RAG PROGRAM ENGNEETING GENERAL INCOR TECHNICAL STANDARD SUN or) REVISION REVIEW AND APPROVAL No. FIREBAG PROGRAM TECHNICAL STANDARD REVISION REVIEW AND APPROVAL Doc. No.: FB-F-5621 Current Rev.No.: 2 Date: 20-Dec-06 Document Title: Flare Gas Stacks Issuing Department: Mechanical Date: _20-Dec-06 To: From: DESCRIPTION OF CHANGE {Attach the draft/revised Technical Standard) ‘+ Reasons for Change — Creation of a Firebag Program Technical Standard Revisions: ‘Section 8.1.8 — Liquid Seal changed to Velocity Seal Section 8.4.4 - whole section changed ‘Additions: «Section 8.1.18 «© Section 8.3.7 * Deletions: ‘Comments | Approval Date 1. | Originator h wl 0 [12 favo ‘Arcot Devender Wore . (Aiso sign tront page of TS) aCe Firebag Mechanical Program Lead y 2. | Engineer Ly Memb ‘Arcot Devender Wark lai — Firebag Mechanical Program Lead 3. | Reviewer Ru Dave Tullis RSL ars Dec. r0foe Firebag Engineering Manager 4. | Approval Authority B. More Ken Hart (Aiso sign hont page ofts) | Pec. Ofoe Firebag Operations Manager 5. | Return to Rita Lewis Jacobs Canada Inc. Attachment — Firebag Program Technical Standard FB-F-5621 — Rev. 2 Issued Date: 20-Dec-06 (ico TROLLED DOCUMENT WHEN PRINTED BU-DECD5] CONTROLLED DOCUMENT WN EWR FILE LOCATION. ———) (Fo EWR 100200%.001 = 733--F- fev Page: Toft]SUNCOR ENERGY Technical Standard No. FB-F-5621 FIREBAG PROGRAM FLARE GAS STACKS SUNCOR ENERGY INC. CANADA th fad [Engineer ‘GRCONTROLLED DOCUMENT WHEN PRINTED G0-Dec08) CONTROLLED DOCUMENT IN JPIEWH 1002004001 2447 File Name: FO-F-5621_- Rev_ 2005 of 12on) "FRERAG PROGRAM MEGHANEAL ENGHEERING Sur Y TECHNICAL STANDARD ‘Sie Taba Raion FLARE GAS STACKS FB-F-5621 2 oa ——REVIsIONTISTORY nl Rav [Date | 2 | —20-Dec 6 | ~Ralaved fr plomentaton [7 an-06 — | isbed tor pemertaon | “alr: —|Tssved for xtomal Squad Cheak [tapes Tested for intemal Squad Check Ths standards bases oh Suncor Energy In. Standard No. 1802 Rev. 4 (Ma _ 1990) and has been developed specicaly for use on Feshog Projects. ‘TABLE OF CONTENTS 1.0 SCOPE OF STANDARD 2.0 INTRODUCTION 21 Location 2.2 Conflict 2.3 Terms and Definitions 24 Units of Measurement 25 Exceptions 3.0 SCOPE OF SUPPLY 40 WORK EXCLUDED 5.0 CODES STANDARDS AND REGULATORY REQUIREMENTS $0 _ FIREBAG PROJECTS STANDARDS 7.0 OPERATING CONDITIONS TA General 8.0 TECHNICAL REQUIREMENTS 84 General Requirements 8.2 Height and Diameter 83 Flare Tip 8.4 _ Ignition Systems 85 Flare Gas Stack Design Requirements 86 Guy Wires and Fittings (Where Specified) 87 Fabrication Tolerances 88 Foundation Loading 8S Guarantees: ‘UNCONTROLLED OOGUMENT WHEN PRINTED (20-Dec-06) CONTROLLED DOGUMENT IN JPIEWR 1002004001 — 24-47 File Name: FB-F.5621_- Rev_2 Page 2 of 12TRGAG PROGRAM NECHANIGAL ENGREERANG su’ cor) TECHNICAL STANDARD Subject amber Revision FLARE GAS STACKS FB-F-5621 2 9.0 PERFORMANCE REQUIREMENTS, 10.0 INSPECTION AND TESTING 10.1 General 10.2 Inspection 10.3 Testing 44.0 SURFACE PREPARATION AND PAINTING 12.0 SHIPPING, HANDLING AND STORAGE ‘UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-08) CONTROLLED DOCUMENT IN JPIEWR 100-2004-001 - 24-8-7 File Name: FE-F-8621_- Rev_2 Page 3 of 12sui on) FRERAG PROGRAN- MECHONER ENENEERNS ene UNCOR TECHNICAL STANDARD Sanjece Taibo ~ Revision: FLARE GAS STACKS FB-F-5621 2 1.0 SCOPE 1.0.1 This standard together with data sheets establishes the basic requirements for the design, 2.0 24 244 22 224 23 234 23.2 24 244 25 25.4 materials, fabrication, testing and inspection of flare gas stacks with external pilot igniters. INTRODUCTION LOCATION The flare gas stacks are required for the Suncor Energy Firebag facility project located approximately 45 km NE of the existing Suncor upgrader plant near Fort McMurray, Aiberta, Canada. CONFLICT ‘Any conflict between this