Oil & Gas Processing Plants

Design and Operation

Training Course

DGEP/SCR/ED/ECP ~ 6th - 17th October 2003

Oil & Gas Processing Course
1
 Relief and Blowdown System

DGEP/SCR/ED/ECP ~ 6th - 17th October 2003

Oil & Gas Processing Course
2
INTRODUCTION

In all production plants, at least one flare system is installed.

The flare system is important to release in safe conditions the

excess fluid in normal operation and also in case of over
pressure.

The flare system is an important parameter for the plot plan.

Description, sizing and installation recommendation.

The following shall be considered as a guide.

The design criteria and recommendation are only one approach.

Some parts of the flare system such as flare tip and ignition
system are proprietary equipment and must be carefully
checked.
Oil & Gas Processing Course
3
CODES AND STANDARDS

API RP 520 : Sizing, Selection and Installation of Pressure Relieving in

refineries

Part 1 - Sizing and selection

Part 2 - Installation

API RP 521 : Guides for Pressure Relieving and Depressuring Systems.

API RP 526 : Flanged Steel Safety Valves.

API PR 14C : Recommended Practice for Analysis, Installation, and

production platforms.

API RP 14E : Design and Installation of Offshore Product Platform Piping

System.

API Std 2000 : Venting atmospheric and Low Pressure Storage tanks
(non refrigerated and refrigerated).

Oil & Gas Processing Course

4
FLARE SYSTEM DESCRIPTION

RELIEVING DEVICES
- Pressure relief valves,
- Rupture discs,
- Blow down valves,
- Control valves.
SUB-HEADERS AND HEADERS
FLARE DRUM
SEALING DEVICES
- Purge gas,
- Water seal,
- gas seal.
DISPOSAL DEVICES
- Cold vent
- Burning tip
- Liquid burner
- burn pit

Oil & Gas Processing Course

5
RELIEF DEVICES

GENERAL DEFINITION
- Maximum allowable pressure ( MAWP )
- Set pressure
- Accumulation
- Back pressure
PRESSURE RELIEF DEVICES
- Pressure safety valves
conventional type
Balanced type
Pilot operated type
RUPTURE DISCS
BLOW DOWN VALVES
PRESSURE CONTROL VALVES ( PCV )
REMOTELY OPERATED VALVES ( HIC, XV, ROV )

Oil & Gas Processing Course

6
PRESSURE SAFETY VALVES

3 TYPES
-CONVENTIONAL
The popping pressure depends partly on the back pressure

Its use is limited to a back pressure less than 10% of the set pressure of
the relief valve

-BALANCED
The popping pressure is independent of the back pressure

The back pressure should be limited to 50% of the set pressure of the
relief valve

-PILOT OPERATED
As balanced type but allows smaller valves bodies

Oil & Gas Processing Course

7
SEGREGATION OF FLUIDS TO BE FLARED

THE NUMBER OF FLARE OR COLD VENT SYSTEM DEPENDS ON :

-The Process scheme
-The characteristics of the fluids
MAIN CRITERIA
-Pressure level
-Operating system :
wet
dry
cold
-Corrosivity
-H2S concentration ( above 10% mole )
-Relieving capacity
-Economical considerations
-Plot plan
-Maintenance / operating philosophy

Oil & Gas Processing Course

8
HEADERS AND SUB-HEADERS

TWO TYPES OF LINES

- Lines upstream the relief devices
- Lines downstream the relief devices which form sub-headers and headers

LINES UPSTREAM THE RELIEF DEVICES

- Self-drainable to the protected capacity without pocket and low point

- For PSVs, line diameter at least equal to the inlet PSV nozzle; short as
possible; pressure drop shall not exceed 3% of the PSV set pressure for
the maximum discharge flow rate to avoid " chattering
- For BDVs, the diameter of the line shall be at least 2

Oil & Gas Processing Course

9
HEADERS AND SUB-HEADERS

LINES DOWNSTREM THE RELIEF DEVICES

- Continuous slope ( 2 mm per m )

- All relief devices installed in high point
- Large enough to avoid excessive back pressure
- From PSV discharge line should be at least one diameter greater than PSV
outlet nozzle
- Block valves, check valves, flow orifice are not installed on flare headers and
sub-headers
- Number of headers and sub-headers are function of the fluid segregation, plot
plan, material selection.

