New LNG Train Skikda Project Liquid Flare & Thermal Oxidizer Manual

SONATRACH
NEW LNG TRAIN SKIKDA PROJECT
SKIKDA, ALGERIA
OPERATING MANUAL VOLUME IV, SECTION 2-2:
UNIT 65 LIQUID FLARE & THERMAL OXIDIZER SYSTEM
DOCUMENT NO: PP-AAA-PP1-144
KBR
JOB NO.: J6404
3 ELG Issued for Implementation 11-Dec-13 MRC RM
2 KM Issued for Implementation (Redlined) 3-May-13 MRC RM
Issued for Implementation

1 KM 24-Oct-12 LTP/MRC SPD
(Updated with HAZOP Action item 379)
0 LTP Issued for Implementation 23 Nov 10 JDS BA AB
B LTP Issued for Client Approval 7 Nov 10 JDS BA -
A MDL Issued for Client Approval 11-Dec-09 GRM BA -
Rev. By Description Date KBR KBR CLIENT
Chkd App App

NEW LNG TRAIN SKIKDA PROJECT DOCUMENT NO.
SKIKDA, ALGERIA PP-AAA-PP1-144
OPERATING MANUAL VOLUME IV, SECTION 2-2: REVISION 3
LIQUID FLARE & THERMAL OXIDIZER SYSTEM 11-Dec-13
TABLE OF CONTENTS
1.0 INTRODUCTION ................................................................................................... 4
2.0 SYSTEM DESCRIPTION ...................................................................................... 8
2.1 Liquid Flare .....................................................................................................................8
2.2 Liquid Flare for Existing Units .........................................................................................8
2.3 Thermal Oxidizer ............................................................................................................9
3.0 OPERATIONS ..................................................................................................... 10
3.1 Normal Running ............................................................................................................ 10
3.1.1 Warm Liquid Drum, 65-MD06 ..................................................................................... 10
3.1.2 Warm Liquid Disposal Pump, 65-MJ04 ...................................................................... 10
3.1.3 Cold Flare Blowcases, 65-MD03A and 65-MD03B ..................................................... 12
3.1.4 Liquid Flare, 65-MB08 ................................................................................................ 14
3.1.5 Flame Front Generator for Liquid Flare, 65-MB10 ...................................................... 14
3.1.6 Common Flare KO Drum, 65-MD10 ........................................................................... 14
3.1.7 Common Flare Blowcase, 65-MD11 ........................................................................... 14
3.1.8 Start-up LNG/BUPRO Flash Drum, 65-MD05 ............................................................ 16
3.1.9 Start-up LNG/BUPRO Blowcases, 65-MD08A and 65-MD08B................................... 16
3.1.10 Cold/Heavy Liquid Drum, 65-MD07 ............................................................................ 18
3.1.11 Cold/Heavy Liquid Blowcases, 65-MD09A and 65-MD09B ........................................ 18
3.1.12 Liquid Flare for Existing Units, 65-MB09 .................................................................... 20
3.1.13 Flame Front Generator for Liquid Flare for Existing Units, 65-MB12 .......................... 20
3.1.14 Thermal Oxidizer ........................................................................................................ 20
3.2 Typical Operating Parameters ...................................................................................... 22
3.3 Temporary Operation .................................................................................................... 22
4.0 START-UP .......................................................................................................... 24
4.1 Steps for Start-up of Liquid Flare .................................................................................. 24
4.2 Steps for Start-up of Liquid Flare for Existing Units ...................................................... 24
4.3 Steps for Thermal Oxidizer Start-up.............................................................................. 25
4.3.1 Purge sequence ......................................................................................................... 27
4.3.2 Start up Sequence ..................................................................................................... 27
5.0 SHUTDOWN ....................................................................................................... 29
5.1 Normal Shutdown ......................................................................................................... 29
5.1.1 Liquid Flare ................................................................................................................ 29
5.1.2 Liquid Flare for Existing Units ..................................................................................... 29
5.1.3 Thermal Oxidizer ........................................................................................................ 29
5.2 Process Upsets and Production Loss ........................................................................... 30
6.0 SAFETY/EMERGENCY SHUTDOWN ................................................................ 34
6.1 Safety Critical Shutdown Systems ................................................................................ 34
6.1.1 I-6500 Thermal Oxidizer Combustion Air Blower Trip ........................................... 34
6.1.2 I-6560 Thermal Oxidizer Main Burners Trip................................................................ 34
6.1.3 I-6570 65-MB07 Thermal Oxidizer Acid Gas Trip ....................................................... 34
6.1.4 Flare Safety During Strong Wind Conditions .............................................................. 34
6.2 Pressure Safety Valve Summary .................................................................................. 34
6.3 Fire Protection Equipment ............................................................................................ 36
7.0 ATTACHMENTS ................................................................................................. 37
Page 2 of 39
7.1 Attachment I: Equipment List ........................................................................................ 38

7.2 Attachment II: Utility Consumption ............................................................................... 39
Page 3 of 39
1.0 INTRODUCTION
This operating manual pertains to the Unit 65 Liquid Flares as shown on Process
Flow Diagrams PR-65-PR32-002 and 003 and P&ID’s PR-65-SYPI-010D and 010E.
This operating manual also pertains to the Unit 65 Thermal Oxidizer as shown on
Process Flow Diagram PR-65-PR32-002 and P&ID PR-65-SYPI – 010C.
Vapors and liquids from the warm flare header and warm liquid headers are sent to
the Warm Flare KO Drum, 65-MD01. Overhead vapors flow from the KO Drum
overhead and are burned in the tip of the Warm Flare Stack, 65-MB01. Warm liquid
is pumped to and burned in Liquid Flare, 65-MB08. A Warm Flare Knock Out Drum
Heater 65-ML01 is provided in the Warm Flare KO Drum 65-MD01 to vaporize the
light hydrocarbons present in the KO Drum.
Vapors and liquids from the cold flare header and cold liquid headers are sent to two
parallel Cold Flare KO Drums, 65-MD02A/B. Vapors flow from the KO Drums
overheads and are burned in the tip of the Cold Flare Stack, 65-MB02.
Liquids collected in the Cold Flare Drums are vaporized using defrost gas. Heavier
liquids that do not vaporize are drained to the Cold Flare Blowcases, 65-MD03A/B,
and then transferred to the Liquid Flare, 65-MB08, for disposal by burning. Liquids
from the LP Flare Blowcase, 71-MD03, are also sent to the cold liquids set of burners
in 65-MB08. Gas is injected into the liquid at the burners to help atomize the liquid
and reduce smoke and coking at the burner tip. Flame Front Generator, 65-MB10, is
provided to light and control burners for 65-MB08.
Defrost gas is supplied to Start-up LNG/BUPRO Flash Drum, 65-MD05, Cold/Heavy
Liquid Drum, 65-MD07, and Common Flare KO Drum 65-MD10 to vaporize liquids in
the bottoms. Warm liquid is pumped from the Warm Liquid Drum, 65-MD06, to Liquid
Flare (for Existing Units) warm liquid burners, 65-MB09, and burned. Cold and heavy
liquids are sent from Common Flare Blowcase, 65-MD11 and Cold/Heavy Liquid
Blowcase, 65-MD09A/B to the cold and heavy liquid burners in 65-MB09 where they
are burned. Cold and light liquid is sent from Start-up LNG/BUPRO Blowcase, 65-
MD08A/B to the cold and light liquid burners in 65-MB09 where they are burned.
Flame Front Generator, 65-MB12, is provided to light and control burners for 65-
MB09.
The liquid flare or the Condair flare uses the energy associated with pressurized
fluids and the Coanda Effect (phenomenon in which a jet flow attaches itself to a
nearby surface and remains attached even when the surface curves away from the
initial jet direction) to entrain air and provide nearly smokeless and low heating
radiation flaring. Mixed phase liquid and gas is ejected radially outward and (at high
velocities) adheres to the curved tulip bowl. As the liquid follows the curve, it draws in
large quantities of air, which reduces the smoke from combustion.
At the completion of liquid flaring the DCS logic will purge all liquids from the
blowcase or pump discharge valve and downstream piping to the flare tip. Failure to
complete this post purge will leave liquids in the lines to the flares after the assist gas
is stopped. This liquid can free drain out the burner tips and ignite as a pool fire
below the burners causing smoke and damage to the flare equipment. Ensure the
assist gas valves remain open anytime there is liquid in the flare piping. The assist
gas valves can only be closed after completion of a post purge.
Page 4 of 39 KBR
Thermal Oxidizer, 65-MB07, is provided to incinerate vent gas from Regenerator

