when the
flare is in operation.

(3) Caution: Purge gas should be flowing at all times to prevent the possibility of an
explosion.

(4) Stop the nitrogen purge flow when the continuous fuel gas purge is established.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 11 OF 17

(5) The fuel gas purge from the emulsion treatment area via 37PRV-004 will be started
after the fuel gas is available from V-1202 Fuel Gas Scrubber.

(6) If possible, visually inspect the appearance of the flare flame once established - from
a safe distance.

Pilot Operation

After a successful start-up, the thermocouples mounted on each pilot will continuously
monitor the pilot flame. The system shall be left in automatic mode for normal operation.
The flare system is considered to be in operation once the purge gas is flowing and all
pilots are confirmed lit. The pilots should be confirmed lit before the admission of flare gas.

If at any time after start-up after the initial flare ignition sequence a flame failure is
detected or a thermocouple should fail, the Pilot Off Lamp at the local control panel will
light up.

When in automatic mode, the system will automatically attempt to re-light any pilot that is
extinguished. It will continue attempting to re-ignite the pilot until the thermocouple senses
flame or if the pilot does not re-ignite after a set period of time preset at 10 minutes, but
can be adjusted. The igniter will stop attempting ignition and an ignition failure alarm will
result. A operator interface will be required to correct the problem and light the pilot.

If the system is left in the manual mode, it is the operator’s responsibility to monitor the
flare system and promptly take corrective action to re-light the failed pilots following the
instructions to re-establish a failed pilot.

3.4 Staging Operation


The flare system operates through 5 stages of flaring. The operation parameters of flows
and pressures are detailed below. staging/destaging is controlled according to pressure
measured by the pressure transmitter 37PT-002.

flare Capacity, Kg/hr1 Operating Pressure, barg

Stage 1 0 → 3825 0 → 0.48

Stage 1 + 2 3825 → 11652 0.06 → 0.48

Stage 1+2+3 11652 → 24177 0.13 → 0.48

Stage 1+2+3+4 24177 → 36717 0.15 → 0.48

Stage 1+2+3+4+5 36717 → 68050 0.15 → 0.48

Note 1: Based on Case 3 as design case for flaring staging.

Staging Up - Opening Additional Stages

Stage one of the flare is always open to atmosphere and ready to accept even the
smallest flare event. The normal operating condition of the flare when not in a flaring event
will be to have all staging valves closed and a continuous purge flowing through stage 1.
All pilots will be lit and burning continuously.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 12 OF 17

During a flare event, as the flow of the flare gas increases, the backpressure upstream of
the flare staging manifold will increase. When the pressure reaches the upper staging
pressure 0.48 barg 7psig the staging valve on the next successive stage will open fully
making available additional flare tips for the flare flow and thus decreasing the flare
manifold pressure.

As the flow continues to increase the pressure will again begin to rise. The system stages
up in successive order as necessary to accommodate the flare event, starting by opening
stage 2, then stage 3, then stage 4, and finally stage 5.

EXAMPLE: staging from stages 1+2+3 to Stages 1+2+3+4

 Staging valves 37SDV-102 and 37SDV-103 are open and the first three stages of
the system are flaring. The flow of the flare event continues to increase; consequently
the backpressure upstream of the flare-staging manifold will increase.

 When the pressure reaches the upper staging pressure 0.48 barg the control
system will automatically open the next stage.

 A signal has already been received to open 37SDV-102 and 37SDV-103. 37SDV-
104 is the next successive valve to be opened, and once a signal has been received to
open this valve and flow will be established to stage 4.

As soon as a valve open signal is received, a timer is activated to prevent the valve from
changing position for 7 seconds this time may be adjusted if necessary. This will hold the
valve in the open position long enough for the pressure swings caused by the sudden
opening of the valve to dampen out and will prevent any fluctuation phenomena. During
the timer duration, the flow and pressure should move beyond the staging set point. Once
the flow is past the staging points and timer has elapsed, normal operation will resume
with the additional stage in service..

Destaging Down – Closing Stages

During a flaring event multiple stages may be in operation. As the flare flow decreases, the
system backpressure will also decrease. When the flare manifold reaches a minimum
destaging pressure varies based on stages in operation a stage will be closed, starting
with the last stage opened. When a stage is closed the flow will be diverted to the
remaining stages, thus increasing the pressure and flow in those stages. The system
destages down in the opposite order of staging up, that is the last valve opened during
staging will be the first closed during destaging, the next to last open will be the second to
be closed, and so on.

EXAMPLE: staging from stages 1+2+3 to Stages 1+2.