document, codes, standards, regulatory requirements or other purchase order documents shall be brought to the attention of the Buyer for resolution before proceeding TERMS AND DEFINITIONS “Buyer” — means purchaser and is defined as Suncor Energy Inc. or its designated agent. “Seller” ~ means vendor, supplier or manufacturer that supplies the materials and services. UNITS OF MEASUREMENT Al units of measure shall be reported in the Intemational System of units (SI) in accordance with CANICSA 2234.1-89, Canadian Metric Practice Guide. Dimensions shall be presented first in SI units followed by the equivalent value in imperial units shown in parentheses. Where imperial-sized materials such as plate are used (or where imperial dimensions are ‘contraling). dimensions shall be first specified in SI units (after hard conversion), with equivalent imperial sizes specified in parentheses. Piping flanges and bolting shall be shown in imperial units only (i. NPS 4). EXCEPTIONS ‘Any exceptions to this standard shall be made in writing at the time of quotation submission. All exceptions shall be clearly identified and explained in the Seller's proposal. Exceptions shall be permitted only after the Buyer has given written approval. "UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-08) CONTROLLED DOCUMENT IN JPIEWR 100-2004.001 245-7 File Name: FO-F-S521_- Rev_2 Page 4 of 12 wooed 2051006Suncor) Ra ERA MEA OH NETTO tweney TECHNICAL STANDARD Soba Naber Rein FLARE GAS STACKS FB-F-5621 2 3.0 SCOPE OF SUPPLY 3.0.1 The Seller is responsible for the complete supply of the flare gas stacks with extemal pilot igniters to meet the performance guarantee and the requirements of this standard, The scope of supply includes all work and resources required to fabricate, test, inspect and provide technical assistance for the installation and commissioning of the flare gas stacks with the flare system described in the purchase order. 3.0.2 All work not described in this standard but necessary for the completion and proper installation of the flare gas stacks with external pilot igniters shall be supplied by the Seller. 3.0.3 Seller shall furnish adequate and appropriate installation and operation instructions for use by the Buyer. 4.0 | WORK EXCLUDED 4.0.1 The following works are not included: Preparation of foundation or structures for installation of flare gas stacks © Connection of instrumentation to control panel or plant Basic Process Control System (Pcs) + Connection to plant utility system if required ‘© Bolts and gaskets required for installation 5.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS 5.0.1 The latest edition and addenda of the following codes, standards, guides and handbook shall be an integral part af this standard, Codes and Standards National Building Code of Canada (NBC) including User’s Guide Alberta Building Code (ABC) Handbook of Steel Construction (Canadian tnstitute of Steel Construction) CSA Standard G4 Steel Wire Rope for General Purpose API RP 521 Guide for Pressure-Relieving and Depressuring Systems Transport Canada Obstruction Marking Recommendations ‘UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-08) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 — 24-47 File Name: F8-F-5621_- Rev_2 Page Sof 12 ested. 200486Suncor) TREAG PROD AES ER cueney TECHNICAL STANDARD abe Naber Fevson FLARE GAS STACKS FB-F-5621 2 Codes and Standards Energy Utility Board (EUB) Guide 60 6.0 FIREBAG PROJECTS STANDARDS Firebag Projects Title Standards FB-A-5673 Equipment Protection During Transit and Storage at Jobsite FB-L-5208 Thermal Insulation of Piping, Vessels, and Equipment FB-L8214 Painting FB-L-5217 ‘Shop and Fieié Welding Requirements 7.0 OPERATING CONDITIONS 74 GENERAL 7.4.1 The flare gas stacks with external pilot igniters shalt be constructed for outdoor installation with a MDMT of -45° C (-49°F). 