CJSC Nizhnekamsk refinery

Refining and Petrochemical

Complex
Contract N° 1CD1213A
FEED Execution
NHR
WORK PACKAGE 2/7
Nizhnekamsk - Republic of Tatarstan

Project Document No : 1CD1213A - DI - 8110 - PD - 0700 - 0001 - E DS FLA

Contract Issuing Discipline Code Doc. category Unit Number Sequential N° Language Optional
Center Equipment Tag identifier

Issuing center Document No

(not mandatory) :

Unit: 0700 - Flare

Discipline: Process Engineering

Document Process Documents

category :

FLARE SYSTEM
DUTY SPECIFICATION

Digitally signed by Franky GRODET

Franky DN: CN = Franky GRODET, C = FR, O =
Foster Wheeler France, OU = Process
Department
GRODET Reason: I have reviewed this document
Date: 2007.03.07 16:40:32 +01'00'

00I 07/03/2007 For comments CJ FG JPA

REV. Issue date Description Prepared Checked Approved

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means,
or used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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CHANGE RECORD PAGE

Revision Description

00I First issue for comments

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used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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DUTY SPECIFICATION FOR FLARE

CONTENTS
1. INTRODUCTION .................................................................................................... 4
1.1. PURPOSE OF THIS DOCUMENT ......................................................................................... 4
1.2. SCOPE ........................................................................................................................... 4

2. REFERENCE DOCUMENTS.................................................................................. 5

3. DESCRIPTION OF THE SYSTEM .......................................................................... 6

3.1. PROCESS DESCRIPTION .................................................................................................. 6
3.2. HP FLARE ...................................................................................................................... 6
3.3. LP FLARE ...................................................................................................................... 6
3.4. SOUR FLARE .................................................................................................................. 6
3.5. FLARE CONNECTIONS ..................................................................................................... 7

4. OPERATING CASES ............................................................................................. 8

4.1. CONSTRUCTION PHASES OF THE COMPLEX ...................................................................... 8
4.2. FLARE LOADS ................................................................................................................ 8

5. UNIT 0700 BASES OF DESIGN ............................................................................. 9

5.1. UNIT CAPACITY............................................................................................................... 9
5.2. FLARE NETWORKS.......................................................................................................... 9
5.3. EQUIPMENT DESIGN REQUIREMENTS ................................................................................ 9
5.3.1. Flare....................................................................................................................... 10
5.3.2. KO drums............................................................................................................... 10
5.4. SAFETY AND SHUTDOWN INTERLOCKS ........................................................................... 10
5.5. SPARING PHILOSOPHY .................................................................................................. 11
5.6. TURNDOWN RATIOS ...................................................................................................... 11
5.7. CONTROL PHILOSOPHY ................................................................................................ 11

APPENDIX 1................................................................................................................. 12

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used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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1. INTRODUCTION

1.1. PURPOSE OF THIS DOCUMENT

The present duty specification defines the design philosophy for flare system (Unit 0700) within
the whole Refining and Petrochemical Complex of Nizhnekamsk, Tatarstan, Russia.

Information in this document, as well as all applicable reference documents, shall be considered
by General Designer as the basis of the front-end engineering design (FEED) study.

In general, all information not explicitly specified, as well as all design features of the Unit 0700,
shall be determined, verified and/or confirmed by the General Designer. General Designer shall
remain fully responsible for the proper design and operation of the Unit

1.2. SCOPE

This document deals only with the flare system Unit 0700 and is limited to the flare KO drums,
piping between the KO drums and stacks, and the stacks. The flare gas piping within the units is
just open piping and is not part of this discussion.

Information on relief flow rates within the process units are preliminary or typical data; all data
provided in this document are subject to revision and will be confirmed after completion of the
balances for those units.

General Designer shall remain fully responsible for the proper design and operation of the
System.

Information in this document, as well as all applicable reference documents, shall be considered
by General Designer as the basis of the front-end engineering design (FEED) study.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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2. REFERENCE DOCUMENTS

This duty specification is to be read in conjunction with the following documents of the project
1CD1213A.

Ref. Doc. Document title Document number

1 Conceptual Process Guidelines 1CD1213A-DI-8110-PD-0000-0001

2 Design Criteria 1CD1213A-DI-8110-PD-0000-0002

3 Basic Engineering Design Data (BEDD) 1CD1213A-DI-8110-AE-0000-0001

4 Flare System Conceptual Scheme 1CD1213A-DI-8110-PD-0700-0002

In addition, all applicable norms, codes and regulatory constraints provided by the client and
pertaining to the design of the unit will be taken into consideration.

