gba flare system installation operating and maintenance manual

Project name: Project n°: Document n°:

HERMES 51-3282 U2G-396-016

INSTALLATION, OPERATING AND MAINTENANCE MANUAL

GBA DOCUMENT No.: 353/70

Client : AIR LIQUIDE ENGINEERING

Project : HERMES

Equipment : FL5711 - FLARE

P.O. No. : 189563

Page Job. No.

1 OF 49 353

1 14/07/2009 FINAL ISSUE M. Borgonovo A. Cabiati 0 22/04/2009 ISSUE FOR APPROVAL T. Fraccaroli A. Cabiati

REV. DATE DESCRIPTION PREP.BY APPROV.

INSTALLATION, OPERATING AND

MAINTENANCE MANUAL 353/70 Pag. 2 of 49

INDEX PART 1 – FOREWORD.....................................................................................................................3

PART 2 – REFERENCE DOCUMENTS...........................................................................................4

PART 3 – STORAGE AND HANDLING INSTRUCTIONS ...........................................................5

PART 4 – OPERATING AND MAINTENANCE INSTRUCTIONS...............................................7

PART 5 – ATTACHMENTS............................................................................................................23

GENERAL ARRANGEMENT ………………………………………………………………… 24 P&ID ……………………………………………………………………………………………. 25 FLARE TIP PF-36 G.A. …………………………………………………………………………26 FFG PANEL – G.A. ……………………………………………………………………………. 27 FFG PANEL – WIRING DIAGRAM ………………………………………………………….. 31 MOLECULAR SEAL MS-36-30 ………………………………………………………………. 41 K.O. DRUM G.A. ………………………………………………………………………………. 42 EQUIPMENT DATA SHEETS ………………………………………………………………... 43



PART 1 – FOREWORD The document gives all the basic GBA instructions for operation and maintenance of the Hermes elevated flare. All instructions must be interpreted and applied after suitable consideration of the needs, of other equipment connected with GBA equipment, and of particular circumstances that might arise during the operations since no instruction manual can cover all the possible situations that one might face during operations activity. The presence of GBA technicians at site will have the purpose of helping client’s personnel to understand the present manual, being understood that the full responsibility of the start up is delegated to the Customer start up team.



PART 2 – REFERENCE DOCUMENTS

DOCUMENT TITLE ALE DOC. NO.

GBA DOC. NO.

1 GENERAL ARRANGEMENT

51-3282-U2G-554-001

353/01

2 P&ID 51-3282-U2G-014-210

353/41

3 FLARE TIP PF-36 G.A. 51-3282-U2G-514-003

353/42

4 FFG PANEL – G.A. 51-3282-U2G-554-010

353/38

5 FFG PANEL – WIRING DIAGRAM

51-3282-U2G-803-741

353/39

6 MOLECULAR SEAL MS-36-30 51-3282-U2G-396-341 353/05 7 K.O. DRUM G.A. 51-3282-U2G-396-342 353/36 8 EQUIPMENT DATA SHEETS 51-3282-U2G-396-015 353/63



PART 3 – STORAGE AND HANDLING INSTRUCTIONS All equipments supplied shall be preserved and protected for a period necessary for staying at the site. Preservation shall remain in effect until after the equipment has been installed. Protection and or preservation activity shall be carried out by the person responsible of the packaging of the equipments. 3.1 STORAGE

After receipt, once the packages have been opened by the receiver for checking, all packages must be resealed and stored in accordance to the indication shown on the packages or in accordance to any different instruction.

3.2 VENTILATION

Not applicable; flare tip does not have refractory inside.

3.3 PRESERVATION

Be sure that during storage all openings in which rain can go through are duly covered.

3.4 HANDLING

Bundles for pipe, ladders, platforms etc. shall be handled with slings positioned to make a correct and safe lift. Each bundle &/or package has to be carefully managed checking the information applied on the outside of the packing (sling positioning, centre of gravity, fragile and so on).