Reflux Drum, 12-MD39. The purpose is to reduce the concentration of volatile
organic carbon (VOC) in the vented gas.
Page 5 of 39 KBR
KBR
NEW LNG TRAIN FLARE PROCESS
New LNG Train Skikda Phase I : 1 open, 2 & 3 closed
Phase II : 1 closed, 2 & 3 open Lines dedicated to existing units
65-MB01 65-MB02 65-MB11
PV-8104
1 3 24"
26'’ BOG from pole 2 30"
PR-71-016 LO
PR-65-015 48" 24'’ Existing Pole 1 flare
2 54" 24"
BOG Compressor
PR-71-021
PR-65-010
PR-65-010B
PR-65-09A
71-PV2129 4'’ from 67-B02
30'’ BOG (LNG,C3,C4) 30" 71-MD01 65-KV1253B
71-MJ05
65-XV1250
Dry gas 65-XV1253C
65-MD10
LO
Warm flare
Cold flare
48" 30'’ Existing Pole 2 flare
SKIKDA, ALGERIA
71-ESDV-2061
FG System 65-MD11
PR-71-021A
71-MD02
New flare for existing Units

65-KV1253A 8'’
71-KV1574C LP Flare
65-KV1253D
71-KV1574B
71-KV1574A
Dry gas
PR-71-021B 54"
71-MD03
71-MB01 12'’
PR-65-007
71-KV1574D
65-MD01
14" BOG from pole 1
4'’
NEW LNG TRAIN SKIKDA PROJECT
24" BOG from 71-FM01 71-XV2121
0.1 b/6.5 b
6" Warm liquide 26 m3/h
Gasoline unit 5P/6P
65-MJ01 3'’
36" Warm flare
42"
48" cold flare 36" 65-MD06
3'’
Gasoline unit 10
12" cold liquid 10"
PR-65-013
Start up scrub bottoms 0.3 b/6.3 b

65-KV1038 6'’ 29.5 m3/h
65-MD02A 65-MD02B 65-MJ04
Page 6 of 39
8" LNG flash drum start up Defrost gas
LIQUID FLARE & THERMAL OXIDIZER SYSTEM
PR-65-008 65-FI
65-MB08
1231
PR-65-010D Liquid 67-B02
OPERATING MANUAL VOLUME IV, SECTION 2-2:
65-FI
65-XV1244 1185
65-MD07 Liquid 67-B03
65-KV1040C
Defrost gas
Burn 65-KV1045B 65-KV1045C 65-KV1040B
Dry gas
pit
65-MD03 B PR-65-012 PR-65-014
65-MD03 A
65-KV1045D 65-FI
65-KV1040D 65-KV1040A 1230
65-FI Liquid V-153/156/300
65-MB09
65-KV1045A
1189
PR-65-010E
11-Dec-13
65-KV1238C 65-KV1243C
65-FIC
Dry gas
REVISION 3
PR-07-010 1183
PR-65-010C 65-KV1195C 65-KV1190C 65-KV1238B
4'’ C3 from 07-MJ02 Dry gas 65-KV1243B
Thermal oxidizer 65-KV1195B New LNG Train Off specs

65-MB07 65-KV1190B 67B03
C3-C4
65-FIC 65-XV1187 65-MD05 65-MD09A
1184
65-MD09B
PR-07-007
DOCUMENT NO.
PP-AAA-PP1-144
3'’ C4 from 07-MJ03

65-MD08A 65-MD08B
PR-65-011 C3/C4 from Unit 10 (61-PV06)
18'’ from 12-MD39 65-KV1238A 65-KV1238D
65-KV1195D 65-KV1243D
3'’ LP.FG 2'’ IA 65-KV1195A 65-KV1190A
65-KV1190D 65-KV1243A
4'’
Start up LNG-Bupro from 5P/6P
KBR
Page 7 of 39 KBR
2.0 SYSTEM DESCRIPTION

2.1 Liquid Flare
The Liquid Flare, 65-MB08, disposes of liquids generated during start-up and
shutdown or from upsets during operation of the New Skikda LNG plant that are not
vaporized in the Warm and Cold Flare Drums. The Liquid Flare, 65-MB08, consists of
two separate sets of burners: one for the Warm Flare Drum liquids and one for the
Cold Flare Drum liquids. Liquids from the LP Flare Blowcase, 71-MD03, are also
directed to the cold liquids set of burners of 65-MB08, Flame Front Generator,
65-MB10, is provided for igniting and controlling pilots and burners for 65-MB08.
Whenever a particular burner is in liquid flaring operation, the adjacent burners are
required to have their associated assist gas valves open to provide cooling for the
burners not in operation. The sequence utilizes the assist gas valve position
feedback status of a burner as the indication that the burner is in operation.
In order to provide cooling to the ignition line of each burner/pilot assembly (which
are normally stagnant with no flow), instrument air is sent to purge these lines when
any burner is in operation. The air is controlled by an on-off ball valve 65-KV-1285.
DCS logic 65-K-1285 opens valve 65-KV-1285 anytime one of the eight burner
assist gas valves are opened, to provide cooling air to all burner ignition lines at the
same time.
Burner assist gas valve Adjacent burner assist

open (for burner in gas valves required to be
operation) open
65-KV-1262 65-KV-1266
65-KV-1266 65-KV-1262, 65-KV-1272
and 65-KV-1269
65-KV-1272 or 65-KV-1269 65-KV-1266 and 65-KV-
1278
65-KV-1278 65-KV-1272, 65-KV-1269
and 65-KV-1275
65-KV-1275 65-KV-1278
2.2 Liquid Flare for Existing Units

Hydrocarbon is blown out from Common Flare Blowcase, 65-MD11 to the liquid line
from Cold/Heavy Liquid Blowcase, 65-MD09A/B to the Liquid Flare for the Existing
Units, 65-MB09, using dry feed gas. The liquid is burned in the cold and heavy
burner section of 65-MB09.
Liquid drained from Start-up LNG/BUPRO Flash Drum, 65-MD05, into the parallel
Start-up LNG/BUPRO Blowcases, 65-MD08A/B, is blown with dry gas to the Liquid
Flare for Existing Units, 65-MB09, where it is burned in the cold and light burners.
Vapors are vented from the top of 65-MD08A/B to the Common Flare KO Drum for
Existing Units, 65-MD10.
Liquid drained from Cold/Heavy Liquid Drum, 65-MD07, into one of the two parallel
Cold/Heavy Liquid Blow Cases, 65-MD09A/B, is blown with dry gas to the Liquid
Flare for Existing Units, 65-MB09, where it is burned in the Cold/Heavy Liquid
Page 8 of 39 KBR
burners. Vapors are vented from the top of 65-MD09A/B to the Common Flare KO
Drum for Existing Units, 65-MD10.
Liquid is pumped from Warm Liquid Drum, 65-MD06, by Warm Liquid Disposal
Pump, 65-MJ04, to the warm burner section of the Liquid Flare for Existing Units,
65-MB09, where it is burned. Vapors are vented from the top of 65-MD06 to
65-MD01. Flame Front Generator, 65-MB12, for Liquid Flare for Existing Units
receives LP fuel and instrument air and provides ignition gas and pilot gas to the
Liquid Flare for Existing Units, 65-MB09. The instrumentation and control system for
the Flame Front Generator, 65-MB12, is supplied on a local control panel system.
Whenever a particular burner is in liquid flaring operation, the adjacent burners are
required to have their associated assist gas valves open to provide cooling for the
burners not in operation. The sequence utilizes the assist gas valve position
feedback status of a burner as the indication that the burner is in operation.
In order to provide cooling to the ignition line of each burner/pilot assembly (which
are normally stagnant with no flow), instrument air is sent to purge these lines when
any burner is in operation. The air is controlled by an on-off ball valve 65-KV-1285.
DCS logic 65-K-1285 opens valve 65-KV-1285 anytime one of the eight burner assist
gas valves are opened, to provide cooling air to all burner ignition lines at the same
time.
Burner assist gas valve Adjacent burner assist

