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Flare system
Satish K. Saxena Sept. 2005
System protection
Primary protection Control system Secondary protection Hard wired trip protection
Tertiary protection
Safety valves, rupture disk
Reliving Scenarios
Fire Power failure Steam failure C.W. failure
-
Refrigeration failure Vaporisation in exchangers Overfilling Tube rupture Entrance of volatile liquid Chemical reaction (Run away reaction) Closed outlet
Sept,2005
Liquid expansion
Reliving devices
Emergency de-pressurisation.
i) Safety valves
Types Conventional. Balance bellows. Pilot operated.
Set pressure equals to design pressure/MAWP of equipment. Allowable Back pressure depends upon the type of safety valve. P = 3% of set pressure of safety valve.
Rupture disk
APPLICATIONS:
The use of rupture disk as pressure-relieving device is preferred in the following cases: Where pressure rise is so rapid that the inertia of a safety valve would be a disadvantage. Where minute leakage of process fluid (Toxic, highly inflammable, safety valve opens to atmosphere) cannot be tolerated under operating conditions. Service conditions led to deposition, which can make safety valve inoperative. Cold ambient condition could prevent a safety valve to operate. Solid containing gas makes safety valve inoperable. Corrosive gases spoil the safety valve internals.
---Continue---
Rupture disk
Rupture disk is used as sole safety device in following cases: --Instantaneous relief is required. --As an additional safeguard for pressure relieve.
Following are the applications, where rupture disc is used in series, of safety valve at up-stream. --To protect the safety valve against corrosion. --To prevent leakage of corrosive, toxic and valuable material. --To prevent total loss of material from the system following rupturing of rupture disc. --To protect the safety valve becoming inoperable due to congealing of material.
iii) Emergency
Vapor De-pressurisation
De-pressurisation during fire minimises the risk of failure of equipment even at lower than its design pressure, due to reduction in Yield Strength of its material of construction with increase of wall temperature during fire. De-pressurisation also reduces the risk of increasing the internal pressure of equipment exceeding the Rupture pressure during external fire, thus preventing the occurrence of major leak of hazardous chemicals, which leads to safety and environment hazards. De-pressurisation helps in reducing the wall temperature thus reduces the risk of pre-mature failure of equipment.
All the process equipment, as part of a system, should have atleast total cumulative inventory of 3 to 5 cubic meters of Butane or more volatile liquid under normal operating conditions, shall be provided with remotely operated depressurisation assembly. As per the API-521 (Clause 3.19.1), the release capacity should be such that the continuous vapour depressurisation should reduce the equipment pressure to 50% of its design pressure within 15 minutes. The API-521 (Clause 3.19.1), further states that when fire is controlling contingency, it may be appropriate to limit the provision of depressurisation facility only for the equipment and sections which operate 250 lbs/square inch and above, where the size and volume of a system is significant. The depressurisation is limited to 100 lbs/square inch or 50% of the design pressure, whichever is lower, within 15 minutes time (for vessels with wall thickness 1 or more, thinner vessel requires higher depressurisation rate, means lower than 15 minutes). ---ContinueAker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 11
Controlled de-pressurisation.
Uncontrolled de-pressurisation.
