APPENDIX 3A TO TECHNICAL SPECIFICATION PART III

SPECIFICATION FOR AIR ASSISTED SMOKELESS FLARE

PACKAGE
 Page 1 of 1

KUWAIT OIL COMPANY (K.S.C.)

(Register of Commerce No. 21835)

APPENDIX 3A
-to-
TECHNICAL SPECIFICATION PART III
-for-
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE
WITH SMOKELESS TYPE FLARES AT NK GCs 15, 23 & 25

SPECIFICATION FOR AIR ASSISTED SMOKELESS FLARE PACKAGE

CONTENTS

1. INTRODUCTION

2. CODES, STANDARDS AND SPECIFICATIONS

3. TECHNICAL REQUIREMENTS

3.1 SYSTEM DESIGN AND PERFORMANCE

3.1.1 GENERAL

3.1.2 FLARE SYSTEM PACKAGE

3.2 INSPECTION AND TESTING

3.3 TESTING

3.4 PERFORMANCE AND GUARANTEES:

 Page 1 of 8

KUWAIT OIL COMPANY (K.S.C.)

(Register of Commerce No. 21835)

APPENDIX 3A
-to-
TECHNICAL SPECIFICATION PART III
-for-
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE
WITH SMOKELESS TYPE FLARES AT NK GCs 15, 23 & 25

SPECIFICATION FOR AIR ASSISTED SMOKELESS FLARE PACKAGE

1. INTRODUCTION

1.1. This Specification defines the minimum technical requirements for the detailed design,
manufacture, supply, testing and commissioning of the following categorized Air Assisted
Smokeless Flare Package system.

1.2. The Flare package shall be supplied in full compliance with this appendix, Technical
Specification, Datasheets, Drawings, KOC Standards and relevant International Standards
whether listed here or not, as well as other standards which are listed in relevant parts of
the Technical Specifications.

1.3. In case of any discrepancy between or within the documents the more stringent shall apply.
All such discrepancies shall be promptly brought to the attention of the Superintendent for
resolution and the decision of the Superintendent shall be final and binding on the
Contractor.

2. CODES, STANDARDS AND SPECIFICATIONS

The system shall be designed in accordance with this specification and the applicable
requirements of the following Standards. The latest edition of all codes and standards
pertinent at the contract award shall apply in each case. The list below is not exhaustive
and it shall be deemed that the Contractor has taken in to consideration all the relevant
International and Local standards, whether listed here or not, while designing the
system.

Please refer Appendix 1B of Technical Specification Part I - General for International

Codes, Standards and Specifications list. Compliance with this specification shall not
relieve the Contractor of the responsibility to supply equipment suited to meet the
specified service conditions and applicable regulations.

All conflicts between the requirements of this specification and other relevant
documents shall be brought in to notice by the Contractor/Vendor to the Company for
prior approval of the applicable requirement. However, the most stringent requirement
shall be applicable unless otherwise approved by the Company.
 Page 2 of 8
APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3. TECHNICAL REQUIREMENTS

The Flares shall be designed to provide stable flame conditions to safely flare
hydrocarbon gas of the composition, flowrate and pressure as specified on the data
sheet.

All components of the flare system shall provide continuous, safe, reliable operation
throughout the range of process condition, working in a windblown desert environment
as described in the KOC-G-007, KOC Standard for Basic Design Data.

3.1. SYSTEM DESIGN AND PERFORMANCE

3.1.1. General

a) The system shall be designed based on the design flow cases as mentioned in Table 1
of Appendix 2A to Technical Specification Part II.

b) The Flare shall be designed for continuous smokeless operation (Ringelmann '0' in
accordance with BS 2742C) over the full range of flare loads from purge gas flow to
100% design load including instantaneous flow changes with sustained wind from zero
to maximum.

c) The flare shall be designed to operate satisfactorily during shutdown/malfunction of

Air blowers and peak loads during emergency depressuring.