open (for burner in gas valves required to be
operation) open
65-KV-1262 65-KV-1266
65-KV-1266 65-KV-1262, 65-KV-1272
and 65-KV-1269
65-KV-1272 or 65-KV-1269 65-KV-1266 and 65-KV-
1278
65-KV-1278 65-KV-1272, 65-KV-1269
and 65-KV-1275
65-KV-1275 65-KV-1278
2.3 Thermal Oxidizer

The Thermal Oxidizer, 65-MB07, incinerates vapors from the Solvent Regenerator
Reflux Drum, 12-MD39. It is controlled by the Plant’s SIS system. The incinerator is
fired with low pressure fuel gas. Motor Driven Blower 65-MB07-MJ01 supplies air to
65-MB07. A pilot burner is provided and receives gas from the feed gas supply
header.
Page 9 of 39 KBR
3.0 OPERATIONS
3.1 Normal Running
This section provides a description of the operating parameters for the Cold Flare,
Liquid Flares & Flare for Existing Units. Refer to the table in Section 3.2 for a list of
typical operating variables for these systems.
3.1.1 Warm Liquid Drum, 65-MD06
The level in this drum is measured with transmitters 65-LT-1223 and 65-LT-1224.
The level is maintained by the operator. Liquids are pumped out with the Warm
Liquid Disposal Pump, 65-MJ04.
3.1.2 Warm Liquid Disposal Pump, 65-MJ04
This pump sends warm gasoline to the Liquid Flare for Existing Units, 65-MB09, from
Warm Liquid Drum, 65-MD06. It is started manually by the operator. When it is
running DCS logic, 65-K-6541, will open discharge valve 65-KV-1273 and assist gas
valve, 65-KV-1275, to help sweep liquid through the line to 65-MB09. If the discharge
valve fails to open, the logic will stop the pump and alarm on the console. Also, DCS
logic, 65-K-6541, will stop the pump on Warm Liquid Drum, 65-MD06, low level
alarm, 65-LAL-1224. When it is stopped, the logic will close valves 65-KV-1273 and
65-KV-1275. Only one drum will fill or blow down at a time.
In the event the flaring sequence is interrupted, refer to Loss of Instrument Air or
Sequence Failure in Section 5.2 ‘Process Upsets and Production Loss’.
Page 10 of 39 KBR
Page 11 of 39 KBR
3.1.3 Cold Flare Blowcases, 65-MD03A and 65-MD03B

Cold hydrocarbon liquid is drained into these vessels from the Cold Flare KO Drums,
65-MD02A/B, and is blown out to the Liquid Flare, 65-MB08, using dry feed gas
under DCS control. DCS logic, 65-K-1045, controls the sequencing of 65-MD03A
valves and logic, 65-K-1040, controls the sequencing of 65-MD03B valves to
accomplish this. DCS logic 65-K-1040 and 65-K-1045 both open the assist gas valve,
65-KV-1266, to help sweep liquids out of the discharge line going to the flare.
Page 12 of 39 KBR
Page 13 of 39 KBR
3.1.4 Liquid Flare, 65-MB08

This flare burns warm liquid pumped from Warm Flare KO Drum, 65-MD01, and cold
liquid from the Cold Flare Blowcases 65-MD03A/B and also from Unit 71 LP Flare
Blowcase, 71-MD03. The pilot and ignition are controlled by the Liquid Flame Front
Generator, 65-MB10. On transfer of any liquid to this flare the DCS sends signal to
open the high pressure atomizing valve 65-KV-1262.
3.1.5 Flame Front Generator for Liquid Flare, 65-MB10
This system receives LP fuel gas and instrument air and provides ignition gas and
pilot gas to the Liquid Flare, 65-MB08. The pilot and ignition are controlled by the
Liquid Flare, Flame Front Generator, 65-MB10. The instrumentation and control
system is supplied in a local control panel.
3.1.6 Common Flare KO Drum, 65-MD10
Level in this drum is measured with transmitters 65-LT-1251 and 65-LT-1252. When
level is above low alarm 65-LAL-1251, the operator should open the defrost gas
valve 65-XV-1250. This is done with DCS switch 65-HS-1250. Defrost gas will
vaporize liquids in the bottom. Low level alarm 65-LAL-1251 will close valve 65-XV-
1250 through DCS logic 65-K-6552.
If the liquid is not vaporized adequately the level will build up in the drum. On high
level alarm, 65-LAH-1252, the operator should start DCS logic sequence 65-K-1253
using Sequence Initiate switch 65-HS-1253F. This will start an automatic drain
sequence utilizing Common Flare Blowcase 65-MD11. The sequence will stop
automatically on drum low level alarm 65-LAL-1252.
3.1.7 Common Flare Blowcase, 65-MD11
Hydrocarbon liquid is drained into this vessel from the Common Flare KO Drum,
65-MD10, and is blown out to the Liquid Flare for Existing Units, 65-MB09, using dry
feed gas under DCS control. DCS logic 65-K-1253 controls the Blowcase sequence.
Also, the logic opens the assist gas valves 65-KV-1269 and 65-KV-1272 to atomize
liquids lines going to the flare 65-MB09. The operation of this control system is
described in Section 3 of the Control and Safety Function Narrative Document No:
IC-65-135-001.
Page 14 of 39 KBR
Page 15 of 39 KBR
3.1.8 Start-up LNG/BUPRO Flash Drum, 65-MD05

Drum level is measured by level transmitters 65-LT-1215 and 65-LT-1216. When
level is above low alarm 65-LAL-1215, the operator should open the defrost gas
valve, 65-XV-1187, with DCS hand switch 65-HS-1187. Defrost gas will vaporize
liquids in the bottom. Low level alarm 65-LAL-1215 will close the valve through DCS
logic 65-K-6531.
If the liquid is not vaporized adequately the level will build up in the drum. On high
level alarm 65-LAH-1216, the operator should start DCS logic sequences 65-K-1190
and 65-K-1195 using Sequence Initiate Switches 65-HS-1190F and 65-HS-1195F.
This will start an automatic drain sequence utilizing both Start-up LNG/BUPRO
Blowcases, 65-MD08A/B. The sequence will stop automatically on drum low level
alarm, 65-LAL-1216. Only one drum will fill or blow down at a time.
3.1.9 Start-up LNG/BUPRO Blowcases, 65-MD08A and 65-MD08B
Cold hydrocarbon liquid is drained into these vessels from Start-up/LNG Flash Drum,
65-MD05, and is blown out to the Liquid Flare for Existing Units, 65-MB09, using dry
feed gas under DCS control. DCS logic, 65-K-1195, controls the sequencing of
65-MD08A valves and logic 65-K-1190 controls the sequencing of 65-MD08B valves
to accomplish this. DCS logic 65-K-1190 and 65-K-1195 both open the assist gas
valve 65-KV-1278 to atomize liquids going to the flare. The operation of this control
system is described in Section 3 of Document No: IC-65-135-001.
Page 16 of 39 KBR
Page 17 of 39 KBR
3.1.10 Cold/Heavy Liquid Drum, 65-MD07