-----Continue----
UN
CO NT RO LL ED
TIME, MINUTES
FIG.3
DEPRESSURISATION TIME
(AREA UNDER BOTH THE CURVES WITHIN THE STIPULATED TIME ARE SAME, MEANS VOLUME HANDLED ARE SAME)
Controlled de-pressurisation
FLARE HEADER
FB LO
SCRUBBER
PROGRAMMED LOGIC CONTROL THE OPENING OF "CV" MAINTAINS CONSTANT FLOW AT ALL UPSTREAM PRESSURE
FC CV XY S ZO ZSO PIC ZC ZSC SDV IA XV PY
PSV
PSV
FUEL GAS
FC
CW
XV
CONDENSER
LIC IA XV S ZO IA ZSO ZC SDV ZSC LY
LIMIT SWITCH
ZO ZSO ZC ZSC
SDV
ACCUMULATOR
FEED,
FC LY
LP STEAM
FC
CONDENSATE
EXCHANGER
LG
LIC
LAH LAL XV S
IA
LIC
WATER
FC
FLASH VESSEL
FIG. 2
PUMP
CONTROLLED DEPRESSURISATION
Uncontrolled de-pressurisation
FLARE HEADER
FB LO RO ZC ZO
ZSC
XV
PY
IA
FO PSV SDV
FUEL GAS
FC
CW
XV
CONDENSER
LIC IA XV S ZO IA ZSO ZC SDV ZSC LY
LIMIT SWITCH
ZO ZSO ZC ZSC
SDV
ACCUMULATOR
FEED,
FC LY
LP STEAM
FC
CONDENSATE
EXCHANGER
LG
LIC
LAH LAL XV S
IA
LIC
TRIP LOGIC CLOSES ALL THE INCOMING/OUTGOING STREAMS BUT OPENS THE BLOW DOWN "SDV" VALVE FOR DEPRESSURISATION
WATER
FC
FLASH VESSEL
FIG. 1
PUMP
UNCONTROLLED DEPRESSURISATION
C.W. FAILURE FIRE PROCESS UPSET Depressurisation Unit no. T/HR MW TEMP T/HR MW TEMP T/HR MW TEMP T/HR MW TEMP 1 UNIT A 2 UNIT B 3 UNIT C
* IT IS NOT NECESSARY THAT IF MASS FLOW IS HIGHER, THE FLARE LOAD WILL BE GOVERNING.
Vapor and liquid relief from safety valve and rupture disk.
De-pressurised vapors.
Any operational inflammable waste stream does not have suitable outlet.
Release occurs only in extreme emergency conditions. Release vapor / gas is lighter than Air (< 0.9 times the air). No risk and consequences of accidental flame ignition. Concentration of toxic / corrosive components in dispersed clouds do not reach in harmful level. Condensation of corrosive vapor should not occur. Stream should be free of liquid. Hot gas venting should not ignite.
Impact of environment. Safety and integrity of disposal system (Products are not
combustible).
Release at various pressure levels, economic reasons to reduce the size of flare headers, sub-headers and stack. Widely differing potentials for liquid release. Corrosive and non-corrosive streams. Meet plant layouts / economics. Cold dry gas with wet gas. Contents of one stream may react with contents of other stream led to chemical reactions, producing heat.
Because off:
H2S spread in entire flare network, shall call for NACE materials for entire system. H2S attack on the CS will make Pyrophoric substance that can lead to fire hazard in presence of explosive mixture (Auto ignition temperature is very low for Pyrophoric substance).
Oxygen forms explosive mixture with hydrocarbons, leads to explosion, if fire source is available.
Oxygen converts H2S in elemental sulfur that plugs, obstruct free flow of gas. As well,H2S produces Pyrophoric substance by reacting with pipe material. If Oxygen laden H/C gas ,already in explosive range, pass can create fire hazards either due to pyrophoric substance or by Static electricity.
Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 22
1:200 B.L
1:200
F.G PURGE
WATER
H/C
K.O DRUM
FLARE STACK
FUEL GAS
Flare stack.
Liquid seal. Flame front generator.
Knock-out drum.
Flare header and sub-headers.
Glaring: Causes inconvenience to the surrounding population and feeling of unnecessary waste of resources. Noise: Causes inconvenience to the surrounding population and prolonged exposure to excessive noise may cause mental irritation, fatigue and even deafness.
Radiation: Effects the surrounding population, properties and vegetation, also effects the working of operating staff in near vicinity.
Ground level concentration (GLC) : Long term effects of toxic, combustion products on population, structures and plant and animals. Smoke: Causes considerable amount of environmental pollution.
Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 25
dBA
8 90
dBA
85
4
2 1 0.5 0.25
95
100 105 110 115
90
95 100 105 110
OSHA Occupational Safety and Health Administration. NIOSH National Institute of Occupational Safety and Health.
Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 26
Conditions/exposure times as per API-RP-521(1) Continuous exposure of personnel Emergency action lasting for several minutes without proper clothes Bruzutowski & sommer 2 hrs.
500
1500
2000
Period of measurement
8 hrs average 1 hr average
Annual arithmetic avg. mean 24 hrs. avg. Annual geometric mean 24 hrs avg.
Conventional : Conventional
flare consists of pipe stack with flare tip and pilot at top. The kinetic energy of the gas does not aid to air mixing for improving the burning efficiency.
injected from a narrow slot follows a profile of curved surface. The tulip of coanda profile aids in formation of hollow cylinder of gas entrains air up to 20 times of gas volume helps in efficient burning. This creates both turbulence and sucking of air.
