DEP SPECIFICATION

FLARE DETAILS
(AMENDMENTS/SUPPLEMENTS TO ISO 25457)

DEP 80.45.11.12-Gen.

February 2011
(DEP Circular 01/12 has been incorporated)

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2011 Shell Group of companies

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.
 DEP 80.45.11.12-Gen.
February 2011
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PREFACE

DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned after
use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
 DEP 80.45.11.12-Gen.
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TABLE OF CONTENTS
PART I INTRODUCTION ........................................................................................................4
1.1 SCOPE........................................................................................................................4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS .........4
1.3 DEFINITIONS .............................................................................................................4
1.4 CROSS-REFERENCES .............................................................................................5
1.5 SUMMARY OF MAIN CHANGES...............................................................................5
1.6 COMMENTS ON THIS DEP .......................................................................................5
1.7 DUAL UNITS...............................................................................................................5
PART II GENERAL...................................................................................................................6
PART III AMENDMENTS/SUPPLEMENTS TO ISO 25457......................................................7
0. INTRODUCTION ........................................................................................................7
1. SCOPE........................................................................................................................7
4. DESIGN ......................................................................................................................7
4.1 INTRODUCTION ........................................................................................................7
4.4 TYPES OF FLARES ...................................................................................................7
4.5 FLARE BURNERS......................................................................................................8
4.6 MECHANICAL DESIGN..............................................................................................8
4.7 PILOTS .......................................................................................................................8
4.8 PILOT IGNITION SYSTEMS ....................................................................................10
4.9 PILOT FLAME DETECTION.....................................................................................11
4.10 PIPING ......................................................................................................................12
5. MECHANICAL DETAILS – ELEVATED FLARES...................................................13
5.1 MECHANICAL DESIGN – DESIGN LOADS ............................................................13
5.2 DESIGN DETAILS ....................................................................................................14
5.3 MATERIALS OF CONSTRUCTION .........................................................................14
5.4 WELDING .................................................................................................................15
5.5 INSPECTION ............................................................................................................15
5.8 AIRCRAFT WARNING LIGHTING ...........................................................................15
5.9 PLATFORMS AND LADDERS .................................................................................15
5.10 DERRICK STRUCTURE...........................................................................................15
6. MECHANICAL DETAILS – ENCLOSED-FLAME FLARE ......................................16
6.4 PILOTS .....................................................................................................................16
7. INSTRUMENTATION ...............................................................................................16
8. ELECTRICAL ...........................................................................................................16
9. NOISE LIMITS ..........................................................................................................16
10. DOCUMENTATION REQUIREMENTS....................................................................17
10.1 PROPOSALS............................................................................................................17
10.2 APPROVAL INFORMATION ....................................................................................17
10.3 FINAL RECORDS.....................................................................................................18
11. REFERENCES .........................................................................................................19
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PART I INTRODUCTION

1.1 SCOPE
This new DEP specifies requirements and provides guidance for the selection, design,
specification, operation and maintenance of flares and related combustion and mechanical
components used in pressure-relieving and vapour-depressurizing systems.
This DEP is based on ISO 25457:2008 / API Standard 537, Second Edition. Part II of this
DEP amends, supplements and deletes various clauses of ISO 25457:2008 / API
Standard 537, Second Edition.
NOTE: ISO 25457:2008 is identical to API Standard 537, Second Edition, December 2008. Further references
in this technical specification will simply be stated as ISO 25457.

Part III follows the clause numbering of ISO 25457 for easy reference. All clauses of
ISO 25457:2008 not modified by this DEP shall remain valid as written.
ISO 25457:2008 Annex E is intended to be used to communicate, record and update
design specification information and serve as permanent record at the end of any new
project work.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual DEM 1 – Application of Technical Standards.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorization to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process should be
implemented; this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine by careful scrutiny which of the
requirements are the more stringent and which combination of requirements will be
acceptable with regards to the safety, environmental, economic and legal aspects. In all
cases the Contractor shall inform the Principal of any deviation from the requirements of
this DEP which is considered to be necessary in order to comply with national and/or local
regulations. The Principal may then negotiate with the Authorities concerned, the objective
being to obtain agreement to follow this DEP as closely as possible.

1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
The Manufacturer/Supplier is the party that manufactures or supplies equipment and
services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
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1.3.2 Specific definitions

Design Class is a categorization defining fit-for-purpose facilities developed through Value

Improvement Processes (VIPs) during a project Front End Development
(FED) phase.