Drum liquid level is measured by level transmitters 65-LT-1232 and 65-LT-1233.
When level is above low level alarm 65-LAL-1233, the operator should open the
defrost gas valve 65-XV-1244 with DCS switch 65-HS-1244. Defrost gas will vaporize
liquids in the bottom. Low level alarm 65-LAL-1233 will close the valve through DCS
logic 65-K-6551.
If the liquid is not vaporized adequately, the level will build up in the drum. On high
level alarm 65-LAH-1232, the operator should start DCS logic sequences 65-K-1238
and 65-K-1243 using Sequence Initiate Switches 65-HS-1238F and 65-HS-1243F.
This will start an automatic drain sequence utilizing both Cold/Heavy Liquid
Blowcases 65-MD09A/B. The sequence will stop automatically on drum low level
alarm 65-LAL-1232. Only one drum will fill or blow down at a time.
3.1.11 Cold/Heavy Liquid Blowcases, 65-MD09A and 65-MD09B
Cold hydrocarbon liquid is drained into one of these vessels from 65-MD07 and is
blown out to the Liquid Flare for Existing Units 65-MB09, using dry feed gas under
DCS control. DCS logic 65-K-1238 controls 65-MD09A and logic 65-K-1243 controls
65-MD09B. The operation of this control system is described in Section 3 of
Document No: IC-65-135-001.
Page 18 of 39 KBR
Page 19 of 39 KBR
3.1.12 Liquid Flare for Existing Units, 65-MB09

This flare burns liquid pumped from Warm Liquid Disposal Pump, 65-MJ04, and
liquid forced from the Cold/Heavy Liquid Blowcases, 65-MD09A/B, and Start-up
LNG/BUPRO Blowcase, 65-MD08A/B, and from the Common Flare Blowcase,
65-MD11. The pilot and ignition are controlled by the Liquid Flame Front Generator,
65-MB12
3.1.13 Flame Front Generator for Liquid Flare for Existing Units, 65-MB12
This system receives LP fuel gas and instrument air and provides ignition gas and
pilot gas to the Liquid Flare for Existing Units 65-MB09. The instrumentation and
control system is supplied with the generator on a local control panel. All operation is
local.
3.1.14 Thermal Oxidizer
The Thermal Oxidizer incinerates vapors discharged from Solvent Regenerator
Reflux Drum, 12-MD39. It is controlled by the Plant’s SIS system. The forced draft
fan motor 65-MB07-MJ01 is started and stopped by DCS switch 65-HS-3182. The
operator sends a start permissive to the control system with DCS switch 65-HS-
3110A. The fan motor should be running first. If all safety interlocks are satisfied the
incinerator can be started from the local control panel using switch 65-HS-3110. The
operator can stop the incinerator from the local control panel using System Stop/Trip
switch 65HZ3112B.
The incinerator is fired with LP fuel gas. The flow to the burners is controlled from the
DCS with a cascade slave controller 65-FIC-3134, which throttles split-ranged gas
valves 65FV3134A and 65FV3134B. The controller output from 65FIC3134 is set on
a spit range where valve 65FV3134A is ranged closed to open on 0 to 35% of the
controller range and the valve 65FV3134B is ranged closed to open on 35 to 100% of
the controller range. The pilot gas is also LP fuel gas. The pilot gas pressure is
controlled with regulator 65-PCV-3119.
Output of 65-FY-3134 to control valve 65-FV-3134B is configured with a High limit of
64% to prevent the valve from being opened beyond the burner high pressure limits.
When the furnace is in the tripped condition, the flow controller 65FIC3134 output to
the control valve is set to 0% for both control valves 65FV3134A and 65FV3134B.
After reset of logic and subsequent opening of both valves 63XV3159 and 63XV3160
the output of 65FIC3134 to control valve 65FV3134A is set with a low limit of 70% to
prevent the valve from closing below the burner low pressure limits.
The stack temperature is measured by transmitter 65-TT-3135. The output of this
controller is sent to high selector 65TY3135A and low selector 65TY3135B. High
selector 65TY3135A selects the greatest of signals from calculation block 65FY3182,
which is a function of fuel gas flow 65-FIC-3134 and oxygen analyzer 65-AIC-3135,
and Thermal Oxidizer stack temperature 65TIC3135. In addition to the primary
temperature controller (65-TIC-3135), there is a secondary temperature controller
65TIC3135A. The secondary temperature controller is provided to increase the excess
air to the thermal oxidizer in the event that the fuel gas flow has been reduced to it
minimum operable limit. Temperature controller 65TIC3135A is direct acting; its output is
sent to the high selector 65TY3135D. High selector 65TY3135D selects the greatest of
signal from 65TY3135A and 65TIC3135A as the output to the forced draft fan ASD (65-
Page 20 of 39 KBR
EAL41). When the temperature exceeds the set point of 65TIC3135A the output of
65TY3135D will rise and exceed the output of the signal from 65TY3135A..
The excess oxygen in the stack is measured by analyzer 65-AT-3135. DCS controller
65-AIC-3135 maintains the excess oxygen at a safe level by sending a control
setpoint to the fan speed controller through DCS to 65-TY-3135C.
Combustion air flow leads fuel gas flow on increasing heating demand and lags fuel
gas flow on decreasing heating demand through the action of DCS low selector
65-TY-3135B and high selector 65-TY-3135A. This ensures there is adequate
oxygen available under all load conditions to provide complete combustion of the
fuel.
Page 21 of 39 KBR
3.2 Typical Operating Parameters

The following table contains typical operating variables for the Cold, Liquid &
Common Flare System.
Operating Variables for the Liquid Flare & Thermal Oxidizer System
Tag No. Description Typical Units

Value
65-AIC-3135 Thermal Oxidizer, 65-MB07, Flue Gas 2 Mole %

Oxygen Analyzer
Off Spec Propane from Unit 7 Flow t/h

65-FIC-1183 0
Controller
65-FIC-1184 Off Spec Butane from Unit 7 Flow Controller 0 t/h
65-FIC-3134 Thermal Oxidizer, 65-MB07, Fuel Gas Flow 200 kg/h

Controller
Start-up LNG/BUPRO Flash Drum 65-MD05

65-LI-1215 < 20 %
Level Indicator
Start-up LNG/BUPRO Flash Drum 65-MD05

65-LI-1216 < 20 %
Level Indicator
65-LI-1223 Warm Liquid Drum 65-MD06 Level Indicator < 20 %
65-LI-1224 Warm Liquid Drum 65-MD06 Level Indicator < 20 %
Cold/Heavy Liquid Drum 65-MD07 Level

65-LI-1232 < 20 %
Indicator
Cold/Heavy Liquid Drum 65-MD07 Level

65-LI-1233 < 20 %
Indicator
65-PCV-1267 Pilot/Ignition Gas from Feed Gas Supply 1.4 barg
65-TIC-3135 Thermal Oxidizer, 65-MB07, Temperature 816 C

