flare and gas flaring

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Basic definations related to Industrial Flares and Flare gas for refineries and petrochemical industries

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Page 1: Flare and Gas Flaring

FLARE -> A flare, also sometimes called a fusee, is a type of pyrotechnic that produces a brilliant light

orintense heat without an explosion.Flares are used for signalling, illumination,

or defensive countermeasures in civilian and military applications.PYROTECHNICS -> Pyrotechnics is the science of using materials capable of undergoing

self-contained and self-sustained exothermic chemical reactionsfor the production of heat, light, gas, smoke and/or sound.

GAS FLARE -> A gas flare, alternatively known as a flare stack, is a gas combustion device,used in industrial plants such as petroleum refineries,

chemical plants, natural gas processing plants as well as at oil or gas production sites having oil wells, gas wells,

offshore oil and gas rigs and landfills.CASES of GAS Flaring ->

1. For burning off flammable gas released by pressure relief valves during unplanned over-pressuring of plant equipment.2. During plant or partial plant startups and shutdowns.3. For the planned combustion of gases over relatively short periods.

(When petroleum crude oil is extracted and produced from onshore or offshore oil wells, raw natural gas associated with the oil

is produced to the surface as well. Especially in areas of the world lacking pipelines and other gas transportation infrastructure,

vast amounts of such associated gas are commonly flared as waste or unusable gas.)4. During well production testing after drilling is completed

After a shale oil/gas well is drilled and hydraulically fractured, a temporary flare is used during well production testing.

Testing is important in order to determine the pressure, flow and composition of the gas or oil from the well.

Flaring at the well site can last for several days or weeks, until the flow of liquids and gas from the well and pressures are stabilized.5.For safety and during emergencies and maintenance

A flare is an important safety device, particularly at gas processing plants. In an emergency situation where equipment

or piping becomes over-pressured, special valves on the equipment automatically release gas through piping to flare stacks.

In the absence of safety flares, plants would be at higher risk for fires and explosions. Flares are also used as an outlet for gas

during maintenance and equipment repairs. In these scenarios, the flare is operated temporarily until the emergency situation is resolved,

or until maintenance activities have been completed.EMERGENICES MAYBE----1.General Power Failure2.Component Failure3.Plant Fires4.Overpressure situations5.Venting of Tank and loading platforms (Limited Application)

6.For managing gas during compression and processingFlare gas systems are used to manage small volumes of waste gas that can

not be efficiently captured and returned to the system for processing. For example,

some natural gas compressor stations have small dehydrator units that remove water from the gas stream before it enters the pipeline system.

There may be a small flare at the compressor station to burn off gas vapors captured by the dehydrator unit.

These flares are typically small and not visible off site.

Page 2: Flare and Gas Flaring

7.Flaring at well sites to recover oil

OIL WELL -- An oil well is a boring in the Earth that is designed to bring petroleum oil hydrocarbons to the surface.

Usually some natural gas is produced along with the oil.

GAS WELL -- A well that is designed to produce mainly or only gas may be termed a gas well.

OIL RIG -- An Oil rig may refer to drilling rig, an aapparatus for on-land oil drilling.

PETROLEUM CRUDE OIL -- Latin Petra (rock) + Latin: Oleum (oil)is a naturally occurring, yellow-to-black liquid found in geologic formations

beneath the Earth's surface, which is commonly refined into various types of fuels. It consists of hydrocarbons of

various molecular weights and other organic compounds.the name petroleum covers both naturally occurring unprocessed

crude oil and petroleum products that are made up of refined crude oil.

CHEMICAL PLANT -- A chemical plant is an industrial process plant that manufactures (or otherwise processes) chemicals, usually on a large scale.

The general objective of a chemical plant is to create new material wealth via the chemical or biological transformation

and or separation of materials

COMBUSTION EFFICIENCY -- Combustion efficiency is a measurement of how well the fuel being burned is being utilized in the combustion process.

This is different from the efficiency number produced on the analyzer, which is reflective of the total amount

of heat available from the fuel minus the losses from the gasses going up the stack.