Delegated is a person who has received delegated authority to approve Derogations

Technical from the Process Safety requirements from the Head of Shell P&T.
Authority

Derogation is an authorised variance or exemption from a Process Safety requirement,

with specified conditions.

BDEP Basic Design Engineering Package

DCS Distributed Control System

EP Exploration and Production

FFG Flame Front Generator

PLC Programmable Logic Controller

RAM Risk Assessment Matrix

SCFH Standard Cubic Feet per Hour

Wobbe Index An Index which measures the combustion value of a fuel and
interchangeability of fuels where Wobbe Index = gross heating value
divided by the square root of the specific gravity of the fuel (relative to air)

1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section
number is shown in brackets. Other documents referenced by this DEP are listed in (11).

1.5 SUMMARY OF MAIN CHANGES

This is a new DEP.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be sent to the Administrator at standards@shell.com, using
the DEP Feedback Form. The DEP Feedback Form can be found on the main page of
“DEPs on the Web”, available through the Global Technical Standards web portal
http://sww.shell.com/standards and on the main page of the DEPs DVD-ROM.

1.7 DUAL UNITS

Amended per
Circular 01/12
Dual units have been incorporated throughout this DEP.

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.
 DEP 80.45.11.12-Gen.
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PART II GENERAL
Part III of this DEP is written as amendments and supplements to ISO 25457:2008.
Wherever reference is made to ISO 25457, it shall be understood to mean ISO 25457 as
amended/supplemented by this DEP.
For ease of reference, the clause numbering of ISO 25457 has been used throughout
Part III of this DEP. Where the clauses in ISO 25457 are unnumbered, they are considered
to be identified numerically in sequence, i.e. 1, 2, 3 etc.
Clauses in ISO 25457, which are not mentioned in this DEP, shall remain valid as written.
 DEP 80.45.11.12-Gen.
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PART III AMENDMENTS/SUPPLEMENTS TO ISO 25457

0. INTRODUCTION
A bullet (z) is shown in the margin of this DEP where further decisions or information are to
be provided by the Principal or Contractor. Refer to Standard Form DEP 80.45.11.80-Gen.
for recording decisions on the bulleted items of ISO 25457 and additional ones added to
this DEP.
For the purpose of additions and amendments to ISO 25457 by this DEP, dash-bulleted
entries within the text of ISO 25457 are uniquely identified with and assumed Roman-
numeral sequence applied to each clause i.e., i, ii, iii etc.

1. SCOPE
Add to this clause:
Although ISO 25457 is intended for “general refinery and petrochemical service” typical for
on-shore facilities, the DEP is intended to cover specification requirements of flares and
related combustion and mechanical components used in pressure-relieving and vapour-
depressurizing systems for EP on-shore and off-shore facilities as well.
Decisions related to the Design Class performance categories for flares are beyond the
scope of this DEP. Such decisions are intended to be made by the Principal in the project
“Define” phase and detailed in project scope defining documentation e.g. equipment BDEP
(Basic Design Engineering Package), flare data sheet, flare checklist, project specific
specifications, etc.
Flares of any design class shall, as a minimum, adhere to Process Safety related
requirements as specified in this DEP.

4. DESIGN

4.1 INTRODUCTION
Add to this clause:
Flare fundamental system design, process definition and flare type and configuration
selections and requirements shall be made by the Principal through a combination of
considerations made through the use of DEP 80.45.10.10-Gen., and this DEP. Such
decisions shall be documented through the use of the flare data sheet, flare checklist,
project specific specifications, etc.

4.4 TYPES OF FLARES

4.4.1 Objective
Add new clause:
Within the general classification of elevated flares, for offshore applications there are three
flare structures types / configurations which may be selected. These include:
• vertical flare stack (platform mounted);
• boom flare (platform mounted) e.g. cantilevered boom mounted at an angle to the
horizontal; and,
• vertical flare stack mounted on a separate flare structure connected to main
platform by a bridge.
z The flare type and configuration shall be defined by the Principal.
For demountable derrick flares, the standard arrangement shall be a structure consisting of
four legs and a rectangular cross-section built up from hot-rolled steel sections. If tubular
members are used, they shall be designed to prevent ingress of rainwater and shall have
adequate drainage of water condensate. Tubular members shall be protected against
internal and external corrosion.
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4.5 FLARE BURNERS