3.4.1 Flare Tip / Molecular Seal The tip & molecular seal are supplied with lifting lugs. These should be used for lifting the supplied items. The flare tip can be moved and installed with a suitable spreader beam if requested by the flare tip size, ensuring that straps or hawsers do not touch the flare tip windshield (Refer to drawing n°51-3282-U2G-514-003).



3.4.2 Riser

Bundles and/or riser trunks shall be handled with slings positioned to make a correct and safe lift.

3.4.3 FFG Panel The FFG Panel is supplied with two lifting lugs, mounted on the top of the frame. No special precautions are necessary for lifting the panel from its case. The panel should be lifted and installed onto its foundations and bolted down securely.



PART 4 – OPERATING AND MAINTENANCE INSTRUCTIONS

4.1 INTRODUCTION

4.1.1 Equipment Description 4.1.2 Flare Design Duties 4.1.3 Utility Consumption

4.2 PRE-COMMISSIONING INSTRUCTIONS

4.2.1 Thermocouple position 4.2.2 Pilot air setting gap 4.2.3 F.F.G. Panel 4.2.4 Blow-off lines (at ground) 4.2.5 Purge 4.2.6 Thermocouples setting gradients 4.2.7 List of verifications and tests

4.3 COMMISSIONING INSTRUCTIONS

4.3.1 Initial Commissioning 4.3.2 Blow-off lines (after erection) 4.3.3 FFG Panel - Pilot Ignition 4.3.4 At the end of pilot ignition 4.3.5 Pilot Performance 4.3.6 Making the System Live 4.3.7 Re-Commissioning

4.4 OPERATING INSTRUCTIONS

4.4.1 Start-up 4.4.2 Normal Flare Operating Procedure 4.4.3 Normal Flare Shutdown Procedure

4.5 MAINTENANCE AND TROUBLESHOOTING

4.5.1 Flare Tip and Pilot Burners 4.5.2 FFG Panel 4.5.3 Flare Stack 4.5.4 Maintenance Schedule 4.5.5 Safety instruction



4.1 INTRODUCTION

This section describes the installation, operation and maintenance procedures associated with the flare supplied for the HERMES PROJECT. Failure to comply with the recommendations and procedures set out in this manual may lead to hazardous operations reduced operating efficiency and service life and may invalidate any guarantee given for the equipment. Operating data in this manual may be revised at commissioning, subject to local site conditions and requirements. It is strongly recommended that operating personnel familiarize themselves with all sections of this document prior to commissioning, operating or maintaining this equipment. GBA supplied equipment is composed of: • X5711 F.F.G. IGNITION CONTROL PANEL • V5711 FLARE K.O. DRUM • FL5711 FLARE STACK • MX5711 FLARE TIP • DERRICK STRUCTURE

4.1.1 Equipment Description

The flare tip is a GBA model PF-36. The PF-36 flare tip is designed to dispose of volumes of low pressure, waste gases in a safe and efficient manner. The flare tip is not fitted with any method of steam injection and smokeless flaring is dependant on the composition of the gas, which is being flared. The flare tip is fitted with 3 off pilot burners which are designed to be constantly lit and therefore to provide a constant source of ignition for the main flame. The tip is complete with flame retention lugs designed to maintain flame stability over a wide range of operating conditions and a slatted wind shield design to reduce the tendency for the flame to be pulled down the leeward side on the flare tip body under cross-wind conditions. Immediately below to the flare tip, a molecular seal is installed in order to prevent air ingress into the flare system. The molecular seal works by relying on the density difference between the purge gas and air. When the purge gas is lighter than air it forms a gas rich zone at the top of the seal that air cannot penetrate, conversely when the purge gas is heavier than air the seal is formed at the base of the device. In this way only a very low continuous purge flow is necessary to maintain conditions within the seal. The molecular seal can maintain safe conditions in the upstream riser for several hours in the event of a loss of purge gas. The flare system is equipped with a vertical type knock-out drum designed to effectively remove hydrocarbon liquids from the main relief gas, in order to prevent the possibility of carryover and “flaming rain” from the flare tip. The sizing of this vessel is based on the criteria defined in API RP 521 (Fourth Edition – March 1997) and considers residence time and drop out velocity of the liquid particles in the vapour flow. The pilots are remotely ignited, by the Flame Front Generator (FFG) panel, located at stack base. It is connected to the flare tip by individual 1” lines to each flare pilot.