7.1.2 _ Refer to the Site Conditions and Data Sheet included with the Purchase Order for further site conditions, 8.0 TECHNICAL REQUIREMENTS 81 GENERAL REQUIREMENTS 8.1.1. The Selier shall provide an elevated flare gas stack and flare system with continuously burning, remote ignition pilots in accordance with the Seller Scope of Supply accompanying this standard. 8.1.2 The Seller shall clearly identify and describe all instrumentation and controVinterlocks included in their proposal. All instruments shall be tagged with Buyer supplied tag numbers. 8.1.3 The flare gas stack and associated equipment shall be supplied shop assembled to the ‘maximum extent possible to minimize field erection. Proper shipping arrangements and care shall be exercised to avoid damage or permanent deformation in the flare gas stacks or accessories. 8.1.4 Flare gas stack shall be self supported unless otherwise indicated on the data sheet. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-08) CONTROLLED DOCUMENT IN JPIEWR 100-2004-001 24-47 Fie Name: FB-F-5621.~Rev_2 Page 6 of 12on) ‘FREDAG PROGRAM -WEGHIOICAL ENGHEERING SUN COR, TECHNICAL STANDARD Subjesk Nuiiber Revision: ELARE GAS STACKS: FB-F-5621 2 8.1.5 The Seller is responsible for the complete design, fabrication, and performance of the flare gas system. The Seller shall conduct a test of the pilot ignition package and control panel and submit successful test results to the Buyer, prior to acceptance by the Buyer. 8.1.6 The flare shall not cause the sound level at ground elevation to exceed 85 dBA measured at a radius equal to the distance between the base of the flare and the knockout drum or any other ‘equipment, which ever is placed closer to the base of the flare gas stack. This shall be based ‘on maximum steam flow to the nozzles at 25% of peak flare load. At 100% flaring load, the flaring noise level shall not exceed 100 dBA measured at the same radius. This noise level requirement is based on the 71-hour exposure limit permitted per the Alberta Occupational Health and Safety Act, Noise Regulation 314/81. 8.1.7 All piping connections shall terminate at the elevation above grade as specified on the flare gas stack data sheet. Seller shall provide all piping including pilot gas, ignition piping, wire ‘and conduit, steam piping, and seal drain piping. The seal drain and dilution steam piping shall be insulated in accordance with Firebag Project Std. FB-L-5208. All piging connections shall be 150 # RF flanged as a minimum. 8.1.8 The Seller shall specify purge gas requirements and shall quote a velocity seal as a base requirement. Other seal arrangements can be quoted as an alternate. The purge gas volume rate calculation or methodology, to prevent intsusion of air down flare gas stacks shall be provided for Buyer's review. 8.1.9 Materials of construction shall be per the flare gas stack data sheet. 8.1.10 The minimum corrosion allowance for the seal drum and flare gas stack riser shall be 1.6 mm (1/16") unless otherwise specified on the data sheets. 8.1.11 The flare gas stacks shall be designed per the requirements of the National Building Code of Canada and all Federal, Provincial and local regulatory requirements. 8.1.12 The flare gas stack and attachments shall be given two final coats of white and alternate bands of international orange paint in accordance with Transport Canada Obstruction Marking Recommendations. 8.1.13 The flare gas stack shall be equipped with aviation obstruction lights in accordance with Transport Canada requirements. 8.1.14 Qualified and experienced tradesmen shall perform the work in a neat and workmanlike manner conforming to industry standards and all applicable code requirements. 