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◼ 1 General
◼2 Typical Flare System
◼ 3 Potentials of Overpressure
◼ 2.2 Miscellaneous
◼ In certain cases, by suitably changing the design pressure of a few
equipment, flare load can be brought down.
◼ • In case of high flare loads, a review is to be done to
check, if by adopting suitable control philosophy, flare
load can be brought down. For example, tripping source of
heat to reboiler by sensing pressurization of column
overhead with 2 out of 3 voting of pressure switches, CRL
reduced their CDU flare load.
◼ • For high temp relief from Hydrogen unit etc ISBL
header is sized as per actual temperature during relief but
OSBL header is maintained of CS because CS can
withstand expected high temperature for the duration of
relief.
• Minimum heating value of gas being flared is between 200-300
BTU/SCF, if value drops below this value, special flare system is
provided, heat value should be maintained.
◼ • In certain cases, by segregating high and low pressure loads by
separate headers , flare system can be made economically attractive.
◼ Possibility of reducing trussel (flare support) height by providing
intermediate KOD may be considered when flare system is very
far(about 2 KM) from process units. Typical system at stack side will
have elevation equivalent to diameter of main KOD+ its elevation
from grade + piping network connecting flare header to KOD. OSBL
header from various units( after their unit KOD s )is with 1:500 slope.
With intermediate KOD having dual slope (part towards intermediate
KOD and rest towards main KOD ), structure cost on support may be
reduced. It is confirmed by comparing cost of additional KOD Vs
reduction in support cost.
◼ • Significant reduction in flare loads is possible with application of
high integrity protection system.
◼ • Reflux pump and cooling water system pumps may be
considered steam turbine driven to avoid flare load for reflux failure
and reduce flare load for cooling water failure case. In such cases,
availability of steam during power failure needs to be assured.
◼ While discussing flare job with client, there may be a need to estimate
flare header size, it may be done for low pressure flare system with
vapor sizing formulae, friction factor chart and procedure given
below:
◼ 2.3 Order of magnitude Flare Header Calculations
◼ Pressure drop calculation of flare header depends on total
equivalent length of flare header after considering
expansion loops and natural bends as per plot plan.
Estimate of expansion loops is based on design
temperature, this requires temperature profile for various
failure cases. Based on temperature, expansion loops are
decided by engineering. Each loop consists of 4x 90 0 bends
( long radius(20D) ) and 20-30 meter straight length.
◼ For quick estimate, expansion loop after every 70 –80
meters of straight length may be considered.
◼ • When no data is available, design temperature of flared gas
going out of stack and main KOD may be taken 100 and 150 0C for
estimated design.
◼ • Pressure drop of ISBL header may be limited to 10% of back
pressure.
◼ • For initial calculation, pressure upstream of main flare KOD
may be considered 0.5-0.7 kg/cm2g.
◼ • For initial guess of main flare header size, total flare load at
average pressure and density (average of pressure @ upstream of
main flare KOD & OSBL) & viscosity 0.01 cp.
◼ This is for low pressure flare systems (up to1.7 kg/cm2 g).
◼ For high pressure (3.5 kg/cm2g and above) flare systems, each
section of header will have significant change in density and
pressure drop & hence estimate can not be done with average
values.
◼ • Estimated properties of gases in the headers can be calculated with following
mixture relationships:
◼ MW= SWi / S(W/MW)I
◼ T=S Wi TI / S WI
◼ From Technical Data Book, 5-21- With VP 1.5 atm. and operating
temp of 170 0F, Normal boiling point for mixture
◼ is 195 0F
◼ Relieving temp @ 5.2 atm is 285 0F.
◼ -Latent Heat of Vaporization
◼ For mixtures of pure components, refer API-520 fig D-3
◼ and average MW of liquid mixture to determine latent heat of
vaporization
◼
-For mixtures containing pseudo components, Use Technical Data
Book, Figures from 7-122 to 7-129.