The FFG works by filling these lines with a combustible mixture of fuel gas air: the mixture is then sparked at the FFG panel. The resulting “flame front” travels along the 1” lines to ignite the pilot burners as it emerges from the tip. After successfully igniting one pilot, further pilots are ignited by selecting the unit pilots via the 3 way flame front diverter valves. The FFG includes equipment to monitor the ignition status of the pilot burners via thermocouples located in the pilot heads. The status is displayed by red/green lamps in the front of the electrical control box on the panel.

4.1.2 Flare Design Duties

Flow Nm3/h 196,400 Temperature °C @ 300

4.1.3 Utility in Consumption

Purge gas Nm³/h 5.0 Pilot gas Nm³/h (*) 2.5 Ignition gas Nm³/h (**) 4.0 Ignition air Nm³/h (**) 40

Power: rating < 1 kW (*) Each pilot (**) During ignition only



4.2 PRE-COMMISSIONING INSTRUCTIONS

4.2.1 Thermocouple Position

Check that thermocouple is correctly positioned as shown in the below sketch.

Thermocouple guide tube

Thermocouple Position in Pilot Nozzle

Pilot nozzle

Thermocouple tobe flush with pilot

nozzle boss

Pilot line



4.2.2 Pilot Air Setting Gap

The adjustable air inlet doors on the pilot inspirators are normally adjusted at the factory to suit the predicted fuel gas composition. Therefore at field, the gap check should be carried out, and the following guide is given for reference.

AIR GAP DETAIL

Gas Gap mm Natural Gas 6 Propane 9 Heavier than Propane 12 Up to 25 mol % Hydrogen as above >25%but<50% Hydrogen 3 >50%but<75% Hydrogen 1 >75% Hydrogen 0 (Closed)

Note that high levels of inerts (CO2 and N2) in the fuel gas will also require the air adjuster to be closed roughly in proportion to the percentage in the fuel gas. For example natural gas with 20% inerts should be set at 6mm less 20% (of setting) = approx. 4,5mm open.

Inspirator Jet

Venturi Casting

Air pulled in bysuction effect

Gas/Airmixture

to Pilot

primary gas jet

GAPnom. 6.0mm

Adjustable Air Door

Locking Ring



SCREEN BARSEGREGATION

TERMINAL STRIPS

1

U2G-LTB-5711

CABLE TRUNKBOX2

7-14

5-12

6-13

3-10

4-11

2-9

1-8

GND

GND1 2

12

U2G-PTB-5711U2G-PTB-5711A

179542 3 6 7 8 13121110 1514 16 2118 19 20 22 2423

U2G-TTB-5711

4.2.3 F.F.G. Panel

The panel piping has been leak tested in the works and usually should not require further testing (refer to DOC No.: 51-3282-U2G-554-010). The electrical power and client alarm connections can now be made using suitable cable glands. Refer to Electrical Schematic and Termination Diagrams (DOC No.: 51-3282-U2G-396-741), and to the explanation detail here below:

After installation please ensure that FFG electrical enclosures are properly sealed against ingress of rain/dust etc.



4.2.4 Blow –Off Lines (at ground)

It is essential that all service pipelines associated with the flare system are free from debris and obstructions.

4.2.5 Purge

At all times when the flare system is on-line (operated) purge gas must be maintained to prevent air infiltration into the stack riser. Purge flow rate is indicated at para 4.1.3. The purge gas should be any gas that does not contain oxygen and is not liable to condense under ambient conditions. Care should be taken to ensure the continuity of supply of purge gas to the flare systems. Loss of purge gas will rapidly result in high oxygen levels in the flare stack with consequent risk of internal detonations.

4.2.6 Thermocouple Setting Gradients

The FFG panel instruments will normally be pre-set at the factory. However, they are repeated here in case it is necessary to re-set them. Pilot Fail Alarm Switches 400°C.

