ONSHORE

and
OFFSHORE

Technical Presentation
ONSHORE and OFFSHORE
FLARE SYSTEM DESiGN

THE FLARE A KEY COMPONENT

The flare is a key component of the closed emergency
release system.
Emergency releases from various sources are routed
through a blow-down drum to separate liquids.
Flare provides safe disposal for personnel and
equipment.
Reduce environmental pollution (smoke, noise, light) by
correct flare system design.

FLARE SYSTEM DESIGN

Capacity and Sizing:
Largest vapour release or combination;
Maximum allowable back pressure on relief valves;
Consider pressure drop through system from relief valve
to flare tip;
Generally limit tip exit velocity to Mach 0.5 onshore (LP)
and Mach 1.0 offshore (HP);
For H2 or inert rich gases limit exit velocity;

FLARE SYSTEM DESiGN

Flare Location and Height:
Predominantly based on radiation;
In some cases toxic gas dispersion;
Radiation:
Limits based on personnel tolerance
500BTU/h.ft2 (1.6kW/m2) Continuous
1500BTU/h.ft2 (4.7kW/m2) Emergency
Solar to be added where appropriate.

Thailand - TOC

KSA - IBN-ZAHR

Khursaniyah SAUDI ARAMCO

OFFSHORE

ONSHORE

GBA SOLUTiONS

Statoil Snorre TLP

Sendje Ceiba FPSO

Exxon Falcon FPSO

ONSHORE

ONSHORE FLARE SYSTEMS

Refineries, Chemical Plants, Oil
Terminals, LPG Terminals,
Steelworks;
Flare System operates at low or near
atmospheric pressure;
Often release high molecular weight
gases that produce smoke;

ONSHORE

TYPiCAL ONSHORE FLARE P&ID

OFFSHORE FLARE SYSTEM

OFFSHORE

Oil and Gas Production Facilities

Platforms, FPSOs and Pipeline
Terminals
Primarily high pressure flare
systems with some associated
low pressure
Low molecular weights less
prone to smoke

OFFSHORE

TYPiCAL OFFSHORE FLARE P&ID

OFFSHORE FLARE TiPS

OFFSHORE

General Purpose low pressure streams

Pipeflare
High Pressure Sonic
Multi-Nozzle (each nozzle with annular gas exit slot
for greater efficiency)
Single Nozzle open pipe
Variable Slot multi-nozzle low radiation and
smokeless from purge to maximum
Water injection to reduce radiation
AirLock seals included in all tips

OFFSHORE
ONSHORE

TYPiCAL RADiATiON PLOTS

ONSHORE

OFFSHORE

OFFSHORE
ONSHORE

FLARE SYSTEMS
Elevated Flare
Derrick Structure
Guyed Riser
Guyed Derrick
Self Support
Ground Flare
Enclosed
Open
Burnpit
Gas and Liquids

OFFSHORE
ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

OFFSHORE
ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

OFFSHORE
ONSHORE

FLARE TiPS
General Purpose
Pipe flare
Smoke Suppression
Steam assist
Air assist
Gas assist
High Pressure
Sonic

FLARE TiPS
PIPE Flare

OFFSHORE
ONSHORE

PF model

Low Velocity Acid Gas

FLARE TiPS
Steam Assist - Smoke suppression

OFFSHORE
ONSHORE

GCT-C STEAM ASSiSTED model

GCT-30C

FLARE TiPS
Steam Assist - Smoke suppression

OFFSHORE
ONSHORE

GAJ-C LOW NOiSE SMOKELESS model

FLARE TiPS
Steam Assist - Smoke suppression

OFFSHORE
ONSHORE

GAJ-AJ-C HiGH CAPACiTY SMOKELESS model

GCT-AJ-54/48-C

FLARE TiPS
Air Assist - Smoke suppression

OFFSHORE
ONSHORE

CAF model

FLARE TiPS
Gas Assist - Smoke suppression

OFFSHORE
ONSHORE

PF-GA model

FLARE TiPS
High Pressure - Sonic

OFFSHORE
ONSHORE

CSF model

SONiC FLARE

OFFSHORE
ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

AiR INGRESS SEALS

AiR LOCK SEAL / MOLECULAR SEAL

To prevent flash back and internal

explosion;

Air
Air Lock
Seal

Air can enter through the flare tip;

Inlet

upstream flare
tip
Outlet

Add an air ingress seal to reduce

purge;
Drain
Inlet

Hand
Hole

Molecular Seal

Purge with hydrocarbon or inert

gas;