Controller
3.3 Temporary Operation

The Thermal Oxidizer, 65-MB07, do not have temporary operations.
Liquid Flare, 65-MB08, disposes of liquids generated during start-up and shutdown or
from systems during operation of the New Skikda LNG plant that are not vaporized in
the Warm and Cold Flare Drums. The burners are in operation only when there is
liquid to be burned and are off when not needed.
Liquid Flare, 65-MB09, disposes of liquids generated during start-up and shutdown or
from off spec liquids during operation of the existing units that are not vaporized in
Page 22 of 39 KBR
the Flash Drum, 65-MD05; Flare Drum, 65-MD10; and Cold/Heavy Liquid Drum,
65-MD07. Liquid from Warm Liquid Drum, 65-MD06, is also burned in the Liquid
Flare. The burners are in operation only when there is liquid to be burned and are off
when not needed.
Page 23 of 39 KBR
4.0 START-UP
This section outlines the steps necessary to place the Liquid Flare & Thermal
Oxidizer System in service. For the purpose of this section of the operating manual,
confirm that the following conditions exist: The system and equipment have been
pre-commissioned, tested and inerted. Low pressure fuel gas is available from Unit
55 and instrument air from Unit 56. It provides ignition gas and air to the Flame Front
Generator for lighting the pilot lights. Defrost gas is available for vaporizing liquid in
the KO Drums, Flash Drum, Flare Drum and Cold/Heavy Liquid Drum.
Commissioning of the system has been completed and system is ready for start-up.
4.1 Steps for Start-up of Liquid Flare
1. Verify that Liquid Flare, 65-MB08 and lines to it are oxygen free.
2. Ensure that headers from Cold Flare Blowcases, 65-MD03A/B, and LP Flare
Blowcase, 71-MD03 are isolated from 65-MB08 until liquid from them is to be
burned.
3. Line up valves in the fuel gas supply line to the Flame Front Generator,
65-MB10, for 65-MB08.
4. Line up valves in the instrument air supply line to 65-MB10.
5. Line up valves from the Flame Front Generator outlet ignition lines to each of
the four Cold Section / Warm Section pilots one a time.
6. Line up valves on the pilot gas lines from the Flame Front Generator to each of
the four Cold Section / Warm Section pilots for 65-MB08.
7. Use the Flame Front Generator, 65-MB10, to light each of the four pilots for cold
section / warm section burners for Liquid Flare, 65-MB08.
8. Notify operating personnel in Units of the plant that are connected to the Cold
Flare Header and Cold Liquid Header that the Cold Flare System is ready for
service.
9. Line up the warm liquid outlet from Warm Flare KO Drum 65-MD01 to the Warm
Flare KO Drum Pump, 65-MJ01 and from the discharge of 65-MJ01 to the
Liquid Flare 65-MB08.
10. Notify operating personnel in Units of the plant that are connected to the Warm
Flare Header and Warm Liquid Header that the Warm Flare System is ready for
service.
11. Monitor the flare system during the plant start-up to ensure controls and
equipment is working properly.
4.2 Steps for Start-up of Liquid Flare for Existing Units
1. Verify that Liquid Flare, 65-MB09, and lines to it are oxygen free.
2. Ensure that headers from Start-up LNG/BUPRO Blowcases, 65-MD08A/B,
Common Flare Blowcase for Existing Units, 65-MD11; Cold/Heavy Liquid
Blowcases, 65-MD09A/B; and Warm Liquid Drum, 65-MD06, are isolated from
65-MB09 until liquid from them is to be burned.
3. Line up valves in the fuel gas supply line to the Flame Front Generator,
65-MB12, for 65-MB09.
Page 24 of 39 KBR
4. Line up valves in the instrument air supply line to 65-MB12.

5. Line up valves from the Flame Front Generator outlet ignition lines to each of
the nine pilots’ one at a time.
6. Line up valves on the pilot gas lines from the Flame Front Generator to each of
the nine pilots for 65-MB09.
7. Use the Flame Front Generator, 65-MB12, to light each of the nine pilots for the
burners for Liquid Flare, 65-MB09.
8. Notify operating personnel in Units of the plant that are connected to the Vapor
Flare Headers and Liquid Headers that the Liquid Flare for Existing Units
System is ready for service.
9. Monitor the flare system during the plant start-up to ensure controls and
equipment is working properly.
4.3 Steps for Thermal Oxidizer Start-up
Listed below is a summary of steps required for start-up of the Thermal Oxidizer,
65-MB07.
1. Confirm that the Thermal Oxidizer System has been checked out and prepared
for start-up.
2. Verify that the vent gas line from Solvent Regenerator Reflux Drum, 12-MD39,
to 65-MB07 has been isolated.
3. Line up valves for pilot gas from feed gas supply to the pilot gas supply control
system from the Thermal Oxidizer.
4. Line up valves for LP fuel gas from the fuel gas supply header to the control
station for Thermal Oxidizer.
Initial Conditions Prior to start of the Thermal Oxidizer:
 Pilot gas valves 65-XV-3154 and 65-XV-3160 will be closed.
 Pilot vent valve 65-XV-3158 will be open.
 Fuel gas valves 65-XV-3146 and 65-XV-3159 will be closed.
 Fuel gas vent valve 65-XV-3155 will be open.
 Vent gas valve 65-XV-3117 will be closed.
 SIS provides force manual zero to DCS controller 65-TIC-3135 which will
result in the output of controller 65-FIC-3134 set to 0% OP maintaining both
fuel gas valves 65-FV-3134A and B closed. After reset of logic and
subsequent opening of both valves 65-XV-3159 and 65-XV-3160 the output of
65-FIC-3134 to control valve 65-FV-3134A is set with a low limit of 70% to
prevent the valve from closing below the burner low pressure limits.
5. Operator at the local panel should press local panel pushbutton 65-HS-3113
"Lamp Test" which will illuminate all local panel lights. If all of the lights are not
illuminated the operator should not proceed with the start sequence until the
lights have been repaired. When the pushbutton is released, only relevant local
panel lights will remain illuminated.
6. Open ball valves on purge instrument air to UV Flame scanner for burner.
Page 25 of 39 KBR
7. Check burner is not lit as indicated by 68-BL-3103 and 65-BL-3104 on the LCP.
If 65-BL-3103 or 65-BL-3104 is lit on LCP, operator must clear flame scanner
fault before proceeding with the next steps.
If either of the flame scanners is in fault, as indicated when local control panel
lights 65-XL-3103 or 65-XL-3104 are illuminated or DCS alarms 65XA3103 or
65XA3104 are active, the operator should not proceed with the start sequence
until the flame scanner fault has been cleared.
8. Check DCS console shutdown pushbutton 65-HZ-3112A must not be in the
shutdown position. Local panel shutdown pushbutton 65-HZ-3112B must not
be in the shutdown position.
9. If the Forced Draft Fan is not already running, the DCS operator will start the
Thermal Oxidizer Forced Draft Fan 65-MB07-MJ01 via DCS handswitch 65-HS-
3182.
10. After the Forced Draft Fan has been started the air flow will increase until flow
switch 65FSL3116 is above low flow trip which will cause local control panel
light 65FLH3116 "Air Flow Permissive" to be illuminated.
11. The DCS operator will reset I-6560 and provide DCS authorization to start the
Thermal Oxidizer via DCS handswitch 65-HS-3110A which will illuminate local
panel light 65-XL-3110 "Permissive to Start from DCS".
12. Check that the oxygen analyser 65-AT-3135 is working and controller 65-AIC-
3135 is reading correctly at 2% excess oxygen.
Note: The flue gas excess oxygen analyser 65-AT-3135 is ranged 0 to 20.9%
O2. The top of scale analyser is set to 20.9% so that air can be used as the
calibration gas. The O2 content measured by analyser 65-AT-3135 is the
process variable for excess oxygen controller 65-AIC-3135. The output of the
direct acting controller increases as the O2 content increases. The oxidizer
manufacturer recommends an excess oxygen level of 2% (wet basis).
13. Push the system reset button 65-HS-3129 on the LCP.
Note: Reset button bypasses “Fuel Gas low low pressure trip” 65-PSLL-3124.
This trip becomes active again 5 seconds after the fuel gas block valves 65-XV-
3146 and 65-XV-3159 have opened during the start sequence.
Note: The BMS will check the following start permissives:
 The emergency trip system push button 65-HZ-3112B on the LCP is not
invoked.
 High high pressure trip 65-PLHH-3124 is not active on the LCP and high
high pressure alarm 65-PAHH-3124 is not active on the DCS.
 High high temperature trip 65-TLHH-3137 is not active on the LCP and
high high temperature alarm 65-TAHH-3137 is not active on the DCS.
 Low combustion air flow trip 65-FLL-3116 is not active on the LCP and low
flow alarm 65-FAL-3116 is not active on the DCS.
 Thermal Oxidizer Air Blower 65-MB07-MJ01 motor is running and indicated
by 65-XL-3182 in the DCS.
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 When the above permissives are satisfied, the BMS will give a signal
“Authorization to start” 65-XL-3110 on the DCS and 65-XL-3110 on the
LCP.
4.3.1 Purge sequence
Note: For the following steps, the operator must stand by the LCP and monitor
the progress of each step in the start sequence in case the sequence fails.
1 Operator presses the “Initiate Start Sequence” push button 65-HS-3110 on
the LCP.
2 Verify that “Purge in Progress” 65-KL-3105A lamp is illuminated on the
LCP.
3 The BMS will start 5 minute timer for purge. Operator to verify that the
lamp “Purge in Progress” 65-KL-3105A is lit.
Note: The purge timer starts immediately after depressing 65-HS-3110. The
following permissives must remain valid during the purge:
 Plant Shutdown from I-0000 not be active
 DCS console shutdown pushbutton 65-HZ-3112A not activated.
 Local panel shutdown pushbutton 65-HZ-3112B not activated.
 Pilot gas valve 65-XV-3154 closed as indicated by 65-ZL-3154 on the DCS.
 Pilot gas valve 65-XV-3160 closed as indicated by 65-ZL-3160 on the DCS.
 Fuel gas valve 65-XV-3146 closed as indicated by 65-ZL-3146 on the DCS.
 Fuel gas valve 65-XV-3159 closed as indicated by 65-ZL-3159 on the DCS.
 Acid gas valve 65-XV-3117 closed as indicated by 65-ZL-3117 on the DCS.
 Combustion Air Flow above the low flow limit as indicated by 65-FLL-3116
not active on LCP and 65-FAL-3116 is not active on the DCS.
 Thermal oxidizer Flue Gas High Temperature trip not activated as indicated
by 65-TLHH-3137 not active on LCP and 65-TAHH-3137 not active on the
DCS.
Note If the Purge cycle fails then the lamp “Purge Fail” 65-XL-3105B is
illuminated on the LCP. Operator will need to troubleshoot the cause of the
failed purge and the above steps will need to be repeated.
4 After completion of purge period the BMS will automatically check for safe
conditions and proceed with start up.
4.3.2 Start up Sequence
After purge sequence is complete, the following will occur