4.2.7 List of the Verifications and Test At least the following verifications and tests shall be performed by the owner/customer representative and then recorded:

4.2.7.1 DURING/AFTER ERECTION

- Thermocouple position in pilot nozzle (see para 4.2.1 of this procedure). - The inspirator orifice must be free from debris and foreign materials. - Air gap at the inspirator (see para 4.2.2 of this procedure).

4.2.7.2 AFTER INSTALLATION

- Power On - Lamp Test - Spark plug test



4.3 COMMISSIONING INSTRUCTIONS

The following procedure may be carried out EITHER with the flare header gas free and spaded off OR after the spades have been removed and the header swept and continuously purged with inert gas. It is recommended that the header is purged with at least 10 times the free volume of the system at a rate at least equal to the minimum purge flow. In any event the headers must be free of gas. This is essential as the following steps will introduce an ignition source into the flare.

4.3.1 Initial Commissioning

It is essential that commissioning is carried out by responsible and experienced personnel. It is therefore recommended that GBA team commissions the flare system. Furthermore, after commissioning, if any serious faults develop, it is recommended that GBA is contacted before any remedial work is carried out.

4.3.2 Blow-Off Lines (After Erection)

All lines should have been blown off prior to commissioning. The blow off velocity should be higher than that encountered during normal operation. GBA recommend a velocity of 60 m/s or greater. It is particularly important that the pilot gas supply lines are cleaned as the pilots have small orifice jets which can be easily closed by debris. - Disconnect the 3 pilot flanges and add a line for checking of the cleanness a for the line from the flange to the pilot. - Remove strainers at ground level. - Pilot and ignition piping blowing can be performed. - Reinstall pilots and strainers.

4.3.3 FFG Panel - Pilot Ignition

The Flare Ignition Panel X-5711 is designed to ignite the flare pilots by using a ball flame generated by a combustion chamber mounted on the panel pipe-line. The initial lighting of the pilots may be undertaken using fuel gas if available or, if more convenient, using bottled LPG.

THE FOLLOWING PROCEDURES SHOULD BE DONE UNDER THE FLARE PLANT RESPONSIBLE APPROVAL. BEFORE TO ATTEMPT ANY IGNITION, THE FLARE RISER SHOULD BE COMBUSTIBLE GAS FREE OR OXYGEN FREE, TO AVOID ANY INTERNAL EXPLOSION DURING IGNITION.



The sequence of the operations is as follows:

1. Connect Power supply to main input terminals L-N-GND (as per para. 4.2.3). Switch isolator “POWER SWITCH” HS 5031 on position “1”. The “Power ON” lamp XL 5031 will light.

2. Check that the three red signal lamps TAL 5021, TAL 5022 and TAL 5023 “PILOT OFF” are light.

3. Check that the three green signal lamps TAH 5021, TAH 5022 and TAH 5023 “PILOT ON ” are off.

4. Check with the “LAMP TEST” HS 5039 push button that all signal lamps are OK.

5. Select the Pilot 1 using the relevant three way valve (See ATTACHMENT A).

6. Open the air isolation valve on INSTRUMENT AIR LINE. (Refer to Doc. 51-3282-U2G-014-210).

7. Set the PCV 5008 at ≈ 1.0 Barg. Check on PG 5008 the correct pressure (provisional pressure).

8. Open the fuel gas isolation valve on FUEL GAS LINE (Refer to Doc. 51-3282-U2G-014-210).

9. Set the PCV 5007 at ≈ 1.0 Barg. Check on PG 5007 the correct pressure (provisional pressure).

10. Open the fuel gas isolation valve for the selected pilot (continuous gas line).

11. Set the PCV 5006 at 1.0 Barg. Check on PG 5006 the pressure setting (provisional pressure).

12. After approx 12 sec press the “ IGNITION SPARK BUTTON ” HS 5040 and observe the sight glass on the combustion chamber. A flame will appear, with a loud “crack” noise.