Air Lock Seal

OFFSHORE
ONSHORE

within flare tip

AiR INGRESS SEALS

OFFSHORE
ONSHORE

AiR LOCK SEAL / MOLECULAR SEAL

Air Lock Seal

Molecular Seal

ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

STRUCTURAL SUPPORTS

ONSHORE

Self-support short stacks, not economic for SS

risers
Guy wire supported riser most economic
Good for heights up to 150m
Limited by differential process temperature
maximum DT~200/300oC
Guy wire supported derrick;
Derrick
Fixed riser
Demounting risers

STRUCTURAL SUPPORTS

ONSHORE

Self-Support

STRUCTURAL SUPPORTS

ONSHORE

Guy wire supported Riser

STRUCTURAL SUPPORTS

ONSHORE

Guy wire supported Derrick

STRUCTURAL SUPPORTS
Derrick

ONSHORE

FIXED RISERS

STRUCTURAL SUPPORTS
Derrick

ONSHORE

DEMOUNTING RISERS

STRUCTURAL SUPPORTS
Derrick

ONSHORE

DEMOUNT STRUCTURE

Multiple flares in one

derrick
Individual flares can be
demounted to access
flare tip for maintenance
Highest flares in world at
204m
(3 derricks for Finaneste,
Antwerp)

STRUCTURAL SUPPORTS
Derrick

ONSHORE

INSTALLATION SERVICES

ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

ONSHORE

WATER SEAL
Provide
Positive seal against air ingress
into header
Flashback prevention
Maintain flare header at positive
pressure
Horizontal or vertical

Manway

Flare Gas Inlet

Water Inlet

Sized to prevent water carryover

except in emergency
fast water make-up required.

Level Inst.
Level Inst.
WL
Level Inst.
Level Inst.

Water
Overflow

Steam In
Steam Out

Internal design critical

to prevent pulsation

Drain

DIA

ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

ONSHORE

KNOCK-OUT DRUMS
Designed to
remove large liquid
droplets that
cannot be burnt by
the flare tip.
Return liquids to
the process or
drain.

Flare Gas Outlet

Flare Gas Inlet

Manway
Pressure
Gauge
Conn.

Temperature Inst.

Level Inst.
Level Inst.

Site as close as
possible to the flare
stack.

LL
Level Inst.
Level Inst.

288
Drain

DIA

No internals that

OFFSHORE
ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

SMOKE EMiSSiON CONTROL

Ringelmann Index

OFFSHORE
ONSHORE

THE PROBLEM

Long smoke plume in typical light wind conditions

Ringelmann 0

SMOKE EMiSSiON CONTROL

Ringelmann Index

OFFSHORE
ONSHORE

THE PROBLEM

Ringelmann 1

Ringelmann 2

Ringelmann 3-4

Ringelmann 4-5

SMOKE EMiSSiON CONTROL

Steam Control system

OFFSHORE
ONSHORE

THE SOLUTION

Accurate control of steam will:

Minimise smoke emission;
Minimise noise emission;
Minimise steam consumption;
Avoid over steaming & possible loss of flame.

Use Infra-red monitor to

provide closed loop steam
control based on flame
condition,
rather than flow/density
measurement.

SMOKE EMiSSiON CONTROL

Air Assist system
THE SOLUTION

OFFSHORE
ONSHORE

Low pressure fans

Axial for low capacities
Centrifugal for high capacities

Air flow control

2 speed motor gives 10% and
100%
Variable speed drive (VSD)
Inlet vane control
Multiple fans 2 x 50%

Duty / standby
2 x 100% or 3 x 50%

OFFSHORE
ONSHORE

FLARE SYSTEM COMPONENTS

Flare tip
Air ingress seal
Structural supports
Water seal
Knock-out drum
Smoke emission control
Ignition system

OFFSHORE
ONSHORE

IGNiTiON SYSTEM
Flame Front Generator [F.F.G.]
Manual
Automatic
High Energy Ignition [H.E.I.]
Automatic easy
Ballistic Spark Ignition
Pilot Monitoring
Thermocouples
Flame ionisation rod
Infra-red camera

IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system

OFFSHORE
ONSHORE

Mix gas and air in correct ratio (10:1);

Fill ignition line with gas/air mixture (allow several
minutes);
Generate spark from push button to ignite mixture
(grunt sound rather than crack);
Flame front travels along pipe to light pilots;
Monitor pilot status with thermocouple (may take a
couple of minutes to heat up);

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

Flame Front Generator (F.F.G.) system

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

Flame Front Generator (F.F.G.) system

Free standing easel;

Open to atmosphere;
Robust;
Operator interface;
Remote monitoring;

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

Flame Front Generator (F.F.G.) system

ADVANTAGES:

DISADVANTAGES:

Generally simple to operate;

Suffers from changes in fuel

gas and air conditions;
Requires operator adjustment;
Difficult to operate in automatic
mode;
Water in lines will prevent
flame front.