4.5.2 Functional requirements
4.5.2 a) Add new clause:
iv No proto-type or first-of designs shall be used. Flare burner selections shall be from
those with demonstrated successful performance commensurate with, as minimum,
providing the functional requirements of ISO 25457. Where step-outs in design are
necessary in consideration of unique process or application requirements, selections
shall be approved by the Principal.
4.5.2 b) Add to this clause:
z The steam muffler shall be provided with a condensate drain pan and drain line to grade. In
cold climate conditions, the muffler drain pan and condensate drain line shall be traced and
insulated. Muffler acoustic linings shall be dense weight, low porosity, chemical setting type
castable refractory or of material that is proven to withstand flare tip mechanical forces and
temperatures. Heat tracing on the surface of the muffler drain pan shall include a steam
tracer, supplied from the smokeless steam supply line, and thermo-dynamic steam trap with
discharge to the drain line. Heat tracing for the drain line should be electric unless
otherwise specified.

4.6 MECHANICAL DESIGN

4.6.2 b) Add to this clause:
The structural design code shall be EN 1990, EN 1991 and EN 1993 or AWS D1.1/D1.1M
unless otherwise specified.
Add new clause:
4.6.2 e) All bolted connections exposed to dynamic loads and vibration shall be provided with lock
nuts.

4.7 PILOTS
4.7.2 Functional requirements
Replace this clause by:
z i All flare systems SHALL [PS] be provided with continuously burning pilots to ignite
the flare gas as it leaves the flare burner. Pilot selections shall be approved by the
Principal.
vi The minimum number of pilots shall be in accordance with Table 1. For the
purposes of this DEP, sour gas with H2S content > 1.5 vol % is considered a “toxic
gas”.
x Individual fuel-supply lines shall be provided for each pilot.
Pilot lines shall sloped back to the pressure regulator station and include an
accessible low point drain at the base of the flare riser / pipe-rack and next to the
pressure regulator station with no low point pockets. Each pilot gas line shall
include a quarter turn isolation valve and pressure gauge at the pressure regulator
station to permit on-line testing of individual pilots, pilot detection and pilot ignition
systems.
xiv Each pilot SHALL [PS] have at least one dedicated means of ignition and one
dedicated means of pilot-flame detection.
 DEP 80.45.11.12-Gen.
February 2011
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Add to this clause:

v The pilots provided at the flare burner SHALL [PS] be capable of sustaining stable
combustion under all flaring and specified meteorological conditions. Proof of pilot
verification testing shall be provided. Refer to (10.2).
vii Pilot weather hood and ignition hood shall be a cast assembly. Thermowells shall
be cast as part of the pilot assembly. Welded attachments are to be avoided where
possible.
ix All pilot assemblies shall include a removable strainer or settling chamber upstream
of the gas orifice irrespective of the fuel piping material.
xiii A secure and reliable source of natural gas shall be the fuel for pilots and pilot
ignition systems, with the exception of off-shore installations where clean, reliable
and non-interruptible supply of fuel gas can be used as a substitute for natural gas.
The hydrocarbon and water dew points of the fuel gas and the water dew point of
the air shall be such that condensation is not possible under any mode of
operation. Therefore, the fuel gas supplied to the pilot and pilot ignition system shall
be dried and filtered. The filter shall be installed between the carbon steel fuel gas
supply line to the flare and the stainless steel supply lines to the pilots and ignition
system. The fuel gas shall be of a constant composition, since a change in the
Wobbe Index (+/- 5%) of the gas will affect flame stability.
A back-up bottled gas supply shall be provided for start-up/normal operation if there
is no other reliable source of fuel gas available.
Add new clauses:
xv Pilots shall be self aspirating type with the venturi air mixer, gas orifice and
windshield integral to the pilot assembly. The air / fuel mixture flow shall not be
interrupted by the pilot ignition system.
z xvi Unless otherwise specified, a thin film ceramic coating shall be applied to the pilot
head and upper 1.8 m (6 ft) of the pilot assembly.
xvii Fuel supplied to the FFG shall be regulated to the supply pressure prescribed by
the FFG Manufacturer. Over-pressure protection shall be provided separate from
the Manufacturer supplied FFG station.
The fuel pressure regulator station shall include an inlet strainer, dual regulators,
with one of them being and on-line spare, and a low pressure alarm to detect loss
of supply, regulator failure or blockage.
xviii Pilot fuel lines, including the fuel pressure regulator station, shall be DN 25 (1 NPS)
with Type 304 SS material.
xix Allowance shall be made for differential expansion between the flare stack and the
pilot lines, with particular attention being paid to the support brackets including
measures to avoid wind induced vibration.
xx Pilot assemblies at the flare burner shall be flanged and accessible from the same
platform as the flare burner connecting flange.
z xxi When cold climate conditions is specified in DEP 80.45.11.80, pilot gas venturi air
mixers / orifices shall be heat traced and insulated. The venturi air mixer windshield
shall be designed in consideration of hoar-frost build-up. Alternate cold weather
designs may be considered and applied when approved by the Principal.
z xxii Retractable pilots shall be provided only when specified.
xxiii The Manufacturer shall provide a documented pilot bench test which includes a
functional check and calibration readings relative to defined acceptance criteria for
any electrical components and thermocouples integral to the pilot assembly with
the pilot operating at its design condition. The test shall also the fuel pressure
reading at the Manufacturer’s recommended alarm / reignition setpoint conditions.
Each pilot assembly shall be uniquely identified relative to the bench test report.
 DEP 80.45.11.12-Gen.
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The bench test shall be included in the Inspection and Test Plan and report
included in the approval and final project documentation.