3.1.2. Flare system Package

The flare system package shall consists of the following as a minimum. The list is not
exhaustive and the Contractor shall ensure that the system is complete is all respects to
safely function as specified in the Contract documents.

a) Vertical, self-supported air assisted smokeless flare stack with flare tips and pilot
burners
b) Flame retention rings
c) Purge gas seals (Buoyancy Seal)
d) Dual element type retractable Thermocouple for pilot flame detection (2 nos. per pilot
burner)
e) Two (2) Infrared Pyrometer type Flame monitoring system for pilot flame detection
f) Windshield
g) Flare gas riser
h) Pilot gas riser
i) Pilot ignition riser
j) High energy Direct Spark Ignition system complete with control panel, cables, spark
probes etc.
k) Flame front generator complete with control panel, flow control valves, mixing
chamber, spark plug, piping, sight glass, drain etc.
 Page 3 of 8
APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

l) Unit Control Panel (UCP) with flare PLCs.

m) Vaneaxial axial-flow direct driven two Speed electric blowers complete with inlet filter,
trash screens, mufflers, inlet and backdraft dampers etc. Vibration switches shall be
provided for the Air blowers.
n) All instrumentation required for the safe and proper functioning of the flare package.
o) Retractable type aircraft warning lights.
p) Radiation shield for all instrumentation.
q) Ladders and Platforms with handrails for access the Flare Tip.
r) Lifting lugs and tailing lugs for lifting the complete unit with all equipment installed.
s) Retractable Davit, rope and all other necessary equipment for flare tip removal and
maintenance.

3.1.2.1. Flare Stack

a) Flare stack shall be vertical, self-supported type complete with base mounting plate
for anchoring to concrete foundation.
b) Flare stack structural design shall take in to consideration the following loads as a
minimum as per Company’s standards KOC-C-001 and KOC-G-007
 Wind loads taking in to account all the appurtenances like ladders,
platforms, air blowers, piping, seal etc.
 Earthquake induced loads
 Wind-induced vibration loads
 Internal Pressure (if applicable)
 Flashback pressure (if applicable)
 Nozzle loads of piping connections
 Thermal loads (if applicable)
 Special loads
 Erection and / or maintenance load
c) The height of the flare stack shall be determined based on the maximum permissible
radiation levels as per Table 12 of API STD 521-2014. In addition, solar radiation
of 950 W/m2 shall be considered in the total radiation computations.
d) The height calculation shall also take in to consideration the ground level
concentration of H2S based on dispersion analysis in the event of a flame out of the
flare. The maximum allowable ground level concentration shall be 10 ppm for H2S
or EPA and NIOSH Standards, whichever is more stringent.
e) Flare stack height calculations as per API STD 521 shall be submitted for the
Company review and approval.
f) Flare stack diameter and thickness shall be as per API STD 521 and calculation
shall be submitted for the Company review and approval.
g) Material of construction of the flare stack shall be as per Appendix 3E-Material
Selection Guide. A corrosion allowance of 3mm shall be provided for the flare
stack.
h) Field erection of stack sections (if applicable) shall be by welding. Welding
requirements shall follow structural design code and pressure design code as
applicable.
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APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

i) Welding inspections shall be carried out as per API STD 537 & relevant KOC
Standard for welding.
j) Flare stack shall be factory coated as per KOC-P-001. Touchups if required shall
be carried out after installation.
k) Nozzle connections for flare gas inlet shall be horizontal flanged connection.
l) Blowers and/or ducting from blowers shall be connected to the flare stack with
flanged connections.
m) Lifting lugs shall be provided on the stack main section to facilitate lifting and
placement for erection. The lifting lugs shall be located to allow the stack to assume
a vertical position when suspended from the overhead. The lifting lug design shall
be adequate to safely handle the loads.

3.1.2.2. Flare Tip (Burner)

a) Flare tips shall be designed as per KOC-ME-021, API 537 and API 521 to safely
and efficiently flare the relief gas as specified in the datasheet and maintain stable
combustion during all service and environmental conditions mentioned in the
datasheet and KOC standard KOC-G-007 and wind speed up to 45 m/sec. when
combined with at least 50mm (2 inch) of rainfall per hour.
b) Flare tips shall be designed to operate satisfactorily over the full range of flare loads
with air assist including the emergency load during depressuring without any
disruption in the flame stabilization mechanisms.
c) Flare tips shall have flame retention devices to provide stable combustion and
protection from flame blow-off.
d) Flare tips shall be sized for maximum exit velocity Mach no. 0.5 and pressure drop
as per API STD 521.
e) Flare tips shall be connected to the flare stack with gastight connection. The flare
burner shall be easily removable for maintenance purposes.
f) All auxiliary piping connections shall be designed to facilitate easy removal of the
flare burner.
g) Flare tips shall be designed to minimize flame impingement on the outside of the
tip or any other support structure due to wind speed, gas glow or wind direction.
Wind shields shall be provided to prevent flame impingement due to wind speed.
h) Material of construction of the flare burner and flame retention rings shall be as per
Appendix 3E to Technical Specification Part III.
i) Refractory lining for flare tips (if required as per vendor manufacturing standards)
shall be provided.
j) Flare tips shall include Pilot ignition systems.
k) Flare burner shall be provided with Lifting lugs or brackets for installation purposes.
The lifting lugs / brackets shall be designed to handle the load of the flare burner.
l) Retractable davit with lifting tackle shall be provided removal of flare burner for
maintenance purposes where crane accessibility is not possible during plant
operation.
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APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.1.2.3. Flare Burner Piping