8.1.15 Bolted flare gas stack riser sections shall not be permitted unless approved by Buyer. 8.1.16 The Seller shall list all loose-shipped instruments and provide detailed installation detail for each, UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 244-7 Fle Name: FB.F-5621_- Rov_2 Page Tott2Suncor) RES ROG OWL ONES Ewency TECHNICAL STANDARD Sure Tomb Revision FLARE GAS STACKS FB.F-5621 2 8.1.17 _Allinstruments must be provided with ISA style instrument data sheets. 8.1.18 Separate fuel gas piping of SS 304L material shall be provided for each pilot from grade level. | 8.2 HEIGHT AND DIAMETER 8.2.1 The flare gas stack height is specified on the flare stack data sheet. Radiation data and calculations shall be supplied for Buyer's record. Calculations shall be based on Brzustowski and Sommer's methods contained in API RP 521, Appendix C.3. 8.2.2 The maximum velocity under peak flaring conditions (gas flow rate, temperature, pressure, molecular weight) shall not exceed 0.5 Mach. 83 FLARETIP 8.3.1 The Seller shall advise the recommended number of pilots, but no less than three (3) pilots shall be supplied for the flare tip. Once lit, the pilots must be able to burn continuously under all design conditions. 8.3.2 The top 3.656 m (12 feet) of the flare gas stack or twice the flare gas stack diameter whichever is greater, the flare tip body, pilot head and associated piping and attachments shall be of a heat resisting alloy or stainless steel material suitable for the operating conditions. 8.3.3 The Seller's proposal shall include a narrative stating how their flare tip design prevents or minimizes flame lick burn-back and flame lift off. 8.3.4 Buyer's preference is for a flare tip that does not contain refractory. If the refractory lining is being used, the Seller shall specify in detail, the used refractory lining and the method of attachment to the flare tip. Failure of the internal lining must not result in blockage of the seal. Refractory shall be shop installed and cured according to the manufacturer’ instructions. 8.3.5 The flare gas stack shall terminate with a flanged connection for mounting of the flare tip. 8.3.6 The Seller shall provide the guaranteed lower heating value ki/sm® (Btu/sf?), that the burner will achieve 99.99% minimum combustion. 8.3.7 If a steam-assisted or ait-assisted smokeless flame is required, the same will be provided as per the flare stack data sheet. UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-06) CONTROLLED DOCUMENT IN JPI EWR 100-204-001 -2-44-7 File Name: FE-F-S621_- Rov_2 Page 8 of 2Suncor) PRE ROSH EWN TS TECHNICAL STANDARD ‘Subject a4 8.41 8.4.2 84.3 844 84.5 84.6 847 85 8.5.1 8.5.2 ‘Rumber Revision: FLARE GAS STACKS FB-F-5621 2 IGNITION SYSTEMS Only proven pilot and ignition systems will be considered. Electronic ignition systems, which do not require flame-front propagation shall be provided. The remote pilot ignition system once activated shall produce a time delayed second spark after the initial spark has been generated to ensure lighting of the pilot. ‘A device such as an infrared sensor type pilot shall be provided to detect the presence of a pilot flame. As an altemative a retractable thermocouple of a proven design is acceptable. If a thermocouple with a retraction system is used, it shauld be accessible from ground level for repair or inspection. Alternatively the thermocouple could be made accessible from a platform located reasonably, close to the grade, subject to Buyer's approval. Each pilot buer shail be provided with a windshield to prevent flame blowout under design wind conditions. Condition lights, permissive status, and ignition hardware shall not be