Oil & Gas Processing Course

10
FLARE DRUM

The flare drum ensures liquid separation for the following :

- To prevent liquid accumulation
- To minimise the risk of burning liquid ( golden rain )
- To recover and reclaim valuable products
One flare drum for each pressure level
Located at low point of the system
Generally installed horizontally
Internals on gas side is forbidden
Design pressure at least 1 bar higher than the maximum back pressure at
the design flow rate, minimum design pressure 3.5 bar g.
Vapour space for sizing taken at the high high level
For large diameter, horizontal drum with a split flow arrangement could be
used
Heating coils
High high level always installed

Oil & Gas Processing Course

11
SYSTEM TO BURN OR RELEASE THE GAS AND / OR LIQUID

To burn or release the gas and / or liquid, different systems can be

user, they are :
-FLARES TIPS
pipe flare
sonic flare
ground flare ( multiple-tips )
combustion chamber

-COLD VENT

-BURN PIT

-BURNER ( mainly for liquids )

Oil & Gas Processing Course

12
FLARE TIPS

PIPE FLARE

- Maximum exit velocity :

0.5 to 0.6 Mach for emergency flow
0.3 Mach for continuous flow
- Variations of the simple pipe flare tip :
Forced draught ( air assisted )
With water injection
With high pressure gas injection
With steam injection

Oil & Gas Processing Course

13
FLARE TIPS

SONIC FLARE
- Exit gas velocity is > 1 Mach
- Back pressure 2 to 10 bar
- Each manufacturer has its own design
Main manufacturers
AIR OIL
BIRWELCO
EET
JOHN ZINK
KALDAIR
Variables slots shall not be used

Oil & Gas Processing Course

14
SONIC FLARE

ADVANTAGES AND DRAWBACKS

- ADVANTAGES
Lower radiation due to lower emissivity coefficient

Higher back pressure smaller headers, sub-headers and flare drum

- DRAWBACKS
More maintenance

Flare tip heaviest

More noise

Cost ( more expensive )

Low pressure flare could not be connected to sonic flare due to back
pressure. In this case a separated low pressure flare system is required
or combined with the sonic tip, the LP flare being installed in the center
of the sonic tip.

Oil & Gas Processing Course

15
GROUND FLARE

MULTIPLE TIPS
- Not recommended

WITH COMBUSTION CHAMBER

- Burner forced draught installed inside a chimney
- Installed :
Onshore local environmental problems or space
Offshore on FPSO space
- ADVANTAGES
Low radiation levels and less space
No visible flame
Less noise

Oil & Gas Processing Course

16
GROUND FLARE

- DRAWBACKS
High cost
Weight
Limited to a relatively small flow
No visible flame for operation point of view
Air blower to be continuously run
Maintenance of air blower, burner and fire resistant material of the
chimney
- The sizing can be performed only by the vendors

Oil & Gas Processing Course

17
COLD VENT

A cold vent is similar to a flare but the gas is released to atmosphere

and not burnt

The cold vent height is governed by dispersion calculations and in

any case admissible radiation levels in case of accidental lighting

The cold vent is fitted with :

- either a sonic tip ( as for flare tip )

- or a pipe flare tip ( as for flare tip ) but without the device for the flame
stability. The gas velocity through the tip is to be about 0.8 Mach in order
to achieve a good dispersion of the gas to atmosphere.

Oil & Gas Processing Course

18
BURN PIT

The burn pit consists of :

- A pit
- A pipe feeding the pit by gravity
- Burner and pilots
The burn pit is used to burn off spec. Liquids and liquids from wells clean-
up. Not used to burn liquids in continuous for a long time.
The combustion of the liquid is very bad with a lot of smoke
When the space is not a problem, it could be used to replace an elevated
flare (desertic countries). In this case the advantages and drawbacks are :
- Advantages
No need of flare drum if permitted by layout
Easier to installed and to do the maintenance of the tip
- Drawbacks
Large pit and civil work
Smoke problem
Refractories to be installed on the pit
Dispersion calculations are subject to discussion

Oil & Gas Processing Course

19
PURGE GAS SYSTEM

When the flow of gas through a flare or cold vent stack reduces to very low or
no flow, air ingress from the mouth of the stack to form an explosive mixture in
the stack or flare header.It is normal to avoid this hazard by continuous
blending a small flow of oxygen-free hydrocarbon or inert gas ( purge gas )
through the stack to deter air ingress. For a flare that can also initiate a risk of
burn back which induces a quickest deterioration of the tip.