1 Shutoff Pilot Gas vent valve 65-XV-3158 will close.
2 After the pilot vent valve 65-XV-3158 is confirmed closed, pilot gas block
valves 65-XV-3154 and 65-XV-3160 open and the igniter 65-BY-3102 is
energized.
3 After 15 seconds, igniter 65-BY-3102 is de-energized.
Page 27 of 39 KBR
4 If flame is not detected by one of the scanners 65-BS-3103 or 65-BS-

3104 within 15 seconds:
i Local panel light 65KL3107 "System Fail to Ignite" will illuminate.
ii Pilot gas block valves 65-XV-3154 and 65XV3160 are closed, and
pilot vent valve 65-XV-3158 is opened.
iii It will be necessary to troubleshoot the cause and begin the start
procedure over.
5 Thirty (30) seconds after a flame is detected by one of the scanners 65-
BS-3103 or 65-BS-3104 the Fuel gas vent valve 65-XV-3155 will close.
Note : 30 Seconds after the pilot gas valves open and flame is confirmed
the fuel gas valves will open. After a further 30 seconds the pilot gas
valves will close.
6 Fuel gas control valves 65-FV-3134A in minimum firing position and 65-
FV-3134B fully closed are confirmed and the Fuel gas vent valve 65-XV-
3155 is confirmed closed, then main fuel gas block valves 65-XV-3146
and 65-XV-3159 open.
Note: Opening 65-XV-3155 will not trip the oxidizer. Instead opening 65-
XV-3155 will close the fuel gas block valves. This will lead to loss of
flame or low low fuel gas pressure and trip the system.
7 Check valve 65-XV-3146 is open as indicated by 65-ZL-3146 on the
DCS.
8 Check valve 65-XV-3159 is open as indicated by 65-ZL-3159 on the
DCS.
9 Ten (10) seconds after main fuel gas block valves 65-XV-3146 and 65-
XV-3159 open, alarm and trip initiator 65-PSLL-3124 is enabled.
10 Thirty (30) seconds after 65-XV-3146 and 65-XV-3159 open a command
is sent to the DCS to release 65-TIC-3135 for automatic control.
11 "System Ready" 65-KL-3106 is illuminated on LCP.
Page 28 of 39 KBR
5.0 SHUTDOWN
5.1 Normal Shutdown
The following steps are based on a planned shutdown of the Liquid Flare & Thermal
Oxidizer System.
5.1.1 Liquid Flare
The Liquid Flare, 65-MB08, will be required to remain in service during a normal
shutdown until flows are stopped from Cold Flare Blowcases, 65-MD03A/B; Warm
Flare KO Drum, 65-MD01; and LP Flare Blowcase, 71-MD03, to 65-MB08.
1. When flow stops from each of the above listed locations, ensure the lines are
isolated from the Liquid Flare.
2. Shut down and isolate Atomizing Gas, Liquid Flare and LP Fuel Gas and
Instrument Air supply to Flame Front Generator, 65-MB10.
3. Purge the Liquid Flare System with nitrogen.
4. If the system is scheduled for maintenance activity, ensure that all plant safety
precautions and procedures are followed.
5.1.2 Liquid Flare for Existing Units
The Liquid Flare for Existing Units, 65-MB09, will be required to remain in service
during a normal shutdown until flows are stopped from Blowcase for Existing Units,
65-MD11; Start-up LNG/BUPRO Blowcase, 65-MD08A/B; Warm Liquid Drum,
65-MD06; and Cold/Heavy Liquid Blowcases, 65-MD09A/B.
1. When flow stops from each of the above listed locations, ensure the lines are
isolated from the Liquid Flare for Existing Units, 65-MB09.
2. Shut down and isolate Fuel Gas from header to Liquid Flare and LP Fuel Gas
and Instrument Air supply to Flame Front Generator, 65-MB12.
3. Purge the Liquid Flare for Existing Units System with nitrogen.
4. If the system is scheduled for maintenance activity, ensure that all plant safety
5.1.3 Thermal Oxidizer
The Thermal Oxidizer, 65-MB07, must remain in service until the AGRU facilities are
shutdown and vent gas flow from Solvent Regenerator Reflux Drum, 12-MD39, has
stopped.
1. When vent gas flow from 12-MD39 is stopped, ensure that the Thermal
Oxidizer, 65-MB07, system is tripped off.
2. Verify that the Pilot Block / Bleed Valves 65-XV-3154 / 3158 / 3160 trip, the
Main Burner Block / Bleed Valves 65-XV-3146 / 3155 / 3159 trip and Blower
(65-MB07-MJ01) is stopped.
3. Ensure that gas lines to 65-MB07 are isolated from the supply headers.
4. Verify that the vent gas feed line from 12-MD39 is isolated from the Thermal
Oxidizer.
5. If the system is going to have maintenance activity, ensure that all plant safety
Page 29 of 39 KBR
5.2 Process Upsets and Production Loss

In the event of an emergency requiring a shutdown of the Liquid Flare & Thermal
Oxidizer System should be shut down as outlined above. However; upsets may occur
due to some of the causes listed below that will require special attention during these
losses or outages.
1. Loss of Electrical Power
Loss of electrical power will not cause Liquid Flares to trip, they can continue to
operate. The Emergency Diesel Generator provides power to the Warm Flare KO
Drum Pump 65-MJ01 and the Warm Flare KO Drum Heater 65-ML01.
Loss of electrical power to Thermal Oxidizer will cause a trip as acid gas flow from
12-MD39 will stop and Blower for 65-MB07-MJ01 shuts down.
2. Loss of Instrument Air or Sequence Failure
Loss of instrument air to any one control valve will result in that valve going to its
designated fail safe position or an interruption to the DCS logic sequence, such as, a
sequence fault or placing the sequence in OFF mode. All valves will return to their
normal sequence position. As indicated on each P&ID, FO valves to a fail open
position and FC valves to a fail closed position.
In the Liquid Flare system, the following valves fail closed:
Flare Drum Defrost Blow- Equal- Pump Assist