mounted so that it would be exposed to solar and flame radiation levels higher than recommended by the manutacturer and in no case greater than 9453 Wim? (3000 Btu/hr-ft”), All instruments and electrical shall conform to the Canadian Standards Association C22. and be approved for installation in Class Division 2, Group D area. Junction box shall NEMA 4X stainless steel. FLARE GAS STACK DESIGN REQUIREMENTS Flare gas stack shall be properly designed for all applicable conditions, including but not limited to wind load, dead load, thermal loads, lifting load, and guy load. Stack deflection shall not exceed 150 mm per 30 m (6" per 100 ft) of fiare gas stacks height. Design shall be in compliance with applicable Canadian Codes and Standards. Seller shall describe the governing design criteria used, regarding flare gas stack deflection in the proposal. The stack and attachments shall be checked as a single unit for wind induced vibration as specified in the National Building Code of Canada. The structure must be stable throughout the range of wind velocities expected at the installation location. If necessary, the stack and / or base support can be modified to stabilize the structure. Vortex breakers or spoilers shalt not be added. UNCONTROLLED DOCUMENT WHEN PRINTED (20-Dec-06) CONTROLLED DOCUMENT IN JPLEWR 100-204-001 —7-4-47 Fle Name: FBLF-S621_- Rev_2 Pages of 12 Moet. 28.Dec8REEAG PROGRAM” MECIANALENONEERING SUNCOR Ewersy TECHNICAL STANDARD Sue ‘Namba Raven FLARE GAS STACKS FB-F.5621 2 8.5.3 Base ring design shall be subject to Buyer's review. 85.4 The Seller shall provide lifting lugs. The fiate gas stacks shell shall be designed to accommodate the lifting loads and maintain the deflection within allowable limits. When required, the Seller shall provide stiffening rings. Lug design shall be stamped by a registered professional engineer of Alberta in good standing. Lugs, their attachment weld and parent metal shall be designed to carry their share of the applied load (minimum twice the equipment weight to account for dynamic effects) distributed in a reasonable manner and based on a minimum safety factor of 5 (based on ultimate tensile strength). In addition lugs shall be designed for a minimum temperature of -45°C. 8.5.5 The flare gas stacks shall be designed for a minimum design pressure of 517 kPag (75 psig). 8.6 GUY WIRES AND FITTINGS (WHERE SPECIFIED) 8.6.1 Guy wires shall be pre-stretched, galvanized steel wire rope, fabricated in accordance with CSA Standard G4. 86.2 The maximum tension in guy cables shall not exceed one-third of the breaking strength as listed by the cable manufacturer. Variations in temperature, which will cause the stack to expand and contract, shall be taken into consideration when determining cable tension. 8.6.3 A minimum of three guy wires is required, spaced at equal angles about the circumference. Multiple sets of guy wires are permissible. Each guy wire shall be sized to carry the entire wind load on the structure. 8.6.4 All wires must be pre-stretched by subjecting them to a repeated tensile load. At least three loadings are required at 50% of the nominal ultimate strength of the rope as manufactured. Elongations of the guy wire at its design load shall be limited to 0.25% of the rope length. 8.6.5 All fittings shall be hot forged and heat-treated galvanized steel, designed for a breaking strength at least equivalent to that of the wire rope. 8.6.6 Poured zinc spelter type wire rope sockets shall be used for guy structure and guy wire-to- tumbuckle connections. They shall be factory installed by the wire rope Seller. The socket- to-rope connection shall be shop tested to a tension of 1.5 times the design load. 86.7 Turbuckles shall be provided for tensioning of guy wires. Take up shall not be Jess than 229 mm (9 inches). 