a) Flare burner piping shall be designed in accordance with ASME B 31.3.

b) Internal pipe connections shall be either welded or flanged as per manufacturer
standards.
c) Flare piping connection to burner shall be flanged. Flange ratings shall be as
specified in API STD 537.

3.1.2.4. Pilot Ignition System

a) Pilot ignition system shall consist of pilot burners, pilot gas riser, ignition riser, Pilot
flame detectors, High Energy Direct Spark ignition system and Flame Front
Generator system. High Energy Direct Spark ignition system and Flame Front
Generator system shall function as primary and secondary ignition systems
respectively.
b) The number of pilots per flare shall be in as mentioned in process design basis. The
minimum number of pilots for a flare burner shall be two (2).
c) Pilots shall remain lit under severe weather conditions as per API STD 537.
d) Pilot tip components shall be heat resistant and material of construction shall be as
per Appendix 3E to Technical Specification Part III.
e) Pilots shall be designed for the specified fuel supply.
f) Each pilot shall consist of a pilot tip, pilot mixer assembly, pilot gas orifice, strainer,
a dedicated ignition system and mounting brackets.
g) Material of construction of pilot riser and ignition riser shall be as per Appendix
3E-Material Selection Guide.
h) Each pilot shall have two (2) numbers of dual element type retractable
thermocouples for flame detection.
i) Two (2) Infrared Pyrometer based flame monitoring system shall be provided to
monitor the pilot flame of the flare.
j) One stainless steel fuel gas supply line along the stack is required for each pilot
burner.
k) A filter shall be installed between the carbon steel fuel gas supply line to the flare
and stainless steel fuel gas supply lines to pilots.
l) The fuel gas lines tie in shall be flanged at the base of the stack where the Carbon
steel fuel gas piping from the field ignition panel shall be connected.
m) All thermocouples, including spares and temperature transmitters shall be
terminated in Ex ’e’ or Ex ‘d’ certified junction boxes located at the base of the flare
stack. Junction boxes shall be protected by radiation shield.
n) Pilot ignition system shall function safely and reliably during the full operating
range, emergency depressuring and even during a complete power outage in the
plant.
o) High Energy Direct Spark Ignition system and Flame Front Generator ignition
system shall be in accordance with P&IDs, KOC standards and technical
specifications. Monitoring, control and sequencing functions for flare system and
air blowers shall be implemented in flare PLC.
 Page 6 of 8
APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.1.2.5. Purge Gas Seals (Buoyancy Seal)

a) Flare stack shall be provided with a buoyancy seal. A transition section from the
seal to the flanged flare tip connection shall provide unimpeded gas flow to the flare
tip.
b) The seal shall be selected to minimize the purge gas flow rate.
c) The buoyancy seal shall be designed to reduce the possibility of air (O2 level)
accumulating in the flare stack at a low gas (purge) flow rates.
d) Material of construction shall be as per Appendix 3E to Technical Specification
Part III.
e) The Seal shall be provided with lifting lugs designed to safely handle the loads.
f) An inspection port and drain connection shall be provided for the buoyancy seal.

