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H
ydrocarbon processing facilities traditionally depend on Valuable information. The new standard is the first public
a single flare system and flare burner for safe, efficient comprehensive coverage of flare system components. Information is
disposal of relief or waste gases. Consequently, optimal presented in an easy-to-read, straightforward manner, starting with
processing performance must be combined with a service life that a “definition of terms” that are frequently used in the flare industry.
is compatible with current long turnaround cycles. The definitions enable a common language to facilitate communi-
The prime public information source for flare system design is cation, learning and discussion among interested parties. The three
the American Petroleum Institute (API) Recommended Practice most common categories of flares—elevated, enclosed and staged
521 “Guide for Pressure-Relieving and Depressuring Systems,” multi-burner—are described and their major components explored
which addresses flare system design criteria. However, this stan- in detail. In addition, information on selection considerations, sys-
dard does not provide guidance for mechanical details for such tem design criteria and mechanical design basis is presented.
units.
Responding to an initiative from within its membership, the Data sheets facilitate communications. The authors
API Committee on Refining Equipment (CRE) formed a task of Standard 537 recognized the need for effective communica-
force to develop a new guide that addresses flare mechanical tion of flare design information between the parties (users, pro-
details. This group was comprised of equipment owners and oper- cess designers, engineers and constructors and flare equipment
ators, designers and manufacturers of flare equipment, engineer- designer/supplier) involved in a project. They also recognized
ing and construction company representatives, and hydrocarbon the desirability of developing and maintaining a record of design
process designers who undertook this grassroots effort. The task information on each flare system and its performance.
force worked together to share their expertise and knowledge of The communications between the parties and the record of
flaring equipment, and the consensus of this group yielded the the project are simplified if a standard set of data sheets is used.
recently published API Standard 537, “Flare Details for General Appendix A of Standard 537 contains two sets of data sheets
Refinery and Petrochemical Service.” This standard provides and 10 pages of instructions for the data sheets: one set of data
proven industry practices and details that can facilitate commu- sheets (17 pages) to be used with the SI system of measures and a
nications between purchasers and manufacturers. second set (also 17 pages) to be used with US customary units.
Each set is made up of three groups of data sheets: general,
BACKGROUND elevated and enclosed. The general data sheets deal with general
Beginning in the late 1940s, hydrocarbon processing plant project and process information and can be used with the elevated
relief and other waste gas releases were converted from unburned or enclosed flare data sheets. The data sheets are designed in a
vents to intentional burning flares. While some users and engi- very flexible manner. This flexibility results in a certain number
neering companies developed their own limited guidelines for of unneeded input listings for any given project. Therefore, one
flares, no publicly available comprehensive guide on the design should not need to make an entry for every item.
of flares or flare systems existed until the API published Recom- An example of a data sheet and a related instruction is shown
mended Practice 521, in 1969. Even in RP-521, flares are not in Fig. 1. The data sheet, General Flare Data Sheet No. 3, is
the only subject covered and are one of many important relief intended for use by the purchaser and sets forth process design
system details. Most of the RP-521 coverage of flares is focused on requirements for the flare. That portion of the instructions
process details and system safety; little information on mechanical relating to line 6, Veq, of the data sheet are inset onto the data
issues is discussed. sheet. Veq is the parameter used in determining the maximum
RP-521 is currently in its fourth edition and work on a fifth hydraulic capacity of the flare.
edition is under way. The CRE’s intent is that RP 521 and Stan- The execution of the data sheets will evolve as the project pro-
dard 537 should be complementary documents—RP 521 dealing gresses. The user or design engineers will input the first informa-
primarily with process and safety issues and Standard 537 address- tion. At this stage, the data sheets can be used as part of the inquiry
ing mechanical details. package. Vendor proposals should return the data sheets with
HYDROCARBON PROCESSING MAY 2004
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FIG. 1 An example data sheet from Standard 537 for a flare system. Several operating scenarios can be listed on one data sheet.
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over-application of smoke suppressant (usually steam or air) can result the “Special Notes” of this standard, API states that one must use
in a noisy, inefficient flame. sound engineering judgment in applying 537 or any other stan-
Maintenance. Some flare equipment, such as certain types of dard. In addition, API notes that its standards in no way inhibit
pilot ignitor, is located at or near grade and is accessible at any time. one from using any other practices.
However, a flare burner is usually located in a remote, elevated Some purchasers and/or users of flare equipment who have
position with limited access. Thus, flare equipment maintenance developed their own experienced-based specifications may choose
opportunities are very limited when a flare is online. Therefore, to deviate from the standard in some way. An example of such
any opportunity to inspect or work on the flare should be fully experience-based input can be found in Section 5.1.7.4 where the
exploited. A well-developed inspection and work plan, together substitution of a material of greater heat resistance than grade 310
with quick access to the appropriate spare parts, can maximize the stainless steel is suggested.
opportunity afforded by a plant shutdown. Wear of flare equipment
is strongly influenced by the circumstances of its operation. Flare Closing. Standard 537 represents a significant increase in the
life can be as short as a few weeks or more than a decade. available information regarding flares and ancillary equipment.
Troubleshooting. One special feature of the new standard is Anyone working with flares or flare systems should have this new
practical troubleshooting information. Troubleshooting infor- source of experience-based engineering and operational informa-
mation is listed in tabular form starting with the statement of tion at hand. In particular, this standard will be of value to those
a potential problem followed by a possible cause and corrective purchasing flare equipment and/or those involved in trouble-
action. Eight troubleshooting tables presenting a total of nearly 60 shooting activities. HP
potential problems are included. Fig. 4 is an example of a portion
of the troubleshooting guide for flame detection systems.
Bibliography. Those interested in an in-depth study of flares Robert Schwartz, P.E., is a vice president and technical specialist for John
Zink Co., LLC., and joined the company in 1967. Throughout his career with Zink,
will find the included bibliography a helpful starting point. Three Mr. Schwartz has provided technical and business leadership in all product areas of
categories of subjects are provided: general information on flares the company and has extensive international experience. His inventions and innova-
and flare systems, mechanical and structural, and emissions. tions are in use throughout the company; he holds 51 US patents and hundreds
of foreign patents. His areas of expertise include combustion, fluid flow and heat
transfer. Mr. Schwartz holds BS and MS degrees from the University of Missouri. He
New or alternative ideas. It is not mandatory for a pur- is a member of ASME, AIChE and the scientific research society Sigma Xi, and is a
chaser to use all of the information found within this standard. In registered professional engineer.
Article copyright © 2004 by Gulf Publishing Company. All rights reserved. Printed in U.S.A.
FLARE SOLUTIONS
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