13. After several minutes, the pilot thermocouple will reach the detection trip point (400°C), and the green lamp TAH 5021 on LCP will lit, otherwise a new trial will be necessary.

14. Now select the Pilot 2 using the relevant three way valve (See ATTACHMENT A).

15. Repeat from the above step No.6 of the sequence.

16. After several minutes, the pilot thermocouple will reach the detection trip point (400°C), and the green lamps TAH 5022 on LCP will lit, otherwise a new trial will be necessary.

17. Now select the Pilot 3 using the relevant three way valve (See ATTACHMENT A).

18. Repeat from above step No.6 of the sequence.

19. After several minutes, the pilot thermocouple will reach the detection trip point (400°C), and the green lamps TAH 5023 on LCP will lit, otherwise a new trial will be necessary.

20. Now all the three pilots are lit.

21. Close air isolation valve and fuel gas valve .



4.3.4 At the end of Pilot Ignition

Water vapour resulting from combustion may condensate in ignition line during cooling down. Ignition line can be purged using the relevant drain few hours after the ignition (ignition lines are sloped to the above mentioned drain valve).

ATTACHMENT A



4.3.5 Pilot Performance

Once ignited the pilots should be checked visually. The flame should be about 300mm long and burn with a bluish, hard flame with some flashes of yellow towards the end. It is almost invisible during daylight but is much more easily seen at night. More reliable response is via thermocouples, with green lamps “ON” at control panel. If the flame is smaller than this, or yellow, or soft, the inspirator jet may be blocked. In this case the pilot must be shut down and the jet must be cleaned. Once the pilots have been shown to work satisfactorily they should be turned off by isolating the pilot fuel gas supply (this should be discussed and confirmed according to Client/Plant schedule). After testing the pilots, the FFG panel should be shut down until required at start-up. To safely shut down the FFG isolate the power supply and then isolate the air and gas supplies using the supplied block valves, and vent the fuel gas lines.

4.3.6 Making the System Live The procedure for bringing the system on-line is as follow:

1) De-spade the flare headers. 2) Purge the headers with inert gas as outlined in 4.1.3. 3) Ignite the pilots in line with 4.3.3. 4) Verify pilot ignition via pilot status lamps.

The flare can now be considered on-line.

4.3.7 Re-Commissioning Re-commissioning of the unit after an overhaul consists of following the commissioning procedure Section 4.2 onwards.



4.4 OPERATING INSTRUCTIONS

4.4.1 Start-Up

A normal sequence for start-up for operation of the flare, fitted with pilots/ignitors and hydrocarbon gas purge system would be as follow: Establish the required minimum gas purge flow through the flare system. It is recommended that the header is purged with at least 10 times the free volumes of the system at a rate at least equal to the minimum purge flow. In any event the headers must be free of oxygen. Establish fuel gas flow to the pilots and ignite them as outlined in section 4.2. Flare is now on-line and ready for use. Notes:

1) It is recommended that a suitable gas analyzer be used to check the flare gas lines, either to establish that they are hydrocarbon free or 100% hydrocarbon as appropriate. If such a meter is not available it is recommended that the lines be purged with at least 10 times their free volume of hydrocarbon at a rate equal to, or exceeding, the specified continuous purge rate before igniting the pilots.

2) During operation, or immediately after shutdown, do not open any flare stack drains or manways until combustion ceases and the system has been made safe by inert gas purging, otherwise air will be drawn into the flare stack creating a potential hazard. It is recommended that personnel do not climb onto the stack with pilots in operation or with flare under purge. Under no circumstances should personnel be on the structure when the flare is operating.

4.4.2 Normal Flare Operating Procedure HYDROCARBON PURGE The hydrocarbon purge gas will normally be ignited from the pilots but the flame may not be visible from grade. INERT GAS PURGE Using inert gas for the purge medium is highly preferable for start-up and optional for normal operation, as it avoids the possibility of burn back inside the flare tip under abnormal wind conditions. PILOT OPERATION The pilots are designed to run on fuel gas (essentially natural gas) at a pressure of 1.0 barg (approx).