Economic;
Mechanically robust.

IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system
NATURAL DRAFT

OFFSHORE
ONSHORE

Uses fuel gas pressure to inspirate its own air;

Fuel gas ejected from jet of venturi inspirator;
Action of gas through centre causes drop in static
pressure;
Drop in pressure causes air to be drawn in to form
correct gas/air mixture;
Ignition line 2 to 3 due to low pressure;
Has a high tolerance to set pressure;
Used over shorter distances < 200m;

IGNiTiON SYSTEM
Flame Front Generator (F.F.G.) system

OFFSHORE
ONSHORE

NATURAL DRAFT

IGNiTiON SYSTEM
High Energy Ignition (H.E.I.) system

OFFSHORE
ONSHORE

Direct electric spark ignition in flare pilot;

High Energy = rapid discharge of large capacitors at
relatively low voltage;
Powerful spark not prevented by dirt, water or oil build
up;
High temperature cable rated to 600oC;
Transmission at 2.5kV - standard cable;
Ignitor unit in control panel up to 300m from pilot;
Fully automatic control using thermocouple or flame

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

High Energy Ignition (H.E.I.) system

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

High Energy Ignition (H.E.I.) system

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

High Energy Ignition (H.E.I.) system

Stainless Steel NEMA 4X Purged

Stainless Steel EExde IIC T3

IGNiTiON SYSTEM
High Energy Ignition (H.E.I.) system

OFFSHORE
ONSHORE

HIGH TEMPERATURE
CABLE
Typically 12m long
Max Temp 600oC
Simple screw connector to
ignitor rod
SS braid over SS flexible
hose

LOW TEMPERATURE CABLE

400m maximum
- 45o C to 200oC
Wire armoure
PVC or silicone rubber sheath
1 cable per pilot

IGNiTiON SYSTEM

OFFSHORE
ONSHORE

Ballistic Spark Ignition

ABB GAS TECHNOLOGY,

NORWAY

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

THERMOCOUPLES

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

THERMOCOUPLES

ADVANTAGES

DISADVANTAGES

Simple
Economic
Easy to replace

Generally >90 sec. response

time
Prone to failure
Cannot be replaced without
shutdown

IGNiTiON SYSTEM
Pilot Monitoring
FLAME IONISATION ROD

OFFSHORE
ONSHORE

Monitors for presence of flame in the pilot nozzle;

DC potential applied to ionization rod and ground;
Weak current passes through ionised gases of the
flame;
Electronic detection remotely located;
Instantaneous detection;
Ionization rod made of high temperature alloy for long

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

FLAME IONISATION ROD

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

FLAME IONISATION ROD

ADVANTAGES

DISADVANTAGES

Instantaneous detection
Control system at ground
level accessible
Relatively resistant to
thermal damage

Relatively expensive
Prone to dirt/carbon build-up

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

INFRA-RED CAMERAS

Continuous monitoring
of pilot flames;
Senses unique
frequency of pre-mix
flame;
Infra-red detector up to
400m away, will monitor
regardless of flame
movement, varying
luminosity, most climatic
conditions;

IGNiTiON SYSTEM
Pilot Monitoring
INFRA-RED CAMERAS

OFFSHORE
ONSHORE

Principle of Operation
All objects above absolute zero emit I/R energy;
Amount of energy emitted is proportional to body
temperature;
Monitor collects energy via focusing optical system;
Energy concentrated onto a sensitive I/R detector;
Specialised amplification circuitry converts signal into DC to
activate relay and mA outputs for signal indications;

IGNiTiON SYSTEM
Pilot Monitoring

OFFSHORE
ONSHORE

INFRA-RED CAMERAS

ADVANTAGES

DISADVANTAGES

Visual detection of pilots

Located at ground level
accessible
Does not suffer thermal
damage
Quick response time

Expensive
Optics require frequent
cleaning
Standard temp range 4 to 52oC
Can add heater and cooler
added utilities

ANCiLLARY FLARE EQUIPMENT

OFFSHORE
ONSHORE

Propane Racks, Snuffing Systems,

Monitoring Equipment, Aircraft Warning Lights

Aircraft Warning Light Control

System
CO2 Snuffing System