 Staging valves 37SDV-102 and 37SDV-103 are open and the first three runners of
the system are flaring. The flow of the flare event starts to decrease; consequently the
backpressure upstream of the flare-staging manifold will decrease.

 When the pressure reaches the lower staging pressure for stage 3, 0.13 barg the
control system will automatically de-stage (close) stage 3.

 A signal will be given to close valve 37SDV-103 and flow will be diverted from
stage 3.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
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OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 13 OF 17

As soon as a valve close signal is received, a timer is activated to prevent the valve from
changing position for 7 seconds, this time may be adjusted if necessary. This will hold the
valve in the closed position long enough for the pressure swings caused by the sudden
closing of the valve to dampen out and will prevent any fluctuation phenomena. During the
timer duration, the flow and pressure should move beyond the staging set point. Once the
flow is past the staging points and timer has elapsed, normal operation will resume.

3.5 Flare K.O. Drum Pumps P-3701A/B, P-3702A/B


Typical start-up procedure for flare KO drum pumps is mentioned below:

(1) Ensure that pump casing drain is closed.

(2) Ensure that pump casing vent is opened.

(3) Open suction valve slightly. Accumulated liquid in respective K.O. drum V-3701, V-
3702 will displace the air in the pump through the vents on top of the pump casing.
When air has been displaced, close the vent valve.

(4) During the displacement of air, the pump will be checked for leaks. If any leaks are
seen, the suction valve should be closed immediately, and the leak repaired.

(5) The outside operator shall fully open suction valve.

(6) The outside operator shall open the pump discharge valve and block valves. Check
that pump discharge line is opened to the incoming crude manifold (FWKO)

(7) Operator shall start the pump. Ensure that the pump is in normal running conditions.

(8) Operator shall change the level control system of K.O drum V-3701, V-3702 to remote.

(9) The pumps are now ready for the automatic operation.

3.6 Normal Shutdown Procedure


The normal shutdown procedure provides all the steps needed to deactivate the flare
system Unit 37 safely. The procedure defines the time to be taken and checks to be made
before proceeding to the next steps.

A normal process shutdown is defined as an operator controlled process facility shutdown


to zero production with utilities held on hot stand-by where possible.

The planned shutdown will leave the system in a “ready for start-up” mode. A tripped
shutdown will leave the system in a “stable and safe” condition. systems are designed
such that automatic shutdown functions will not be activated as a result of normal
operational conditions.

The shutdown should occur in the reverse order of start-up, in that it is run down first and
then the utility systems are shutdown.

Restart after a manual shutdown will usually require re-purging of section of the flare
system Unit 37 as air ingress may occur.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 14 OF 17

Refer to the vendor manual for the flare system (VD-E09335-ME021-A3701-098/099/101).


This package equipment will be shutdown strictly in accordance with the respective vendor
shutdown procedures.

The shutdown procedure for overall system is as follows:

(1) Ensure that all units on which vent line or pressure relief valve outlet line is connected
is in shutdown, and Battery Limits valves of flare sub-header in each unit is closed.

(2) Close block valves at upstream/downstream of 37PRV-001 on pilot gas line.


(3) Check that pilot burner on each flare system is off.
(4) Close block valves of fuel gas purge lines upstream/downstream of the 37PRV-
003/004/005

(5) Open 3/4” drain valves of each pump, and drain out accumulated liquid in V-3702 and
V-3701.

(6) Connect temporary nitrogen purge lines to end of the flare header.
(7) Slowly open the nitrogen supply valves to the flare header.
(8) Continue nitrogen purging until hydrocarbon concentration is less than 2.5%.
(9) After completion of nitrogen purging, close nitrogen injection valves.

Note: The flare system shall not be shutdown during the plant in operation. If the system
is shutdown, the whole plant should be shutdown.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 15 OF 17

4.0 OSD AND ESD


4.1 Operational Shutdown
The operational shutdowns are designed to shut down a part or all of the facility on
detection of a potentially unsafe or faulty condition. The initiation of an OSD does not
clear the unsafe condition and operator intervention is necessary to analyse the situation
and to solve the problem before restarting the facility. The initiation of the OSD should;
however, prevent the actuation of a safety shutdown or relief devices.

4.1.1 OSD Level 1

OSD Level 1 is not provided for flare system Unit 37.

4.1.2 OSD Level 2

OSD Level 2 is not provided for flare system Unit 37.

4.1.3 OSD Level 3

Level 3 OSD shuts down individual items of equipment. There will be PAS initiated stops
for each pump. These stops are not part of the SIS. Restarts will be from the PAS.