3.1.2.6. Air Assist System

a) For the flare system to be 100% smokeless throughout the flare gas load range air
blowers shall be provided for the flare stack.
b) Blowers shall be selected for the full range from purge gas flow to 100% flare load
as specified in the P&IDs.
c) Air blowers shall be axial flow, vaneaxial type, direct driven two speed electric
blowers complete with inlet filter, trash screens, mufflers, inlet and backdraft
dampers etc.
d) The operation of the air blowers shall be fully automatic with manual override.
Automatic operation shall be through the ultrasonic flowmeters in the flare pipeline.
The Motor speed (low or high) shall control the airflow rate based on the signal
from the flowmeter.
e) The air blowers shall be designed to provide sufficient air for smokeless flaring
throughout the operating range as mentioned in the datasheets.
f) The air blowers shall either be installed directly to the flare stack through flange
connection or through air ducting. For ducted air blowers adequate vibration
isolators shall be provided between the flare stack and the ducting.
g) Provide paved areas below the air blowers attached directly to flare stack to prevent
soil erosion.
h) Vibration switches shall be provided for the Air blowers.
p) Material of construction shall be as per Appendix 3E-Material Selection Guide.
i) Blowers shall be specifically selected for continuous air assisted smokeless
operation. Blowers shall be with Total Enclosed Fan Cooled (TEFC) motors and
suitable for operation for the specified area classification and environmental
conditions.
j) The air assisted system design shall take in to consideration to prevent any possible
leak of the assist air in to the flare gas riser during low flow conditions.
k) The design shall take in to consideration the use of radiation shields for the blowers
to increase life span.
 Page 7 of 8
APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

3.1.2.7. Miscellaneous Items

a) Retractable aircraft warning lights (Aviation Lighting System) shall be mounted on

all flare stacks in accordance with the requirements of relevant International
Standards & practices and the specific requirements given in the Technical
Specification Part IV-Electrical Works. The Flare Stacks shall be suitably
constructed for mounting the aviation lights at appropriate locations. All light
fittings and accessories shall be supplied loose for installation at site.
b) The control system associated with the flare stack shall be connected to DCS in
accordance with Technical Specification Part V – Instrumentation works.
c) The flare stack shall include fixing brackets for the pilot, the pilot gas supply lines,
ignition piping, other piping / tubing and cable trays (150mm) for thermocouple
cables.
d) The caged ladders, platforms and railings as needed shall be included in the supply.
e) All the cables for electrical and instrumentation works for the complete flare system
shall be supplied by the Contractor /Vendor.

3.2. INSPECTION AND TESTING

3.2.1. Inspection & Test Documentation

The following documents in 4 Copies shall be submitted by the Contractor for the
Company review and approval:

 QA/QC Manual
 Manufacture Record Book which shall include the following as a minimum

o Scope of Supply
 Bill of Materials
 Inspection and Test Plan
 General Assembly Drawings
o Procedures
 Welding Procedures
 Pressure Testing and NDE procedures
 Surface preparation and coating procedures
 Functional / Performance Test Procedures
o Certifications
 Certificate of Conformity
 Material Test Certificates
 Material Traceability Certificate
 Welders Certificate
 Heat Treatment Certificates
 NDT Operators Certificate
 Calibration Certificates
 Weight Certificate
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APPENDIX 3A TO TECHNICAL SPECIFICATION PART III
REPLACEMENT OF EXISTING LP & HP NON-SMOKELESS TYPE FLARE WITH SMOKELESS TYPE
FLARES AT NK GCs 15, 23 & 25

o Reports
 Calculations
 Weld Reports
 Pressure Test and NDE Reports
 Electrical Insulation test data and records
 Motor and controller test record/sheets
 Manufacturing Reports
 Functional / Performance Test Reports for the flare stack and the main
auxiliary items.
 Dimensional and Tolerance Records
 As Built drawings

3.2.2. Assembly & Installation Procedures

3.2.3. Contractor's method, arrangement & Tests to check smokeless operation for the entire
range of flare load in accordance with BS 2742 & BS 2742C.
3.2.4. Commissioning and Start Up Procedures

Note: All the Inspection & Test Plans and Procedures shall be submitted at least 30 days prior
to the related activity for Company review and Approval.

3.3. TESTING

The following shall be tested as a minimum for the Flare Stack and auxiliary equipment:

3.3.1. Workmanship, Dimensional Checks and general adherence to the specifications

3.3.2. Pressure Testing
3.3.3. NDE Testing
3.3.4. Insulation Tests
3.3.5. Full operational/functional tests for the flare system including the flare stacks, flare system
main equipment, electrical and instrument items.
3.3.6. Site performance test and commissioning by the Manufacturer along with the Contractor.

Note: All Tests shall be witnessed by the Company and/or the Company approved Third party
Inspector

3.4. PERFORMANCE AND GUARANTEES

The Contractor shall guarantee the performance of the system as mentioned in

Appendix 2A to Technical Specification Part II.