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used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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3. DESCRIPTION OF THE SYSTEM

3.1. PROCESS DESCRIPTION

The function of the Flare System Unit 0700 is to collect all gases vented from the other units of
the complex during continuous and emergency operations and all discharges of pressure relief
valves. It must also cater for the possibility of depressurisation of equipment during
emergencies. Released liquid is recovered by KO drums and gases are burned.

Due to the size of the complex and to major expected release rates for units dealing with gas
under high pressure or with low molecular weight, two levels of pressure have been considered
for collecting systems. It would else lead to excessive size for flare system (flare stack height,
network …). Sour gases have to be burnt in a specific system.

As per doc ref.n.1, three flare systems are hence foreseen: HP flare, LP flare and Sour flare.

3.2. HP FLARE

The HP flare network (FA) collects discharges from high pressure systems (operating pressures
50 barg and above) that may or may not contain water. The HP flare header is connected to HP
Flare KO Drum where any condensates and water are removed from the flare gas before flaring.
The collected liquids are pumped from the HP Flare KO Drum using HP Flare Pumps (one in
service, one spare) which are automatically started and stopped by high and low level detection
in the HP Flare KO Drum. Condensates are sent to closed drain system.

HP flare flow is assumed to be sonic.

3.3. LP FLARE

The LP flare network (FB) collects discharges from low pressure systems (operating pressures
less than 50 barg) that may or may not contain water. The LP flare header is connected to LP
Flare KO Drum where any condensates and water are removed from the flare gas before flaring.
The collected liquids are pumped from the LP Flare KO Drum using LP Flare Pumps (one in
service, one spare) which are automatically started and stopped by high and low level detection
in the LP Flare KO Drum. Condensates are sent to closed drain system.

LP flare flow is assumed to be subsonic.

3.4. SOUR FLARE

The Sour flare network (FS) collects discharges from medium and low pressure systems that
may or may not contain water and acidic compounds such as H2S (volume concentration above
10%). The Sour flare header is connected to Sour KO Drum where any condensates are
removed from the flare gas before flaring. The collected liquids are pumped from the Sour Flare
KO Drum using Sour Flare Pumps (one in service, one spare) which are automatically started
and stopped by high and low level detection in the Sour Flare KO Drum. Condensates are sent
to closed drain system.

Sour flare flow is assumed to be subsonic.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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3.5. FLARE CONNECTIONS

Flare connections for process units are shown on document 1CD1213A-DI-8110-PD-0700-0002-

E-DS FLA and are summarised in the table below:

All units are supposed to be connected to LP flare network.

Units connected to HP flare header Units connected to Sour flare header

Naphtha HDT (U-1300) Crude distillation (U-1100)
Kerosene HDT (U-1500) Amines unit (U-3200)
Diesel HDS (U-1600) Sour water stripper (U-3300)
Hydrocracker (U-4100) Kerosene HDT (U-1500)
Coker Heavy GO HDT (4200) Diesel HDS (U-1600)
Hydrocracker (U-4100)
Spent Acid Regeneration (U-4500)
Sulfur Unit (U-3400)
Delayed Coker (U-5100)

Drums specified for collecting drains from process units have to be vented to appropriate flare
header.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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4. OPERATING CASES
4.1. CONSTRUCTION PHASES OF THE COMPLEX

As specified in doc ref. n.1, § 1.5, the new Oil Refining and Petrochemical Complex of
Nizhnekamsk will be constructed in several phases (steps 1a, 1b, 2 and 3).
In first approach, staged construction leads to foresee an implementation of all three flare stacks
at same place on east side of the complex in order to facilitate the construction of the units built
during steps 2 & 3.

General Designer may investigate, during FEED stage, the possibility to construct certain
portions of the Unit 0700 in different stages.

As a preliminary approach, it is foreseen that the Flare system Unit 0700 will be entirely
constructed at Step 1a.

The Unit 0700 must therefore be designed with adequate capacity and flexibility to cope with the
successive evolutions of Flare systems along all the Project Steps.

4.2. FLARE LOADS

The flare loads table (refer to Appendix 1) summarises the maximum flow rates released by
safety devices when all process and utility units operate at their nameplate capacities.

Information on relief flow rates within the process units are very preliminary or typical data; data
provided by licensors do not allow developing proper design for flare system at this stage of the
project. All data provided in this document are subject to revision and will be confirmed after
completion of the balances for those Complex units.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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5. UNIT 0700 BASES OF DESIGN

5.1. UNIT CAPACITY

The Unit 0700 shall be sized to, at least, cover 100 % of the maximum potential relief of the
Complex at any Project Step.

