Flare System Class Activities

Q1\ What is flare system?

A flare system collects and discharges gas from atmospheric or
pressurized process components to the atmosphere to safe locations
for final release.
Q2\ Why do we need a flare system in a plant?
The emissions from the process cannot be directly vented to the
atmosphere, as it is hazardous. For the safe disposal of gases, Flares
are used. We burn the process emissions at an elevated or isolated
position.
Q3\ What are the relief gases?
These gases represent an unwanted excess gases which would cause
the tank or the vessel to be overloaded and over-pressured in a
potentially dangerous manner.
Q4\ When does flare emission take place?
- Startup
- Normal operation
- Shutdown
Q5\ Make a sketch for flare system, showing and labeling its main
parts?
Q6\ List down the names of the main parts of a typical flare system?
- Flare Header
- Knock-out Drum
- Water seal
- Flare stack
- Molecular seal
- Flare tips
 - Igniters
- Pilot tips
- Monitoring devices
Q7\ Describe the functions for the following utilities in flare
systems?
- Gas Collection?
- Gas collection is header and piping for collecting gases from
processing units
- Knockout Drum?
- A knockout drum is used to remove and store condensable and
entrained liquids
- Water Seal?
- A proprietary seal, water seal, or purge gas supply is used to
prevent flash-back
- Gas Igniter?
- Gas pilots and an igniter is used to ignite the mixture of waste
gas and air
- Steam Injection?
- It is a provision for external momentum force used for
smokeless flaring
Q8\ As one of main parts of flare system, define flare head?
It is basically a 20" - 30" pipe running throughout the plant and
finally coming to the flare area. It is connected with other utilities
such as safety valves, pressure controllers, closed sampling points,
and emergency vent.
Q9\ Does the flare header work at a negative or positive pressure?
Why?
The Header is always operated at a positive pressure slightly above
the atmosphere to avoid ingress of air (O2) which leads to explosion.
Q10\ What is the purpose of the knock out drum in flare systems?
The purpose of the knock out drum is to trap and collect the liquid,
which might come from the main plant due to a lifting of the safety
valve. Also, it separates liquid from gas due to condensation.
Q11\ Does the knock out drum send gas or liquid to
the flare tips? Why?

The knock out drum avoids sending any liquid

material to the flare tips and allows only the gases to
pass through and reach the flare tips. The liquid
collected at the bottom is pumped back to the tanks
and used as fuel in the heaters.

Q12\ Water Seal is one of the main parts of flare

system, define it?
It is basically a small vessel located after the knock out
drum and before the flare tips. It prevents the back-
fire from the flare tips to the main header by avoiding
the ingress of oxygen from atmosphere and creating
back pressure. It traps all the soluble gases coming
from the plant.
Q13\ Molecular Seal is one of the main parts of flare system, define
it?
It is used to prevent the entry of oxygen back into the flare by
providing continuous purge of nitrogen going to this system. Also, it
helps to maintain a pressure and thus avoids the entry of air back
into the flare.
Q14\ What is the main purpose of flare tips?
Flare tips are provided to ensure that whatever gases are coming
from the main plant, they are being released in to the atmosphere
after being burned completely and not as a hydrocarbon.
Q15\ Define flare and mention its types?
The flare is a last line of defense in the safe emergency release
system in a refinery or chemical plant. Flares are classified into two
types:
1- Elevated flare
2- Ground flare

Q16\ What are the factors influencing the selection of flare’s type?
1- Availability of space
2- The characteristics of the flare gas (composition, quantity and
pressure); economics;
3- Investment and operating costs;
4- Public relations and regulation.
Q17\ What are the dis-advantages for elevated flares?
1- Noise pollution resulting from steam injection / air injection.
 2- Malodorous and toxic combustion products.
3- Capital costs are relatively high.
Q18\ What are the dis-advantages for ground flares?
Ground flares have poor dispersion of combustion product because
it’s stack is near to ground, this may result in severe air pollution or
hazard if the combustion products are toxic or in the event of flame-
out.
Q19\ What are the major factors influencing flare system design?
- Flow rate
- Gas composition
- Gas temperature
- Gas pressure available
- Utility costs and availability
- Safety requirements
- Environmental requirements
- Social requirements