Jet Mix flare :- These are multiple nozzles and arms. The flare gas is
spread out to the ambient air at high velocity promoted rapid turbulence mixing with air and thus produces efficient burning.
Air Assisted flare:- These are provided with special mixing heads. Air
is blow into the stack through a concentric pipe results in turbulence mixing of air, ensuring efficient burning. --Continue--Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 29
Flare tips
BURNER
AIR
AIR
CONVENTIONAL TIP
This flare achieves the smokeless capability by mixing steam with the effluent. The steam is introduced at various points to suck secondary air and turbulence to improve mixing. The steam also reduces flame temperature by dilution and thus reduces the thermal radiation.
CnH2n+2
Flare tips
STEAM NOZZLE WIND SHIELD JET-MIX NOZZLE
STEAM
L.P. GAS
COANDA PROFILE
SLOT
STEAM
STEAM
FLARE GAS
INDUCED TANK
INLET
LABYRINTH SEAL
AIRRESTOR SEAL
AIR
SEAL
DRAIN
PURGE GAS
FLUIDIC SEAL
INLET DRAIN
MOLECULAR SEAL
API RP-521 recommends sizing should be based on gas flow area 3 Times inlet pipe cross sectional area.
4
DdSept,2005 Page 38
( D d ) 3.
2 2
Disengaging height 2 to 3 Times the diameter. Minimum seal height: 4 w.c. Pipe height = 10 feet. Slotted / V-Notches dip tube controls surging flow. Seal height : 1.75 Times the back pressure. Design pressure = 7.0 kg/cm2g, Design temperature = As per header design.
Knock-out drum
Liquid from the flare gas is required to be separated out before it is routed for flaring because: Liquid particles 90 burn in flare unnoticed except marginally change in flame colour.
D2
W 360 (dL dV ). M .P / T
Length : ---Decided on liquid hold up basis. ---Normally 10 minutes Hold-up for liquid, removed by pump, on/off operations. Design pressure : 7.0 kg/cm2g, withstanding internal explosion. Design temperature :
IGNITION AUTO/MANUAL
ON PB OFF POWER
CONROL PANEL
IGNITION PG
PURGE
1/2"
1" TO PILOTS WINDOW
PLANT AIR
All the dead ends of flare sub-headers / main header requires gas purging. The dry gas seal also requires continuous purging to avoid air ingress in the flare header due to chimney effect and during vacuum pulling. Normally gas for purging should be heavier than the air. The rate of purge flow should be sufficient to overcome any tendency of Flash back (1.0 fps min with H/C and up to 10.0 fps for hydrogen. Higher purge is required for the hydrogen because it has highest Flame propagation velocity). ----- Continue--Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 45
In order to control the purge rate, a sample point is provided below the dry gas seal to monitor the oxygen content. As per API-521, oxygen should be less than 6%V. Any increase in oxygen content calls for increase in purging rate. Purge gas lighter than air is more effective than heavier gas. In case of heavier than air purge gas, there is no buoyancy mechanism causing air entry into the stack, and there is thus no incentive to include a dry gas seal.
PSH
0.8 MMSCFD
Flash Gas Recovery Comp. 29 psig 1st Stage FGC
PSH
LP 1 MMSCFD
HP
PSH
?? MMSCFD
LP ?? MMSCFD
?? MMSCFD
HP
Glaring: Controlled combustion inside the enclosed chamber, invisible from outside.
--Continue--
Noise: - Enclosed chamber is provided with noise insulation from outside, which arrests noise emission from the burning. Radiation :-Enclosed chamber provided with refractory inside, acts as the barrier, does not allow heat radiation at outside working area. Ground Level Concentration:- Chimney at the top of box flare and controlled complete combustion helps in controlling the GLC rising above the dangerous level. Smoke :- Combustion is controlled by stages to ensure that gas should burn completely. Besides, there is check to divert the excess gas above its capacity towards elevated flare, thus ensures no smoke to emit from box flare.
Aker Kvaerner Powergas Pvt. Ltd.
Sept,2005 Page 52
Box flare
BOX FLARE
FLARE TIP
ELEVATED STACK
WATER
K.O DRUM
SEAL DRUM
WATER
ELEVATED FLARE
PIC
WATER
PIC
PIC
CLOSED CHAMBER
THANK YOU