Potential relieves shall include:

• all gases vented from the other units of the complex during continuous start up, shut
down and emergency operations
• all discharges of pressure relief valves
• depressurisation of equipment during emergencies (as per Ref Doc.n.1, depressuring
system should be designed in a way such as to be not the sizing case for flare system).

For pressure relief valves discharges, individual contingencies as well as general failure shall be
considered.
General failures shall be determined after a close process analysis of each unit and have to be
confirmed after determination of depressurisation sequence.

This sizing shall include all any variation of composition due to seasonal considerations (winter
or summer). For the moment, no data taking in account this particular point are available from
licensors.

5.2. FLARE NETWORKS

Flare headers and lines shall be sized as per requirements of doc ref. n.2 and design conditions
specified in doc ref. n.1. All hydraulic sizing shall be based on 110 % of the maximum
continuous flow rates defined in § 4.2.

As per client requirement, all flare lines shall be traced and insulated for heat conservation and
avoiding icing or hydrates formation.

After a first analysis of existing data, there is no risk of discharge of LPG leading to brittle
fracture risk, except for Gas Plant (U-1400) and FCC (U-4300) which require use of material of
appropriate metallurgy. As flare network is traced and insulated, impact of chock chilling is
limited: detailed engineering stage will determine required modifications of piping.

5.3. EQUIPMENT DESIGN REQUIREMENTS

All equipment in the Flare system shall be designed in agreement with Ref. Doc.n.2.

According to client requirements, all equipments and piping of the systems will be designed for 9
bar g in order to avoid any risk of internal explosion.
All vessels linked directly to flare header shall be designed for 9 bar g whereas all equipments
protected with pressure safety valves may be designed at a lower pressure.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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5.3.1. Flare

A flare package shall include the following as a minimum:

• Flare stack
• Flare tip
• Purge reduction seal
• 3 pilots (minimum) and ignition system
• Ignition panel including: Remote ignition system
flame detectors
automatic reignition system
• Steel supporting structure
• Flanged connections for auxiliary piping
• Suitable technology to enable smokeless flaring (steam might be needed)

All equipment in the Flare system shall be designed in agreement with Ref. Doc. n.2.

Flare shall be designed to be smokeless as per Ref. Doc.n.3.

Thermal radiation and noise levels shall be in accordance with the API standards. These criteria
shall be applied to all identified design flare scenario.

5.3.2. KO drums

One KO drum should be provided for each flare as described on PFD 1CD1213A–DI–8110-PD–
0700–0002–E DS FLA. The KO drums shall be designed to catch fuel condensate in order to
avoid sending liquids to burners. The recovered condensate shall be sent to close drains
system.

KO drums shall also be provided for each major process units or groups of process unit
operating in the same process area as intermediate liquid catcher, in order to avoid sending
important amount of liquid to flare network. General Designer may investigate the possibility of
connecting close drains headers directly to these intermediate KO drums leading to the
suppression of drains drums. An allowance of KO drum liquid volume shall hence be taken
during detailed engineering stage.

For units with solvent such as Aromatic Complex, ISBL blow down tanks have been provided to
avoid sending huge amount of solvent to flare. Design of such systems shall be confirmed
during detailed engineering stage.

As not enough data are available, surimposed back pressure will be defined later and will have
to be confirmed by flare vendors.

5.4. SAFETY AND SHUTDOWN INTERLOCKS

Three levels of shutdown are provided to ensure safety and operability of the plant.

A Cause and Effect Chart will be developed during Basic Engineering and will provide a detailed
description of unit 0700 interlocks.

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used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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Note that in case of fire or gas detection in the flare fire zone, automatic closure of safety
isolation valves will happen and pumps inside the unit will be tripped. The only lines which are
equipped with isolation safety valves in the flare unit are the liquid HC outlet lines to the slops
tank. No automatic shutdown of the other units is foreseen.

The detection of high high liquid level in the flare KO drums leads to the automatic shutdown of
connected units. A 2 out of 3 voting system is installed to avoid the risk of spurious shutdown
due to level instrument air failure.

In case of detection of low low liquid level in a particular flare KO drum, the flare pumps
dedicated to that KO drum are tripped and isolation safety valve on the pump suction line
closed.

5.5. SPARING PHILOSOPHY

All flare pumps are spared even though these services are discontinuous. This reduces the risk
of phase trip in case of high high level detected in flare KO drums.

No spare flare stacks are provided. If any flare stack is out of service for any reason, the whole
process production phase of the flare concerned will be out of service.