4.8 PILOT IGNITION SYSTEMS

4.8.2 Functional requirements
Add to this clause:
i Proof of pilot with combined pilot ignition system verification testing shall be
provided. Refer to (10.2).
ii Electrical requirements for pilot ignition systems shall be supplied from emergency
power.
Add new clauses:
iv All pilot ignition systems shall be proven in-use. Acceptable pilot ignition systems
include:
• spark ignition of a portion of the pilot gas / air mixture prior to the pilot tip;
• compressed air flame front generator.
Alternate systems that may be considered when specified and approved by the
Principal include:
• spark ignition at the pilot tip;
• inspirating flame front generator.
v Pilots shall have a "dual-diverse" ignition system when a flare system is Design
Class 1, unmanned or high RAM risk ranked facilities. The primary pilot ignition
system shall be automatic upon detection of individual pilot flame failure with the
secondary means of ignition provided as a manual backup.
The Principal may designate the backup system as automatic as well.
Unless otherwise specified, the arrangement for Design Class 1 or high RAM risk
ranked facilities shall be as follows:
• high energy spark ignition of a portion of the pilot gas / air mixture prior to
the pilot tip as the primary means of pilot ignition (automatic) and
compressed air flame front generator as the secondary means of pilot
ignition (manual).
A single pilot ignition systems may be used where the ignition system is
maintainable on-line (e.g., flame font generator or with a retractable pilot with
integral ignition / detection system).
Intermittent operating or low RAM risk ranked operating facilities may include a
single means of pilot ignition, the minimum requirement being flame-front generator
(FFG) type.
z Pilot ignition system requirements shall be specified by the Principal.
NOTE Dual-diverse - two systems that are unaffected by the same mode failure.

vi The FFG lines be shall be DN 25 (1 NPS) with Type 304 SS material. FFG lines
shall sloped back to the FFG station and include a long swiping elbow at the base
of the flare riser / pipe-rack with no low point pockets and accessible low point drain
next to the FFG station.
vii The FFG station materials and components shall be in Type 304 SS and fabricated
in accordance with the specified Shell piping class, instrumentation and electrical
specifications.
viii Fuel supply shall be consistent with the requirements for pilots. See (4.7).
 DEP 80.45.11.12-Gen.
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ix Air supply used for a compressed air flame front generator ignition air shall be from
a secure source of instrument air and regulated to the supply pressure prescribed
by the FFG Manufacturer. Over-pressure protection shall be provided separate
from the Manufacturer supplied FFG station.
x Air used for instrumentation shall be from a secure source of instrument air and
supplied, regulated and protected to a pressure no greater than 700 kPag
(100 psig) outside of the FFG station. Further pressure letdown, as required by the
Manufacturer, shall be handled within the station.
xi When “cold climate” conditions are specified for the pilots (see (4.7.2 xxi)), the FFG
station shall be designed to include a 1 sm3/hr (35 SCFH) instrument air purge
provided on each FFG line. A rotometer to regulate flow control flow to each line
shall be used.
xii Pilot ignition and detection systems shall be indentified per pilot including relative
position on the flare burner e.g., N, S, E, W etc., on drawings and labelling to assist
visual assessment of performance.
xiii All electrical wiring and connections to the pilot assembly shall be designed for high
temperature / severe service and include heat shielding, SS junction box and
ceramic bases for electric contacts.