When using a purge gas with a molecular weight below the molecular weight of
air ( 29 ) a large part of the flare piping could be under partial vacuum.

The purge gas is generally a produced gas such as fuel gas.

It is recommended to used the heaviest gas molecular weight as the flare

purge gas.

Nitrogen with a purity at least of 95% can be used as an alternative source.

The purge gas must be injected at the beginning of the largest flare headers
and sub-headers in order to purge the whole flare system.

Oil & Gas Processing Course

20
HYDRAULIC AND GAS SEALS

To reduce the purge gas flow, a seal system can be installed.

Two main systems of seals exist :
- Hydraulic seals

bottom of the flare stack

Horizontal water seal drum located not so far from the flare stack

- Gas seals

static inverted seals

dynamic baffle seals

double purge baffle seals

Oil & Gas Processing Course

21
FLARE SEAL SYSTEM

MOLECULAR SEAL
- Not to be used with sonic flare tip
- Needs some operational attendance ( particular periodic
draining )
FLUIDIC SEAL
- Could be used with a sonic flare
WATER SEAL DRUM
- Not to be used with a sonic flare due to the back pressure
- Needs some operational attendance ( check of water levels )
- To be avoid in cold countries

Oil & Gas Processing Course

22
PILOTS AND IGNITION SYSTEM

PILOT BURNERS
Pilot burners are provided to ensure a continuous ignition source at the
flare tip.
The design is done by the flare vendor but typical figures are :
Tip diameter Nb of pilots
8 and below 2
10 - 36 3
Greater than 36 4
Gas consumption per pilot burner is typically 8 to 10 Nm3/h.
One individual line per pilot.

PILOT IGNITION
Generally, flame propagation type. It is designed by flare vendor.
Manual system.
Special gun.

Oil & Gas Processing Course

23
FIELDS OF APPLICATION

ONSHORE

- Generally elevated flare with pipe or sonic tip.

- Ground flare with combustion chamber if the local regulations do not permit to
have a visible flame.
- For the disposal of off-spec. Liquids burn pit or liquid burner.

Oil & Gas Processing Course

24
FIELDS OF APPLICATION

OFFSHORE

- For installation of flare or cold vent, the following possibilities can be

envisaged :
elevated on the platform

inclined boom

remote, connected to the platform by bridge or with a sealine

- The choice between these possibilities requires economical and risk

analysis studies and depends on :
the relieving capacity

the sea water depth

- On FPSO, ground flare with combustion chamber if it is not possible to

install an elevated flare.
- For well clean-up and off-spec. liquids liquid burner.
Oil & Gas Processing Course
25
SIZING CRITERIA

FLARING FLOW RATE

- Determination of individual relieving rates
- Loads summary

RADIATION LEVEL AND DISPERSION

- Position and height

LINES SIZING

FLARE DRUM

PURGE GAS

Oil & Gas Processing Course

26
DETERMINATION OF INDIVIDUAL RELIEVING RATES

POSSIBLE CAUSES
- Blow down
- Blocked outlet
- Fire
- Blow-by
- Loss of power
- Loss of cooling
- Loss of reflux
- Excessive heat input
- Loss of control ( instrument air, power, )
- Heat exchanger tube rupture
- Etc.