◼
◼ Example-Naphtha Splitter reflux drum
◼ 0API of overhead liquid 63
◼ =(T1+T2)/2
◼ Tma- mean ambient temperature (0K )
◼
◼ E - Emissivity (0.9)
◼
◼ =103.5-28.603=74.9 ft
◼ 5.7 Molecular Seal/ Fluidic Seal
◼ If air enters flare stack, it will mix with combustible gases resulting in
an explosive mixture Entry of air is prevented by using continuous
purge with oxygen free gas and use of gas seal. Seal gas , inert gas or
nitrogen are commonly used as purge gases.
◼ Various types of gas seal like fluidic or molecular seal are available.
Molecular seal is commonly used. In this seal, gas is forced to make
two 1800 bends as it flows through the seal( air thus encounters a trap
caused by difference in mol. wt. between air and purge gas. If purge
gas is lighter than air, trap is formed in the upper portion of outer
cylinder.
◼
◼ Ignition System
Commonly used Flame Front Generator system requires
compressed air (15 psig) , fuel gas (15 psig ),and electricity
(110V, 220V or 440 V) in an ignition panel. Air and gas are
mixed and mixture is ignited to generate a spark that
travels through ignition piping (stainless steel) to the pilot.
◼ 5.8 Design criteria for utility
◼ • No of burners required-If dia < 24 inch; burners=2
◼ 24inch < dia <36 inch,burners=3
◼ dia>36 inch, burners=4
◼ • Fuel gas requirement (Nm3/hr) 4x Number of burners
◼ • Purge gas requirement(Nm3/hr) –based on 0.1 ft/sec
for molecular seal and 0.35 ft/sec for fluidic seal
◼ • Steam requirement, kg/hr
◼ = Hydrocarbon load x(0.68-10.8/ Mol Wt)
◼ 6.0 Pressure Safety Valve
◼ 6.1 Types of PSV
◼ Generally three types of safety valves are used:
◼ • Conventional: back pressure is 10% of set pressure
◼ • Balance bellow type: Back pressure varies from 40-
50% of set pressure
◼ • Pilot Operated valves: back pressure is 70% of set
pressure
◼ •
◼ • Relief valves are usually sizes for failure condition which results
in maximum load, however during other mild upsets, fraction of that
amount is discharged through the valve. The fluid volume under such
condition may be insufficient to sustain large load and valve
operation would be cyclic. This type of service results in chattering &
relief valve, s ability to reseat may be affected. When such variation
is frequent, use of
◼ multilple valves of smaller capacity with staggered
◼ setting. With this arrangement valve with lowest setting
◼ will be able to handle minor upsets.
◼
◼ 6.2 Relieving pressure for single/multiple valve:
◼ 6.2.1Determination of Relieving Pressure for a Single Valve
◼ • Valve set pressure less than MAWP
◼ Operating case Fire case
◼ Protected vessel, MAWP, psig 100 100
◼ Max accumulated pressure, psig 110 121
◼ Valve set pressure, psig 90 90
◼ Allowable overpressure, psi 20 31
◼ Relieving pressure, psia 124.7 135.7
◼
◼
◼ Additional valve
◼ (Set pressure equal to 105 percent of MAWP)
◼ Operating case Fire case
◼ Protected vessel, MAWP, psig 100 100
◼ Max accumulated pressure, psig 116 121
◼ Valve set pressure, psig 105 105
◼ Allowable overpressure, psi 11 16
◼ Relieving pressure, psia 130.7 135.7
◼
◼ 6.2.3 Determination of Relieving pressure for a supplemental valve
◼ Supplemental valves are used only in addition to valves sized for
operating(non fire) contingencies.
◼
◼ Supplemental valve
◼ (Set pressure equal to 110 percent of MAWP)
◼ Fire case
◼ Protected vessel, MAWP, psig 100
◼ Max accumulated pressure, psig 121
◼ Valve set pressure, psig 110
◼ Allowable overpressure, psi 11
◼ Relieving pressure, psia 135.7