4.9 PILOT FLAME DETECTION

4.9.2 Functional requirements
Add to this clause:
i Proof of pilot with combined pilot flame detection system verification testing shall be
provided. Refer to (10.2).
ii Electrical requirements for pilot flame detection systems shall be supplied from
emergency power.
Add new clauses:
iv All pilot flame detection systems shall be proven in-use. Acceptable pilot flame
detection systems include:
• fixed in-place thermocouples – ‘K’ type, located in a thermowell integral to
the pilot head;
• retractable thermocouples, and,
• acoustic system.
NOTE Acoustic systems shall only be used in combination with pilots proven in-use with acoustic
monitors and applied to the same type of flare burner being used.

Alternate systems that may be considered when specified and approved by the
Principal include:
• flame ionization.
• remote flame detection using IR and UV
v Pilots shall have a dual-diverse" detection system when a flare system is Design
Class 1, unmanned or high RAM risk ranked facilities. Single pilot flame detection
systems may be used when it is maintainable on-line.
The primary flame detection system shall be used for automatic activation of pilot
ignition upon detection of individual pilot flame failure with the secondary means of
pilot flame detection provided as an alternate to the primary system. When dual
systems are provided, the operator selects which detection system shall be used
for primary pilot flame detection.
Unless otherwise specified, the arrangement for Design Class 1 or high RAM risk
ranked facilities shall be as follows:
 DEP 80.45.11.12-Gen.
February 2011
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• one fixed in-place thermocouple plus one additional means

NOTES: 1 Since pilot flame detection systems, aside from thermocouples, are typically proprietary
and specific to pilot Manufactures, as the DEP default, the “one additional means” shall be
a fixed in-place thermocouple unless an alternate system is specified by the Principal.
2 Preference shall be given to Manufacturers who are capable of providing alternate pilot
flame detection systems which meet the requirements of ISO 25457 and this DEP.

Single pilot flame detection systems may be used where the flame detection
system is maintainable on-line (e.g., with a retractable thermocouple) and approved
by the Principal.
Intermittent operating or low RAM risk ranked operating facilities may include a
single means of pilot flame detection, the minimum requirement being a fixed in
place thermocouple.
Pilot monitoring shall be continuous and trended in a DCS system or equivalent.
Failure of a pilot shall be indicated in a local panel as well as in the control room by
an alarm.
A local multifunctional PLC system should be used to handle pilot monitoring and
ignition systems.
z Pilot flame detection system requirements shall be specified by the Principal.
vi Extended thermowells which extend to the base of the pilot shall be provided for all
pilots with fixed in-place thermocouples. The thermowell (SS tubing) shall the same
material grade as the pilot assembly.
xiii All electrical wiring and connections to the pilot assembly shall be designed for high
temperature / severe service and include heat shielding, SS junction boxes and
ceramic bases for electric contacts.

4.10 PIPING
4.10.2 Functional requirements
Add new clauses:
z a) The Contractor shall specify the required Shell piping class. Auxiliary piping shall
be fabricated in accordance to DEP 31.38.01.31-Gen. unless otherwise specified.
All piping shall be designed inherently safe with any over-pressure protection
requirements being separate and upstream of any Manufacturer supplied piping.
Refer to (4.7.2) and (4.8.2) for material type used for pilot fuel and FFG lines.
Auxiliary piping includes pilot fuel gas, FFG, instrument air, and may include steam,
condensate and air where applicable.
b) FFG lines are open ended and although specification and fabrication may be
according to a Shell piping class and fabrication specification, pressure testing to
the Pressure Design Code is not required. All other piping shall be tested to the
Pressure Design Code.
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5. MECHANICAL DETAILS – ELEVATED FLARES