Refer to API RP 520 Part I and API RP 521

Oil & Gas Processing Course

27
HEAT RADIATION LEVELS

FLARE AND COLD VENT

HEAT RADIATION LEVELS PERMIT TO DETERMINE :
- Flare height
- Sterile, prohibited and impacted areas
HEAT RADIATION CACULATION FACTORS
- Maximum relieving flow rate
- Flaring fluid composition and temperature
- Wind velocity
- Wind direction
- Solar radiation
- Emissivity factor
- Relative humidity
- Occurrence with other flares ( if any )

Oil & Gas Processing Course

28
HEAT RADIATION LEVELS

CALCULATION METHOD API RP 521

- Recommended BRZUSTOWSKI and SOMMER

- Radiation levels calculated are not exactly those given by vendors

Oil & Gas Processing Course

29
ACCEPTABLE RADIATION LEVELS INCLUDING SOLAR RADIATION

Location Blow down = short Blocked outlet = more

peak duration than 10 minutes

Steril area = no equipment 3 000 btu/hr.ft 3 000 btu/hr.ft

Flare drum 2 000 btu/hr.ft 1 500 btu/hr.ft

Process equipment 1 500 btu/hr.ft 1 000 btu/hr.ft

Continuously manned 1 000 btu/hr.ft 550 btu/hr.ft

Oil & Gas Processing Course

30
EMISSIVITY COEFFICIENT

ALL THE HEAT RELEASED IN A FLAME IS NOT COMPLETELY

TRANSITTED AS RADIATION

PRESENCE OF LIQUID INCREASES THE EMISSIVITY FACTOR

RECOMMENDED EMISSIVITY COEFFICIENT

- For pipe flare :
Natural gas molecular weight of 18 : 0.21
Natural gas molecular weight of 21 : 0.23
Ethane : 0.25
Propane : 0.30
See also API RP 521
- For sonic flare :
All gases without liquid carry-over : 0.13
All gases with liquid carry-over, 5%wt. : 0.15
EMISSIVITY COEFFICIENT USED BY VENDORS SHALL BE CHECKED.

Oil & Gas Processing Course

31
AIR HUMIDITY

AIR HUMIDITY REDUCES SLIGHTLY THE HEAT INTENSITY

TRANSMITTED AND CONSEQUENTLY THE RADIATION LEVELS.

AIR HUMIDITY IS EXPRESSED IN PERCENT OF THE RELATIVE AIR

HUMIDITY.

FOR RADIATION LEVELS IT IS RECOMMENDED TO USED THE

MINIMUM RELATIVE HUMIDITY STATED ON THE BASIS OF DESIGN
( METEOROLOGICAL DATA ).

Oil & Gas Processing Course

32
LINES SIZING

CRITERIA

- Velocity

- V

- P for upstream relieving devices

- Back pressure for downstream relieving devices

Oil & Gas Processing Course

33
LINES UPSTREAM RELIEVING DEVICES

PSVs
The maximum capacity of PSV shall be considered.
P between the protected equipment and the PSV < 3% of the PSV set
pressure.
PSV inlet size.
V 25 000 kg/m/s for 2.
V 30 000 kg/m/s for P 50 bar g.
V 50 000 kg/m/s for P > 50 bar g.

BLOW DOWN DEVICE

Minimum line size : 2
V criteria : the same as for PSVs.

Oil & Gas Processing Course

34
LINES DOWNSTREAM RELIEVING DEVICES, FLARE AND COLD VENT
HEADERS AND SUB-HEADERS

MINIMUM LINE SIZE : 2

BACK PRESSURE

VELOCITY AND V

Monophasic ( gas ) :
intermittent flow :
Lines downstream relieving devices and sub-headers :
0.7 Mach maxi. and V < 150 000 kg/m/s considering the
maximum capacity of the relieving device and the relevant
occurrence.
Headers :
0.7 mach maxi. and V < 150 000 kg/m/s considering the
maximum flow rate due to process limitations and for the
relevant occurrence, however, a velocity of 0.8 Mach can be
accepted for long straight line without bends and connections.
For V > 100 000 kg/m/s vibration and line support studies are
required.

Oil & Gas Processing Course

35
LINES DOWNSTREAM RELIEVING DEVICES, FLARE AND COLD VENT
HEADERS AND SUB-HEADERS

VELOCITY AND V

- Monophasic ( gas ) :
Continuous flow :
Velocity < 0.35 Mach maxi. and
V 50 000 kg /m/s.
- Multiphase :
Velocity < 0.35 Mach maxi. and
V 50 000 kg /m/s.