DEPRESSURISATION-- (DEPRESSURIZE - To reduce the pressure of air or gas within (a chamber or vESSEL, for example))

DEBOTTLENECKING -- This is a term used to describe the act of remeding or removing the problems or constraints within a piece of equipment or a process.

To de-bottleneck is to remove obstacles that are preventing a process from being more efficient or workable.however they all

come down to 4 different fundamentals � repair, optimization, upgrading, and expansions.

DOWNSTREAM -- The downstream sector commonly refers to the refining of petroleum crude oil and the processing and purifying of raw natural gas,

as well as the marketing and distribution of products derived from crude oil and natural gas. The downstream sector touches

consumers through products such as gasoline or petrol, kerosene, jet fuel, diesel oil, heating oil, fuel oils, lubricants, waxes,

asphalt, natural gas, and liquefied petroleum gas (LPG) as well as hundreds of petrochemicals.

DOWNWIND -- In the direction in which the wind is blowing.

ELEVATED FLARE -- Elevated flares, where the flare tip is between 20 to 150 meters above ground.

ENCLOSED GROUND FLARE --

Page 3: Flare and Gas Flaring

MULTIPOINT GROUND FLARE --

FLARE TIP -- The tip includes a flame retention device along with a pilot. The upper portion is typically

constructed of 310SS and the lower portion of carbon steel. Flare Tip includes Pipe Tip and Sonic Tips.

The pipe flare is the most basic type of flare tip. It is sometimes called a "utility flare".

FLARING -- Flaring is the controlled burning of natural gas in the course of routine oil and gas production

operations. This burning occurs at the end of a fl are stack or boom.

FLASH BACK PREVENTION SYSTEM -- Flashback protection (the possibility that the flame will travel upstream into

the system) should be considered for all disposal systems because flashback can

result in pressure buildup in upstream piping and vessels.

FLAME ARRESTORS -- lame arrestors are used primarily on atmospheric vents and are not recommended on

pressurized systems. Because of the acceleration of the flame, the flame arrestor

must be installed approximately 10 pipe diameters from the exit, which prevents

the flame from blowing through the arrestor.The length of the tube and surface area provided

keep the metal cool.

FLUIDIC SEAL -- Fluidic seals are an alternative to gas seals. Fluidic seals use an open wall-less venturi,

which permits flow out of the flare in one direction with very little resistance but strongly

resists counterflow of air back into the stack. The venturi is a series of baffles,

like open-ended cones in appearance, mounted with the flare tip.

FPSO -- Floating, production, storage and offloading is a type of oil platform

GAS PROCESSING PLANT --

GROUND FLARE -- Ground flares, where the flare tip is about two to three meters above ground,

which is fenced off with a high heat-shield fencing, which also acts as a safety zone.

The ground flare is not visible in the day. At night, it may cast an orange glow in the night

sky, depending on cloud cover.

IGNITION SYSTEM --

ISBL -- InSide Battery Limits,with reference to the initial development of process plant projects in the construction industry.ISBL is considered

as the process area where the real product is created.

KNOCKOUT DRUM (Relief Drums or Flare or Vent Scrubbers) -- The knockout drum removes any liquid droplets that carry over with the gas relief sent to the flare.

LIQUID SEAL DRUM --

Page 4: Flare and Gas Flaring

LEL/LFL --Lower flammable limit (LFL) or Lower Explosive Limit (LEL) is minimum vapor concentration in air which a mixture will burn when an

ignition source is present. Upper flammable limit (UFL) or Upper Explosive Limit (UEL) is maximum vapor concentration in air which a

mixture will burn when an ignition source is present. Concentration of mixture of vapor in air below LFL/LEL (too lean) or

above UFL/UEL (too rich), mixture will not burn even an ignition source is present.

Therefore, flammable range or explosive range is concentrations between LFL/UFL and UFL/UEL.