5.1 MECHANICAL DESIGN – DESIGN LOADS

5.1 a) Wind loadings
Add to this clause:
z Unless otherwise specified, the hourly wind pressure probability factor shall be
taken as 1 in 50 years.
5.1 c) Wind-induced vibration loads
Add to this clause:
z Unless otherwise specified, the wind-induced vibration loads shall be in accordance
with ASME STS-1
5.1 d) Internal pressure
Replace this clause by:
z Flare stacks are generally operated at near-atmospheric pressure and are not
specifically designed as pressure equipment. Exceptions to this include conditions
when the flare burner creates a backpressure in the flare riser that causes the
pressure design code to become applicable. In some cases, the bottom portion of
the stack incorporates a knockout drum or liquid seal, or both. When specified in
the data sheets, the stack portion containing the knockout drum or liquid seal may
be designed as a pressure vessel including, if specified, hydrostatic testing and
code stamping. In such cases, the design of the pressure-vessel portion shall be in
accordance with the pressure design code.
The wall thickness for the flare gas riser of near-atmospheric pressure stacks,
originating at either the inlet flange or at the outlet connection from any integral
liquid seal, shall be determined in accordance with the structural design code or the
pressure design code for 350 kPag (50 psig) plus 3.2 mm (1/8th in.) corrosion
allowance (if applicable), whichever is greater.
It is common practice that the riser section of the stack be designed for structural
loads and the anticipated maximum operating pressure when the base section of
the stack is designed as a pressure vessel. For design purposes, the riser section
is deemed to start at the pressure vessel outlet. The design of a stack base section
that is a pressure vessel shall include provision for internal pressure loads and for
simultaneous wind loads based on 70 % of the design wind velocity. The design
pressure (maximum allowable working pressure) of a stack-base section that is a
pressure vessel shall not be increased due to any material thickness that is in
excess of that thickness required to meet the design pressure.
5.1 f) Flashback pressure
Add to this clause:
z The Principal shall specify any flashback pressure requirements greater than
defined in (5.1d).
5.1 g) Nozzle loads
Add to this clause:
z Unless otherwise specified, the nozzle-allowable forces and moments specified in
Table 2 shall be used.
5.1 h) Thermal loads
Add to this clause:
• The designer shall identify and include considerations taken and recommended
requirements for protection of the flare support structure adjacent to the flare
burner that may be subject to high thermal gradients such as in offshore
 DEP 80.45.11.12-Gen.
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installations. Preferred measures include the use of heat shields and / or protective
paints /passive fire protection for critical members. Final selection of protection
measures shall be subject to approval by the Principal.
5.1 j) Special loads
Add to this clause:
z 6) Dynamic loading considerations specific to offshore installations and structures as
specified by the Principal.

5.2 DESIGN DETAILS

5.2 e 2i) Replace with:
ISO 2408:2004, Quality B for 10 mm to 50 mm (3/8 to 2 in.) diameter, class 6X36WS-IWRC
with steel core.
5.2 e 4) Replace with:
The stack designer shall determine the initial tension required preventing an overload of the
stack and guy wire while maintaining the stack deflection within the allowable limits set forth
in 5.2 a). The initial guy wire tension shall not be less than 2% or greater than 12.5% of the
minimum breaking force for the guy wire. Initial guy wire tension shall include consideration
of the normal design ambient temperature and stack temperature under non pressure-
relieving conditions with or without insulation and heat tracing as applicable.
Add new clause:
5.2 e 7) The minimum breaking force for the guy wires shall be based on a minimum safety factor of
3.0.
Add new clause:
5.2 f) For elevated flare stacks, whether of guyed or self supported design, if a single piece lift
z design is specified, the flare burner, all piping, insulation, ladders and platforms etc., shall
be installed with all testing completed as applicable prior to the lift.

5.3 MATERIALS OF CONSTRUCTION

5.3 1 Add to this clause:
z All materials for the gas riser in contact with process gas shall be specified and selected
from the pressure vessel code e.g., ASME BPVC Section VIII, Part II. All materials for the
support structure shall be standard structural steel selected from the structural steel design
code. The Principal shall specify any additional material selection requirements. Material
selections shall be approved by the Principal.
Add new clauses:
5.3 6 Where it is necessary to use special steels (e.g. stainless steel, Incolloy 625 etc) for the
derrick structure on off-shore derrick structures, the speciality steel shall be galvanically
isolated from the standard structural steel to prevent electrolytic corrosion. The same
considerations are required for the gas riser, ladders, platforms, stairs etc., which may be in
contact with the speciality steel.
5.3.7 The material of construction for the upper section of the flare burner on elevated flares that
are exposed to direct flame, whether or not any assist media is used, i.e., steam or air, the
standard material selection for on-shore and most off-shore facilities shall be Type 310 SS.
The lower flare burner section material, approximately 0.6m (2 ft) can be Type 304 SS
including mounting flange if agreed by the Principal. The minimum material thickness for all
plate materials for fabrication of the flare burner, including internals, shall be 9 mm (3/8 in.).
All ancillary attachments to the flare burner shall be the same material grade as the base
material, i.e., avoiding dissimilar metal welds.
 DEP 80.45.11.12-Gen.
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For offshore facilities with angled booms, Inconel alloy 625 or equivalent shall be used for
the flare burner with 12 mm (1/2 in) plate thickness. Flange joints shall be heat shielded
and use metallic gaskets.
The nominal length of flare burners up to1.2 m (4 ft) in diameter is 3 m (10 ft).
z Any additional material selection requirements including the use of ceramic coatings for
flare burners shall be specified by the Principal.