Gas Valve Dry Gas Gas
/Blow- case Inlet ization Discharge
Valve Valve
cases Valve Valve /Drain Valve
65-XV-
65-MD03A 65KV1045A 65KV1045B - - -
1038
65-XV-
65-MD03B 65KV1040A 65KV1040B - - -
1038
65-MD06 - - - - 65KV1273 -
65-XV-
65-MD08A 65KV1195A 65KV1195B - - -
1187
65-XV-
65-MD08B 65KV1190A 65KV1190B - - -
1187
65-XV-
65-MD09A 65KV1238A 65KV1238B - - -
1244
65-XV-
65-MD09B 65KV1243A 65KV1243B - - -
1244
65-XV-
65-MD11 65KV1253A 65KV1253B - - -
1250
Page 30 of 39 KBR
In the Liquid Flare system, the following valves fail open:
Defrost Blow- Assist

Gas Dry Pump Gas
Flare Drum case Equalization
Valve Gas Discharge Valve
/Blow-cases Inlet Valve
Valve /Drain Valve
Valve
65-MD03A - - - 65KV1045C 65KV1045D -
65-MD03B - - - 65KV1040C 65KV1040D -
65-MD06 - - - - - -
65-MD08A - - - 65KV1195C 65KV1195D -
65-MD08B - - - 65KV1190C 65KV1190D -
65-MD09A - - - 65KV1238C 65KV1238D -
65-MD09B - - - 65KV1243C 65KV1243D -
65-MD11 - - - 65KV1253C 65KV1253D -
In the Liquid Flare system, the following valves fail last:

Secure instrument air vessel is supplied to maintain the current position of all assist
gas valves in the event of overall facility instrument air loss.
Defrost Blow- Assist Gas

Gas Valve Pump Valve
Flare Drum case Dry Gas Equalization
Discharge
/Blow-cases Inlet Valve Valve
/Drain Valve
Valve
65-MD03A - - - - - 65KV1266
65-MD03B - - - - - 65KV1266
65KV1275
65-MD06 - - - - -
65KV1283
65-MD08A - - - - - 65KV1278
65-MD08B - - - - - 65KV1278
65KV1272
65-MD09A - - - - -
Page 31 of 39 KBR
Defrost Blow- Assist Gas

Gas Valve Pump Valve
Flare Drum case Dry Gas Equalization
Discharge
/Blow-cases Inlet Valve Valve
/Drain Valve
Valve
65KV1269
65KV1272
65-MD09B - - - - -
65KV1269
65KV1272
65-MD11 - - - - -
65KV1269
In the event the blowcase sequence is interrupted due to loss of instrument air or
sequence fault, all the above valves will fail to their fail safe position which will
depressure the blowcases. During this scenario, liquids may remain in the blowcase
and liquid lines to flare. To ensure the liquid flaring continues with assist gas, the
assist gas valves will fail in their last position. If a flare burner was in service during
the interruption the assist gas valve will remain open. If a flare burner was not in
service during the interruption the assist gas valve will remain closed. To safely
restart the blowcase system, the vent valve (C valve) will need to be closed and the
motive (dry) gas valve (B valve) will need to be opened to empty the blowcase and
purge the line. After the appropriate purge times are reached (shown on P&IDs,
Control Narratives, and schematics listed in this manual), the assist gas valve can be
manually closed and the system can return to normal operation.
At the completion of liquid flaring the DCS logic will purge all liquids from the
blowcase or pump discharge valve and downstream piping to the flare tip. Failure to
complete this post purge will leave liquids in the lines to the flares after the assist gas
is stopped. This liquid can free drain out the burner tips and ignite as a pool fire
below the burners causing smoke and damage to the flare equipment. Ensure the
assist gas valves remain open anytime there is liquid in the flare piping. The assist
gas valves can only be closed after completion of a post purge.
3. Loss of Assist Gas
Loss of assist gas will not cause the Liquid Flare, 65-MB08 and Liquid Flare for
Exiting Units 65-MB09, to shut down; however, if the normal supply of dry gas from
the outlet of the Mercury Adsorber supply is lost to the main collection headers, the
assist gas is provided with a back up from the feed Gas metering station.
4. Loss of Fuel Gas
Loss of fuel gas will cause the Cold Flare, 65-MB02; Liquid Flares, 65-MB08 and
65-MB09; and Flare for Existing Units, 65-MB11 to lose pilot and atomization gas and
require the flares to shutdown.
5. Loss of Defrost Gas
Loss of gas from the defrost gas header will cause lighter liquid collected in the
Common Flare KO Drum, 65-MD10; Cold/Heavy Liquid Drum, 65-MD07; Startup
LNG/BUPRO Flash Drum, 65-MD05; and Cold Flare KO Drums, 65-MD02A/B not to
Page 32 of 39 KBR
vaporize and result in more liquid being drained to their blowcases for disposal in
Liquid Flare, 65-MB09, to maintain liquid level in the flare drums.
Page 33 of 39 KBR
6.0 SAFETY/EMERGENCY SHUTDOWN

6.1 Safety Critical Shutdown Systems
There is no safety interlocks associated with the Liquid Flare System, 65-MB08.
Thermal Oxidizer, 65-MB07, has three safety interlocks. A brief description of the
safety interlocks are provided below.
6.1.1 I-6500 Thermal Oxidizer Combustion Air Blower Trip
The Thermal Oxidizer Combustion Air Blower ESD Interlock I-6500 is activated by
the Plant ESD Interlock I-0000.
6.1.2 I-6560 Thermal Oxidizer Main Burners Trip
On high high temperature (65-TT-3137) on the Thermal Oxidizer or high high or low
low pressure of the fuel gas (65-PT-3124A/B/C) or manual initiator 65-HZ-3112A/B or
low flow switch 65-FSL-3116 on thermal oxidizer air blower, the following valves
65-XV-3146, 65-XV-3154, 65-XV-3159, and 65-XV-3160 trips closed and 65-XV-
3155 and 65-XV-3158 bleed valves open and vent to the atmosphere at a safe
location.
On loss of flame detected by 65-BS-3103/3104, the following valves 65-XV-3146,
and 65-XV-3159 trip closed and 65-XV-3155 bleed valve opens and vent to the
atmosphere at a safe location.
6.1.3 I-6570 65-MB07 Thermal Oxidizer Acid Gas Trip
Interlock I-6570 will trip the Thermal Oxidizer on loss of Acid Gas. On loss of flame
or manual initiation with handswitch 65-HZ-3112A/B or low flow switch 65-FSL-3116
on thermal oxidizer air blower, the Acid Gas valve 65-XV-3117 trip closed, and 12-
XV-1351 (Solvent Regeneration Reflux Drum Vent) valve opens and vents to the
atmosphere at a safe location.
On closure of acid gas valve (65-XV-3117), Solvent Regeneration Reflux Drum Vent
(12-XV-1351) valve opens and vents to the atmosphere at a safe location.
6.1.4 Flare Safety During Strong Wind Conditions
Since all burner tunnels of Liquid Flare 65-MB08 and 65-MB09 are facing in the
South direction, there is a potential for flame blowback onto the burners during a time
of strong southerly winds. Therefore, the wind speed and direction instruments are
utilized to provide an informational message to the Utility panel operators as follows:
Whenever the wind direction (00-ZT-2002) is measured to be between 70 to 290
degrees and wind speed (00-ST-2003) magnitude is greater than 30 km/hr for more
than 30 seconds, the following message will appear on the DCS graphic of the liquid
flare:
“Unfavorable wind condition – delay flaring if possible”
This message will repeat every 30 minutes as long as the condition exists.
6.2 Pressure Safety Valve Summary