5.6. TURNDOWN RATIOS

Turndown ratios for all flare systems will be defined during EPC of project following detailed flare
studies. Turndown of flare system for inspection purpose will imply a total shutdown of the
complex.

5.7. CONTROL PHILOSOPHY

To avoid air ingress into the flares headers, low pressure fuel gas is injected into the extremity of
all main flare headers and sub headers. The fuel gas flow rate to each header and sub header is
set using a manual control valve and flow indicator.

The main source of air ingress to the flare system is via the flare stack. For this reason, the flare
stacks are purged with fuel gas taken from fuel gas network. The fuel gas flow rate to each flare
stack is set using a manual control valve and flow indicator. In case of emergency shut down
occurring in any fire zone in the plant and inducing the closure of isolation safety valve on the
fuel gas line of the concerned fire zone, the total purge gas flow will be reduced. Therefore, to
ensure a sufficient purge flow, an isolation safety valve installed on the fuel gas purge manual
control valve bypass will open. In case of failure of the fuel gas system, flare stack sweeping is
backed up by nitrogen. Nitrogen for flare stack sweeping is supplied to each flare stack when
low pressure is detected in the corresponding flare stack sweeping gas supply.

Flare pilots are fed by dedicated C3 supply lines. Back up is ensured by LPG bottles.

All flare KO drum pumps are automatically started and stopped by high/low level control in the
corresponding flare KO drum: one pump is started on high level 1, the spare pump is started on
high level 2 an both pumps are stopped on low level.

© This document is the property of Foster Wheeler France. No part of this document may be reproduced or transmitted in any form or by any means, or
used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.
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APPENDIX 1

PRELIMINARY ESTIMATE FOR FLARE LOADS, STEP 3 - 16/02/2007

UNIT Maximum Flow Rate Notes

1100 Atmospheric distillation HOLD
1200 Vacuum distillation HOLD
1300 Naphtha Hydrotreater 127 000 kg/h 1
1400 Gas Plant HOLD
1500 Kerosene Hydrotreater 62 000 kg/h 2
1600 Diesel Hydrotreater 30 720 kg/h 3
2100 BTX Reformer 42 000 kg/h
2500 Aromatic Extraction 78 000 kg/h
2600 Para-xylene separation 355 000 kg/h
2700 Xylene isomerisation 206 000 kg/h
2800 Transalkylation/Disproportionation 18 000 kg/h
3100 Hydrogent Plant 210 000 Nm3/h 4
3200 Amine wash and regeneration 22 000 kg/h
3300 Sour Water Stripper 10 000 kg/h
3400 Sulfur Recovery 10 300 kg/h 5
6 200 kg/h 6
4100 Hydrocracker 322 000 kg/h 8
4200 Coker HGO HDT 98268 kg/h 10
4300 FCC 358 065 kg/h 7
4310 Hydrogenation Selective Unit 24 000 kg/h
4400 Alkylation 75000 kg/h 13
4500 Acid Regeneration HOLD
5100 Delayed Coker 343 838 kg/h 9
5200 Gasifier
5300 Air separation 483 850 kg/h 12
5400 Combined Cycle
6100 PP Unit 120 000 kg/h 11
6200 LAB Complex HOLD
6300 PTA Unit HOLD
6400 PET Unit 0

Note 1 : Average MW = 51.2, average T = 78°C. The flare load results mainly from the discharge of the fractionation towers overheads
Note 2 : Average MW=61
Note 3 : During high rate depressuring
Note 4 : Composition, vol% : H2 = 55.17, N2 = 0.14, CO2 = 4.0, CO = 13.31, CH4 = 4.56, H2O = 22.82
Note 5 : Water vapour from AG KO Drum. SWS Gas KO Drum and Desuperheater / Contract Condenser. To Sour Flare
Note 6 : Hydrocarbon vapour from Fuel Gas KO Drum
Note 7 : Power failure, MW = 47.1. Cooling water failure 333 200 kg/h MW =45.6
Note 8 : Power failure
Note 9 : Power failure, MW = 77, T=191 °C and 349.3 t/h MW = 78.6, T=192 °C for loss of cocker pumperaround
Note 10 : Gas blow by from hot separator, MW=37.4, T=153°C but 15.57 t/h, MW = 4.23, T=55°C for blocked vapor outlet for cold HP separator
Note 11 : Fire case, MW = 42
Note 12 : MW =20. Given value is for Gasifier, Air Separation and Combined Cycle Units
Note 13 : MW=58, T=60°C, blocked in of debutanizer

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used for any purpose other than that which it is specifically furnished without the written consent of Foster Wheeler France.