5.4 WELDING
5.4 a) Replace with:
z Relief gas containing portions of the flare riser shall be welded in accordance with
DEP 30.10.60.18-Gen.
5.4 b) Replace with:
Portions of the stack designed in accordance with the pressure design code shall be
welded in accordance with DEP 30.10.60.18-Gen.
5.4 c) Replace with:
z Non-gas containing portions of the support structure including the air riser in air assisted
flares, shall be welded in accordance with DEP 34.28.00.31-Gen.

5.5 INSPECTION
5.5 a) Replace with:
z Relief gas containing portions of the flare riser shall be inspected in accordance with
DEP 30.10.60.18-Gen.

5.8 AIRCRAFT WARNING LIGHTING

5.8.1 Replace with:
z For aviation warning lights requirements see DEP 34.24.26.31-Gen. If a retractable flare
stack system is selected, the aviation warning lights shall be retractable without shutting
down the flare relief system.

5.9 PLATFORMS AND LADDERS

5.9.1 Replace with:
a) Platform access shall be provided for al connections, valves and any other item
needed for maintenance purposes.
b) For non-retractable flares, a 360 degree platform shall be provided around the flare
burner for maintenance access.
c) The manufacturer shall trial shop fit all ladders and platforms and match-marked.
The ladder and platform clips shell be welded to the flare riser / structure and
predrilled in the fabrication shop. Ladders and platforms shall be bolt on.
z d) Ladder and platform spacing and design shall be in accordance with project
specification.
Add new clause:

5.10 DERRICK STRUCTURE

z The following requirements apply when derrick structures are specified.
5.10.1 A typical arrangement for a derrick structure is provided in Standard Drawing S 28.028.
5.10.2 The Principal shall specify whether 100 % availability of the flare system is required (as is
often the case for refinery, petrochemical and production facilities). If 100 % availability is
required, two flare stacks may be considered (one operating and one spare). These stacks
 DEP 80.45.11.12-Gen.
February 2011
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should be installed in one derrick structure and it should be possible to retract one flare
stack while the other remains in operation, without personnel having to work above the riser
removal/replacement platform. If 100 % availability is required, the flare structure above the
riser removal/replacement platform shall be designed so that no maintenance whatsoever
is required during its entire service life (e.g. 30 years or more). The materials and coating
system shall be selected to meet this requirement. For this reason, making the structure
with tubular members, and assuring that the tubes have adequate drain holes, shall be
considered.
5.10.3 A derrick structure shall be supplied with the following access equipment:
a) a stairway from grade to the riser removal/replacement platform;
b) a ladder from the riser removal/replacement platform to the top platform
c) step-off platforms at intervals of 9 m (30 ft) to the top platform at the flare tip;
d) platforms with ladder access for all manways and handholes; and,
e) ladders from the riser removal/replacement platform to all eyes attached to the
derrick structure that are used to raise, lower and tilt the riser sections.
5.10.4 When riser removable / replacement platforms comprise more than one level, they shall be
a retractable type.
5.10.5 The distance between the burner tips and the top of the structure shall be determined by
the Manufacturer. The heat radiation from the burner tips shall not affect the structure itself,
nor the conservation system or personnel. Suitable heat radiation screens may be
considered to achieve this.

6. MECHANICAL DETAILS – ENCLOSED-FLAME FLARE

6.4 PILOTS
The pilot ignition and pilot flame detection systems shall meet with the requirements of
clauses 4.8.2 v and 4.9.2 v.

Add new clauses:

7. INSTRUMENTATION
z Instrumentation requirements shall be in accordance with project specifications including
supply and certification with all local codes and standards.

8. ELECTRICAL
z Electrical requirements shall be in accordance with project specifications including supply
and certification with all local codes and standards.

9. NOISE LIMITS
9.1 Noise requirements shall be in accordance with DEP 31.10.00.31-Gen.
9.2 For emergency conditions:
• The noise level at the base of the stack shall not exceed 115 dB (A). If the stack is
provided with a derrick structure, including a platform for coupling/uncoupling
segments of the retractable stack, the noise limit applies to this platform.
For normal operation (including starting-up and shutting-down):
• Noise levels at the perimeter of the sterile area shall not exceed 85 dB (A) at flow
rates up to 15 % of maximum flaring capacity or at the maximum relief rate that
may occur during normal operation (including starting-up and shutting-down),
whichever is higher.
 DEP 80.45.11.12-Gen.
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• If there are limits on the allowable noise levels outside the plant, then the sound
power level generated during normal operation shall be taken into account when
assigning sound power levels to noise sources.