Oil & Gas Processing Course

36
TERMS DEFINITIONS

Mach = velocity (m /s) / sonic velocity (m/s)

Sonic velocity in m/s = 316*(K*P/)0.5
K = Cp/Cv
P = pressure in bar abs.
= density in kg/m3
m = mean density of the mixture in kg/m3
= ( M gas + M liq. ) / ( Q gas + Q liq. )
M is in kg/h
Q in m3/h at actual conditions
Vm = velocity of the mixture in m/s
= ( Q gas + Q liq. ) / ( 3 600**D/4 )
d is the line diameter in m

Oil & Gas Processing Course

37
FLARE DRUM

For flare and cold vent, the drum sizing follows API RP 521 method
with the following droplets size in microns :

Vertical flare or cold vent onshore : 600

Vertical flare or cold vent on platform

> 45 from horizontal : 150

45 from horizontal : 400

Remote flare or cold vent offshore : 600

Oil & Gas Processing Course

38
PURGE GAS

Vendors underestimate the purge gas flow rate

Purge gas flow rate should not be lower than the following value :
- Without gas seal :
Purge gas flow rate = 2 4000*D3*MW - 0.565
- With gas seal :
Purge gas flow rate = 1 2000*D3*MW - 0.565
Purge gas flow ( Sm3/h )
D is the tip internal diameter ( m )
MW is the purge gas molecular
weight ( kg/kmole )
The heaviest available gas should be preferably used as the
normal source of purge gas to minimise vacuum
The purge gas system ( lines, valves, .. ) shall be oversized.

Oil & Gas Processing Course

39
VAPOUR DEPRESSURISATION ( BLOW DOWN )

A VAPOUR DEPRESSURISATION SYSTEM IS MANDATORY on equipment ( or

piping ) containing hydrocarbons that can be both isolated and exposed to fire
simultaneously.

FLUID BLOW DOWN CRITERIA

Flammable gas P > 7 bar g AND PV > 100 bar.m3
Liquid HC No
Two phase P > 7 bar g AND PV gas > 100 bar.m3
Liquefied HC M gas or M liq > 2 tonnes of C4 and more volatile
Toxic gases As required for the protection of personnel

FINAL PRESSURE : 7 bar g considering the fire heat input or 50% design
pressure considering no fire heat input, whichever the most stringent.
DEPRESSURISATION TIME : by default 15 minutes for piping and equipment
containing both gas or liquid and 8 minutes for equipment containing LPGs or
light condensate.

Oil & Gas Processing Course

40
INSTALLATION

PRESSURE SAFETY VALVES

RUTURE DISCS

BLOW DOWN DEVICE

HEADERS AND SUB-HEADERS

- No low points, continuous slope

- Block valve; no check valve
- Flow orifice or flow meter
- Connections preferably on the top of the header and sub-header
- Connections at 45 except for small diameter until 4
TYPICAL ARRANGEMENT AROUND A FLARE DRUM

PURGE GAS TYPICAL

Oil & Gas Processing Course

41
CONVENTIONAL PSV s DESIGNATION

Orifice Letter Effective area Inlet nozzle Outlet nozzle Designation

Sq. inches inches inches
D 0.110 1 2 1D2

E 0.196 1 2 1E2

F 0.307 1 2 1F2
1 2 1F2

G 0.503 1 2 1G2
2 3 2G3
H 0.785 1 3 1 H3
2 3 2 H3

2 3 2J3
J 1.287 2 4 2J4
3 4 3J4

K 1.838 3 4 3K4
3 6 3K6

Oil & Gas Processing Course

42
CONVENTIONAL PSV s DESIGNATION

Orifice Letter Effective area Inlet nozzle Outlet nozzle Designation

Sq. inches inches inches

L 2.853 3 4 3L4
4 6 3L6

M 3.600 4 6 4M6

N 4.340 4 6 4N6

P 6.379 4 6 4P6

Q 11.045 6 8 6Q8

R 16.000 6 8 6R8
6 10 6 R 10

T 26.000 8 10 8 T 10

Oil & Gas Processing Course

43