The Liquid Flares & Thermal Oxidizer Pressure Relief Valve Summary contains a
listing of all the pressure relief valves associated with this system.
Page 34 of 39 KBR
Liquid Flare & Thermal Oxidizer System Pressure Relief Valve Summary
Set Pressure
Valve Number Description/Location (barg)
65-PRV-1013A/B Cold Flare Blowcase, 65-MD03A/Relief to Cold 10.00

Flare KO Drum, 65-MD02A/B
65-PRV-1015A/B Start-up LNG/BUPRO Blowcase, 65- 10.00

MD08A/Relief to Common Flare KO Drum, 65-
MD10
65-PRV-1016A/B Cold/Heavy Liquid Blowcase, 65-MD09A/Relief 10.00

to Common Flare KO Drum, 65-MD10
65-PRV-1017A/B Cold Flare Blowcase, 65-MD03B/Relief to Cold 10.00

Flare KO Drum, 65-MD02A/B
65-PRV-1018A/B Start-up LNG/BUPRO Blowcase, 65- 10.00

MD08B/Relief to Common Flare KO Drum, 65-
MD10
65-PRV-1246A/B Cold/Heavy Liquid Blowcase, 65-MD09B/Relief 10.00

to Common Flare KO Drum, 65-MD10
65-PRV-1257A/B Common Flare Blowcase, 65-MD11/Relief to 10.00

Common Flare KO Drum, 65-MD10
Page 35 of 39 KBR
6.3 Fire Protection Equipment

The Liquid Flares & Thermal Oxidizer System Fire Protection Equipment Summary
contains a listing of fire protection equipment associated with these systems.
Liquid Flares & Thermal Oxidizer Fire Protection Equipment Summary
Description Quantity
DHD - Flare Stack Area No. 1
63-SP-011 Hydrant Cabinet 4-Way 1
DHE Flare Stack Area No. 2
63-SP-025 Two-Way Hydrant with Monitor 4
DHE Flare Drum Area Liquid Flare
63-SP-024 Four Way Hydrant with Monitor 1
DHG - Thermal Oxidizer
63-SP-008 Fire Water Monitor (Grade) 1
Page 36 of 39 KBR
7.0 ATTACHMENTS
The following attachments are included in this section of the Operating Manual:
7.1 Attachment I: Equipment List
7.2 Attachment II: Utility Consumption
Page 37 of 39 KBR
7.1 Attachment I: Equipment List

The following is a list of equipment associated with the Liquid Flares & Thermal
Oxidizer System.
Liquid Flares & Thermal Oxidizer System Equipment List
Design Design
Equipment Pressure Temp
No. Description (barg) (ºC)
65-MB09 Liquid Flare for Existing Units _ _
65-MB10 Flame Front Generator for 65-MB08 _ _
65-MB12 Flame Front Generator for 65-MB09 _ _
65-MD03A Cold Flare Blowcase 10.0 85/-165
65-MD03B Cold Flare Blowcase 10.0 85/-165
65-MD05 Startup LNG/BUPRO Flash Drum 5.5 85/-165
65-MD06 Warm Liquid Drum 5.5 180/-7
65-MD07 Cold/Heavy Liquid Drum 5.5 85/-165
65-MD08A Startup LNG/BUPRO Blowcase 10.0 85/-165
65-MD08B Startup LNG/BUPRO Blowcase 10.0 85/-165
65-MD09A Cold/Heavy Liquid Blowcase 10.0 85/-165
65-MD09B Cold/Heavy Liquid Blowcase 10.0 85/-165
65-MB07 Thermal Oxidizer 10.8 kg/s capacity
65-MB08 Liquid Flare 9.8 kg/s capacity
65-MD11 Common Flare Blowcase 10.0 180/-185
65-MJ04 Warm Liquid Disposal Pump 29.5 m3 rated

capacity
Page 38 of 39 KBR
7.2 Attachment II: Utility Consumption

Following are the electric motors associated with the Liquid Flares & Thermal
Oxidizer System and their expected consumption.
Cold, Liquid & Common Flare System Motor List
Available
Motor Load
Equipment No. Description (kW)
65-MJ04-M Warm Liquid Disposal Pump Motor 14.0
65-MJ01-M Warm Flare KO Drum Pump Electric Motor 11.0
65-ML01 Warm Flare KO Drum Heater 297.0
Page 39 of 39 KBR

New LNG Train Skikda Project Liquid Flare & Thermal Oxidizer Manual

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SONATRACH

NEW LNG TRAIN SKIKDA PROJECT

2 KM Issued for Implementation (Redlined) 3-May-13 MRC RM

Issued for Implementation

0 LTP Issued for Implementation 23 Nov 10 JDS BA AB

B LTP Issued for Client Approval 7 Nov 10 JDS BA -

A MDL Issued for Client Approval 11-Dec-09 GRM BA -

Rev. By Description Date KBR KBR CLIENT

Chkd App App

7.1 Attachment I: Equipment List ........................................................................................ 38

Thermal Oxidizer, 65-MB07, is provided to incinerate vent gas from Regenerator

New flare for existing Units

24" BOG from 71-FM01 71-XV2121

Start up scrub bottoms 0.3 b/6.3 b

Thermal oxidizer 65-KV1195B New LNG Train Off specs

3'’ C4 from 07-MJ03

2.0 SYSTEM DESCRIPTION

Burner assist gas valve Adjacent burner assist

2.2 Liquid Flare for Existing Units

Burner assist gas valve Adjacent burner assist

2.3 Thermal Oxidizer

3.1.3 Cold Flare Blowcases, 65-MD03A and 65-MD03B

3.1.4 Liquid Flare, 65-MB08

3.1.8 Start-up LNG/BUPRO Flash Drum, 65-MD05

3.1.10 Cold/Heavy Liquid Drum, 65-MD07

3.1.12 Liquid Flare for Existing Units, 65-MB09

3.2 Typical Operating Parameters

Tag No. Description Typical Units

65-AIC-3135 Thermal Oxidizer, 65-MB07, Flue Gas 2 Mole %

Off Spec Propane from Unit 7 Flow t/h

65-FIC-1184 Off Spec Butane from Unit 7 Flow Controller 0 t/h

65-FIC-3134 Thermal Oxidizer, 65-MB07, Fuel Gas Flow 200 kg/h

Start-up LNG/BUPRO Flash Drum 65-MD05

Start-up LNG/BUPRO Flash Drum 65-MD05

65-LI-1223 Warm Liquid Drum 65-MD06 Level Indicator < 20 %

65-LI-1224 Warm Liquid Drum 65-MD06 Level Indicator < 20 %

Cold/Heavy Liquid Drum 65-MD07 Level

Cold/Heavy Liquid Drum 65-MD07 Level

65-PCV-1267 Pilot/Ignition Gas from Feed Gas Supply 1.4 barg

65-TIC-3135 Thermal Oxidizer, 65-MB07, Temperature 816 C

3.3 Temporary Operation

4. Line up valves in the instrument air supply line to 65-MB12.

4.3.2 Start up Sequence

After purge sequence is complete, the following will occur

4 If flame is not detected by one of the scanners 65-BS-3103 or 65-BS-

5.2 Process Upsets and Production Loss

Flare Drum Defrost Blow- Equal- Pump Assist

In the Liquid Flare system, the following valves fail open:

Defrost Blow- Assist

65-MD03A - - - 65KV1045C 65KV1045D -

65-MD03B - - - 65KV1040C 65KV1040D -

65-MD08A - - - 65KV1195C 65KV1195D -

65-MD08B - - - 65KV1190C 65KV1190D -

65-MD09A - - - 65KV1238C 65KV1238D -

65-MD09B - - - 65KV1243C 65KV1243D -

65-MD11 - - - 65KV1253C 65KV1253D -

In the Liquid Flare system, the following valves fail last:

Defrost Blow- Assist Gas

Defrost Blow- Assist Gas

6.0 SAFETY/EMERGENCY SHUTDOWN

6.2 Pressure Safety Valve Summary

65-PRV-1013A/B Cold Flare Blowcase, 65-MD03A/Relief to Cold 10.00