MIDSTREAM -- The midstream sector involves the transportation (by pipeline, rail, barge, oil tanker or truck), storage, and wholesale marketing of

crude or refined petroleum products. Pipelines and other transport systems can be used to move crude oil from production sites to

refineries and deliver the various refined products to downstream distributors.

MOLECULAR SEAL -- Molecular seals cause flow reversal. They normally are located below the flare tip and serve to prevent air entry into the stack.

Molecular seals depend on the density difference between air and hydrocarbon gas. Light gas is trapped at the top of the U-tube. A continuous stream of purge gas is required for proper functioning of the gas seal

OSBL -- OutSide Battery Limits, with reference to the initial development of process plant projects in the construction industry.OSBL is considered

as the non-process/infrastructure. PILOT BURNER --

PILOT FLAME --

PRESSURE RELIEF VALVE --

PRESSURE SAFETY VALVE --

PURGE GAS -- Purge gas is injected into the relief header at the upstream end and at the major branches to

maintain a hydrocarbon-rich atmosphere in each branch, into the off-plot relief system,

and into the flare stack.When there is enough PSV leakage or process venting to maintain the

desired backpressure, no purge gas is injected.

RAW NATURAL GAS -- It is the gas extracted from underground gas fields and brought up to the surface by gas wells.

Raw natural gas typically consists primarily of methane, the shortest and lightest hydrocarbon molecule alongwith other hydrocarbons, acid gases, liquid hydrocarbons, water and other gases (N2 and He) with a very small amount of mecury.

REFIENRY -- A refinery is a production facility composed of a group of chemical engineering unit processes and

unit operations refining certain materials or converting raw material into products of value.

REVAMPING -- (REVAMP - give new and improved form, structure, or appearance to)This is a term used to describe the act of improving,

modifying, or re-structuring a process in order to obtain improv

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ed (or increased) production from it.It also can mean changes made to a process for the purpose of ch

anging the operation or production of other products.

SEAL DRUMS -- Liquid seal drums are vessels that are used to separate the relief gases and the flare/header stack

by a layer of liquid. Water (or water/glycol mixture) is normally the sealing fluid.

The flare gas (or purge gas) is forced to bubble through a layer of water before it reaches the

flare stack. This prevents air or gas from flowing backward beyond the water seal.

Seal drums serve as a final knockout drum to separate liquid from the relief gases.

TURNAROUNDS -- Turnarounds (or TAR's) are scheduled events wherein an entire process unit of an industrial plant (refinery, petrochemical plant,

power plant, pulp and paper mill, etc.) is taken offstream for an extended period for revamp and/or renewal. Turnaround is a

blanket term that encompasses more specific terms such as I&Ts (Inspection & Testing), debottlenecking projects, revamps and

catalyst regeneration projects. Turnaround can also be used as a synonym of shutdowns and outages.

UPSTREAM -- The upstream oil sector is also commonly known as the exploration and production (E&P) sector. The upstream sector includes the

searching for potential underground or underwater crude oil and natural gas fields, drilling of exploratory wells, and subsequently

drilling and operating the wells that recover and bring the crude oil and/or raw natural gas to the surf there has been a significant

shift toward including unconventional gas as a part of the upstream sector, and corresponding developments in LNG processing and transport.

UPWIND -- Against the direction of the wind.

VENTING -- Venting is the controlled release of gases into the atmosphere in the course of oil and gas production operations.

These gases might be natural gas or other hydrocarbon vapours, water vapour, and other gases, such as

carbondioxide, separated in the processing of oil or natural gas.In venting, the natural gases associated with the oil production are rel

eased directly to theatmosphere and not burned. Safe venting is assured when the gas is relea

sed at high pressure and islighter than air. Because of the strong mixing potential of high-pressur

e jets, the hydrocarbongases discharged mix well with the air down to safe concentrations at wh

ich there is no risk ofexplosion. Venting is normally not a visible process. However, it can ge

nerate some noise,depending on the pressure and flow rate of the vented gases.

OIL PLATFORM -- An oil platform may refer to anapparatus for offshore drilling rig, or a large structure with facilities to drill wells,to extract

and process oil and natural gas,or to temporarily store product until it can be brought to shore for refining and marketing.