86.8 Clip and thimble attachments shall be used to connect guy wires at their anchors. Attachment preparation shall be subject to Buyer's approval. ‘UNCONTROLLED DOGUMENT WHEN PRINTED (20-Dec-06) CONTROLLED DOCUMENT IN JPIEWR 100-2004001 244.7 Fe Name: FBLF-5621 - Rev? Pago 10 of 12Suncor) re ROSH MEN HENGE tweney TECHNICAL STANDARD ‘Subject Number Revision: FLARE GAS STACKS FB-F-5621 2 8.7 FABRICATION TOLERANCES 8.7.1 At any given section, the difference between the maximum and minimum diameter of the completed flare gas stack (out of roundness) shall not exceed 1% of the nominal diameter of that section. 87.2 Misalignment between the plates at any joint shall not exceed 25% of the nominal plate thickness or 3.2 mm (1/8") whichever is smaller. 8.7.3 The maximum deviation of the flare gas stack shell from a 3.048 m (10 ft) ong straight edge, applied to any section of the completed flare gas stacks shall not exceed 3.2 mm (1/8") 88 FOUNDATION LOADING 88.1 The Seller shall provide the Buyer with loads for foundation design (by others) for the loading conditions including erection, operating, and wind. The following data shall be included in Seller's foundation loading diagram: a. Flare gas stack layout and detail of base plate as follows: i. Size and thickness of base plate Location and diameter of base plate anchor boltholes. b. Foundation Loads ~ Vertical and horizontal loads acting at the bottom of the base plate due to’ i, Empty weight. Operating weight. iii, Wind load. iv, Base moments 8.9 GUARANTEES The Seller shall guarantee the packaged flare system against defective workmanship or materials, improper design, and failure to perform as specified at the design conditions specified on the data sheets. ‘UNCONTROLLED DOCUMENT WHEN PRINTED (20:0ec06) CONTROLLED DOCUMENT IN JPIEWR 100-2004-001 —2-44.7 Fie Name: FO-F-5621 - Rev? Page 11 of 12su or) IRERAG PROGRAM - MEGHAIOOAL ENGREERING Thee INCOR TECHNICAL STANDARD ‘Sibiect Taba Fever FLARE GAS STACKS FBF.5621 2 ‘| 9.0 PERFORMANCE REQUIREMENTS 9.0.1. All performance requirements shall be based on continuous operation. 10.0 INSPECTION AND TESTING 10.1 GENERAL 10.1.1, Acceptance of shop tests does not constitute 2 waiver of requirements to meet field performance under specified operating conditions, nor does inspection relieve the Seller of his responsibilities. 10.2 INSPECTION 10.2.1 The Seller shall provide the Buyer with advance notification of inspections as outlined in the purchase order. 10.3. TESTING 10.3.1 Testing shall be performed as shown on the data sheets and in the purchase order. All specified tests shall be certified. 10.3.2 Test reports shall be submitted far Buyer's approval at least two (2) weeks before shipment. 11.0 SURFACE PREPARATION AND PAINTING 11.0.1 All surface preparation and painting shall be in accordance with Firebag Projects Standard FB-L-5214, Painting Standard. 44.0.2. {f the Seller desires to use manufacturer's paint standard, the Seller is required to obtain Buyer's approval. 12.0 SHIPPING, HANDLING AND STORAGE 12.0.1 Equipment shall be adequately prepared to prevent the entry of dirt or water during shipment. All flanged openings must be provided with wooden or metal closures securely fastened with bolts or clamps. All drains, vents and small piping connections shall be capped or plugged. 12.0.2 Arust preventive compound shall be applied to all unpainted internal and external surfaces. 42.0.3 The equipment shall be packaged and shipped in accordance with Firebag Projects Standard FB-A.5673. “UNCONTROLLED OOCUWENT WHEN PRINTED (20-Dee-06) CONTROLLED DOGUMENT IN JPIEWR 100-2004.001 - 244-7 Fila Namo: FB-F-5621_- Rov_2 Page 12 of 12 Meats 22006