High-high liquid level in the flare KO drum V-3701 activates level transmitter 37LZAHH-
007. On high-high level in the flare KO drum V-3701 the SIS will start to open crude divert
valve 11SDV-852 so that the incoming crude goes to the crude storage tanks T-xx.

The flare KO drum pumps P-3701A/B, the gas plant flare KO drum pumps P-3702A/B and
the flare KO drum sump pump P-3703 are protected from low-low liquid level in the
respective suction drum identically. These pumps will stop on low-low level in respective
drum.

4.2 Emergency Shutdown


There is no emergency shutdown of flare system. Only planned shutdown is
acceptable. There is no requirement for an ESD shutdown and no signal for an ESD
originates the flare system.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 16 OF 17

5.0 HEALTH, SAFETY AND ENVIRONMENTAL


5.1 Area Classification
The objective of the flare system design is to provide safe disposal of all fluids
released from Bonny Terminal as a result of equipment overpressure or facility
upsets. This system Consist of the following equipment.

 ZONE: 1 & 2

 Group of Gas: IIA

 Grade of Release: Secondary

 Ventilation & Location: Open Area

Refer to Hazardous Area Classification report Document. No E09335-10-34-2S-013 &


Area Classification Drawing No E-030625-03.

5.2 Fire and Gas system


A fire and gas station is not applicable to the flare system Unit 37.

5.3 Fire Extinguishing System


Active Fire Protection

These fire extinguishing equipment needs to be activated in order to perform its function.
Automatic or manual intervention is required to activate protection.

The following fire extinguishing equipment has been provided for flare system Unit 37:

 Water Hydrant

 Portable Fire Extinguisher

All Hydrants to be used in the Utilities systems has two outlets with monitor connection.

Refer Process Engineering Utility Flow Scheme PEUFS for Fire Protection system E-
068902-05:Unit 34 Fire Water Ring Main – Process Area

Passive Fire Protection

Passive Fire Protection is applied to prevent the escalation of fire due to the collapse of
fire potential equipment during the early stage of fire. In the early stage of fire, the active
fire protection measures are not deployed adequately and non-fireproofed pipe and
equipment supports lose their strength and collapse due to the fire related heat exposure.

In this area, the hydrocarbon gas is generally treated but the K.O drum is considered as
the source of hydrocarbon liquid pool fire. 9m of fireproofing zone from flare K.O. drum is
to be fireproofed. The flare K.O. pump is also assessed by FRED 13.5m of fireproofing
zone from PSL. flare K.O. drum pump is to be fireproofed as shown in Fireproofing Zone
Drawing. No.: E-069030-01. Refer to Fire and Explosion Study - Doc. No.: E09335-10-34-
2S-009.
CONTRACT E-09335 Doc. No. :
BTIP – ONSHORE FACILITIES / OFFSHORE PIPELINES
E-09335-10-09-6S-012
OPERATIONS MANUAL VOLUME 14
Rev No. : 2
UNIT 37 FLARE SYSTEM Page : 17 OF 17

Safety Equipment

Safety equipment such as First Aid Cabinet, Safety Shower/Eyewash & Face Shield is
located to prevent the injuries of personnel in the emergency situation as shown in Safety
Equipment Layout Safety Equipment Layout Drawing. No.: E-031203-03.

5.4 Effluents and Emissions


5.4.1 Gaseous Effluent

No gaseous effluent is available except fugitive gaseous emissions through


valves and piping components.

5.4.2 Liquid Effluent

In normal operation, there will be intermittent drainage of hydrocarbon and


water from tanks and drains, which is likely to be associated with dissolved
hydrocarbons. Another source is occasional leakages/drippings of lubricating
oils around the various rotating equipment like pumps and compressors.

During floor washings, waste water is generated which is likely to be


contaminated with oil. During rainy seasons there are chances of rain/storm
water also getting contaminated with oil.

These effluents are collected in AOC system and sent to a LLOD.

5.5 Noise
Noise levels during normal plant operations have been estimated for the
equipment. Noise estimates have been produced from vendor supplied data.
The noise level of machinery such as pumps, compressors, etc. depends on its
characteristics. Refer to the Noise Report Document No E09335-10-00-2S-054.

The noise level sources are shown in the following table:

Noise Level dB A
Noise Source
Overall Noise Ceiling

Flare KO drum pump P-3701 A/B 64.0 85.0

Gas plant flare KO drum pump P-


< 85.0 85.0
3702 A/B/C/D

Flare stack A-3701 75.0 85.0

Gas plant pit purge blower K-3702 64.0 85.0