-> Depending on the circumstances, the platform may be fixed to the ocean floor, may consist of an artificial island, or may float.

Remote subsea wells may also be connected to a platform by flow lines and by umbilical connections.

Page 6: Flare and Gas Flaring

TYPES OF OIL PLATFORMS-->

1.Fixed platforms -->These platforms are built on concrete or steel legs, or both, anchored directly onto the seabed,

supporting a deck with space for drilling rigs, production facilities and crew quarters.

Such platforms are, by virtue of their immobility, designed for very long term use.2.Compliant towers-->These platforms consist of slender flexible towers and a pile foundation supporting a conventional deck for drilling

and production operations. Compliant towers are designed to sustain significant lateral deflections and forces,

and are typically used in water depths ranging from 370 to 910 metres (1,210 to 2,990 ft).3.Semi-submersible platform-->These platforms have hulls (columns and pontoons) of sufficient buoyancy to cause the structure to float,

but of weight sufficient to keep the structure upright.Semi-submersible platforms can be moved from place to place;

can be ballasted up or down by altering the amount of flooding in buoyancy tanks; they are generally anchored by combinations

of chain, wire rope or polyester rope, or both, during drilling or production operations, or both, though they can also be kept

in place by the use of dynamic positioning. Semi-submersibles can be used in water depths from 60 to 3,000 metres (200 to 10,000 ft).

4.Jack-up drilling rigs--> Jack-up Mobile Drilling Units (or jack-ups), as the name suggests, are rigs that can be jacked up above

the sea using legs that can be lowered, much like jacks. These MODUs (Mobile Offshore Drilling Units) are typically used in

water depths up to 120 metres (390 ft), although some designs can go to 170 m (560 ft) depth.

They are designed to move from place to place, and then anchor themselves by deploying the legs

to the ocean bottom using a rack and pinion gear system on each leg.5.Drillships--> A drillship is a maritime vessel that has been fitted with drilling apparatus. It is most often used for exploratory drilling

of new oil or gas wells in deep water but can also be used for scientific drilling.Most drillships are outfitted with a

dynamic positioning system to maintain position over the well. They can drill in water depths up to 3,700 m (12,100 ft).6.Floating production systems-->The main types of floating production systems are FPSO (floating production, storage, and offloading system).

FPSOs consist of large monohull structures, generally (but not always) shipshaped, equipped with processing facilities.

Some variants of these applications, called FSO (floating storage and offloading system)

or FSU (floating storage unit), are used exclusively for storage purposes, and host very little process equipment.

This is one of the best sources for having floating production.7.Tension-leg platform--> TLPs are floating platforms tethered to the seabed in a manner that eliminates most vertical movement of the structure.

TLPs are used in water depths up to about 2,000 meters (6,600 feet).8.Gravity-based structure--> A GBS can either be steel or concrete and is usually anchored directly onto the seabed.

Steel GBS do not usually provide hydrocarbon storage capability.9.Spar platforms--> Spars are moored to the seabed like TLP's, but whereas a TLP

Page 7: Flare and Gas Flaring

has vertical tension tethers, a spar has more conventional mooring lines.Spars have to-date been designed in three configurations: the "c

onventional" one-piece cylindrical hull, the "truss spar" where themidsection is composed of truss elements connecting the upper bu

oyant hull (called a hard tank) with the bottom soft tankcontaining permanent ballast, and the "cell spar" which is built

from multiple vertical cylinders.10.Condeep platforms11.Normally unmanned installations (NUI)-->These installations are then added to the sea water.(sometimes called toadstools) are small platforms,

consisting of little more than a well bay, helipad and emergency shelter.They are designed to be operated

remotely under normal conditions, only to be visited occasionally for routine maintenance or well work.12.Conductor support systems-->These installations, also known as satellite platforms, are small unmanned platforms consisting of

little more than a well bay and a small process plant. They are designed to operate in conjunction with a

static production platform which is connected to the platform by flow lines or by umbilical cable, or both.