10. DOCUMENTATION REQUIREMENTS

10.1 PROPOSALS
10.1.1 The Manufacturer’s proposal shall include a completed set of data sheets in accordance
with the inquiry and form consistent with ISO 25457 Annex E. Lack of proposal detail shall
be a basis for rejection.
10.1.2 The proposal shall include documentation verifying that the pilot, pilot detection system and
pilot ignition system being proposed have been certified in accordance with ISO 25457
Annex A.6.
10.1.3 A proposal drawing shall be provided including overall dimensions, general structural
support information including guy wire radius as appropriate, location of platforms, extent of
scope of supply.
10.1.4 The proposal shall include a general arrangement drawing (at least typical) for the
proposed flare burner indicating information on materials, material thicknesses and
connection information.
10.1.5 The proposal shall include Manufacturer’s catalogue information on the pilot, pilot ignition,
pilot flame detection equipment and systems being proposed.
10.1.6 The proposal shall include predicted radiation levels and plots through both a top view and
a side view for the following levels:

Radiation Level

kW/m2 Btu/h ft2

1.58 500
2.37 750
3.15 1000
4.73 1500
6.30 2000
12.0 3800
22.1 7000

10.1.7 The proposal shall include a detailed description of any exceptions to the specified
requirements.

10.2 APPROVAL INFORMATION

10.2.1 General arrangement drawings including:
a) all overall dimensions,
b) materials
c) material thickness;
d) terminal connection - location and flange rating;
e) support connection details;
f) lifting lug location
g) pilots
 DEP 80.45.11.12-Gen.
February 2011
Page 18

h) pilot detection systems

i) pilot ignition systems
10.2.2 Completed data sheets
10.2.3 Burner detail drawing including material type, thickness, weld map, surface preparation,
surface treatment, parts listing and all critical dimensions required for inspection throughout
the life of the flare burner.
10.2.4 Calculations required for structural and pressure design code requirements, lifting lug /
trunion designs and this DEP.
10.2.5 Weld maps, all proposed welding procedures
10.2.6 Inspection and test plan (ITP)
10.2.7 Pilot bench test procedures
10.2.8 Any additional engineering information required from the Manufacturer for installation,
operation, maintenance or inspection during erection or operation.
10.3 FINAL RECORDS
10.3.1 As built data sheets
10.3.2 As built drawing including:
a) general arrangement drawing,
b) burner drawing
c) pilots
d) pilot detection systems
e) pilot ignition systems
10.3.3 Pilot bench test results. See (4.7.2 xxiii).
 DEP 80.45.11.12-Gen.
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11. REFERENCES
In this DEP Specification, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used,
together with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.

SHELL STANDARDS
Welding of metals (Amendments/Supplements to API RP 582) DEP 30.10.60.18-Gen.
Noise limits DEP 31.10.00.31-Gen.
Shop and field fabrication of piping DEP 31.38.01.31-Gen.
Aircraft warning lights DEP 34.24.26.31-Gen.
Steel structures DEP 34.28.00.31-Gen.
Design of pressure relief, flare and vent systems DEP 80.45.10.10-Gen.
Flare details checklist DEP 80.45.11.80-Gen.
STANDARD DRAWINGS
Flare structure – Erection Procedure S 28.028
AMERICAN STANDARDS
Flare details for general refinery and petrochemical API 537 2nd edition
service
Issued by:
American Petroleum Institute
Publications and Distribution Section
1220 L Street Northwest
Washington DC. 2005, USA.

Steel stacks ASME STS-1

Issued by:
American Society of Mechanical Engineers
ASME International
Three Park Avenue, M/S 10E
New York, NY 10016, USA.

Structural welding code - Steel AWS D1.1/D1.1M

Issued by:
American Society for Testing and Materials
100 Barr Harbor Drive, West Conshohocken
PA 19428-2959
USA.

INTERNATIONAL STANDARDS
Steel wire ropes for general purposes - Minimum requirements ISO 2408
Flare details for general refinery and petrochemical ISO 25457:2008
service
Issued by:
International Organisation for Standardisation
Case Postale 56
Geneva 20, Switzerland. CH-1211
Copies may also be obtained through the national standards
organisations
Eurocode – Basis of structural design EN 1990
Eurocode 1 – Actions on structures EN 1991
Design of steel structures EN 1993
 DEP 80.45.11.12-Gen.
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Issued by:
CEN
Rue de Stassart 36
B-1050 Brussels
Belgium