KO DRUM The vertical type KO drum is designed to separate droplets which diameter is bigger than 600 µm.

4.4.3 Normal Flare Shutdown Procedure The normal shutdown operation for the flares is as follow:

1 Allow flare gas flow to decline to zero. 2 Close pilot fuel gas isolation valves. Change the purge gas to nitrogen. 3 After verifying pilot fail lamps are on, isolate power and fuel gas supplies. 4 Shutdown purge system by isolating nitrogen supply. 5 Fit spades to all flare headers and fuel gas lines as required. 6 The flare is now safe and any work can be undertaken, providing that usual

site safety procedures are observed.



4.5 MAINTENANCE AND TROUBLESHOOTING

4.5.1 Flare Tip and Pilot Burners

The flare tip and pilots are only accessible for maintenance during the shut-down of the plant. At other times a useful amount of information can be gained by observing the tip through high powered binoculars or telescope. When access is possible it is advisable to check the condition of the flare visually looking for corrosion and/or thermal damage. All ancillary parts such as the pilots and windshield should be securely attached. If in doubt as to the condition of the flare tip it is possible to carry out in-situ dye penetrant testing to check for cracks etc. Minor distortions and small cracks are of little significance for a flare tip but gross deformations and/or major cracks are causes for concern, particularly if the time until the next planned shut-down is extensive. Check all flare tip bolting for tightness and condition. Renew if in any doubt as to its condition. Whenever the flare is shut down for any period, it is advisable to clean out any line strainers and associated pipework. Maintenance of the pilots is only required where blockage or damage is evident, or after a failure to ignite. Each flare pilot is fitted with an air inspirator assembly, which features a small gas jet. These should be inspected and cleaned whenever the flare is shutdown or more frequently if blockage proves to be a problem.

4.5.2 FFG Panel

If no spark is observed at the combustion chamber:

• Ensure that the fuses for surge protection are OK.

4.5.3 Flare Stack

The flare stack riser, derrick structure, platforms and ladders do not require extensive maintenance. They should be visually checked at every flare shut-down for the quality of the paint coating, the integrity of the welding and spot checks made on the stack and members wall thickness.



4.5.4 Maintenance Schedule

The flare package does not require extensive routine maintenance.

MONTHLY

• Drain condensate from pilot gas and/or air lines. • Check function of panel lamps using the lamp test facility provided.

SIX MONTHLY

• In addition to the above checks, examine gas lines, pilot burners, pressure gauges, electrical connections for wear/corrosion.

EVERY SHUTDOWN

• Inspect the flare tips and pilots. • Check the flare pilots function.

• Check paint/galvanizing and wall thickness.

• Inspect/clean molecular seal drain via handhole.

• Perform internal inspection of KO drum.

4.5.5 Safety Instruction

- High voltage capable of causing death. - Use extreme caution when servicing control panels. - Do not operate flare system unless instructed from plant manager, and unless the

purge of the system has been completed (purge flow rate shall be at least 10 times the entire volume of the flare main headers and sub headers).

- An explosion may occur if pilots are ignited without purging the entire system.



PART 5 – ATTACHMENTS

DOCUMENT TITLE ALE DOC. NO.

GBA DOC. NO.

1 GENERAL ARRANGEMENT

51-3282-U2G-554-001

353/01

2 P&ID 51-3282-U2G-014-210

353/41

3 FLARE TIP PF-36 G.A. 51-3282-U2G-514-003

353/42

4 FFG PANEL – G.A. 51-3282-U2G-554-010

353/38

5 FFG PANEL – WIRING DIAGRAM

51-3282-U2G-803-741

353/39

6 MOLECULAR SEAL MS-36-30 51-3282-U2G-396-341 353/05 7 K.O. DRUM G.A. 51-3282-U2G-396-342 353/36 8 EQUIPMENT DATA SHEETS 51-3282-U2G-396-015 353/63

Project name: Project n°: Document n°:

HERMES 51-3282 U2G-396-015

EQUIPMENT DATA SHEETS (GBA FORMAT)

GBA DOCUMENT No.: 353/63

Client : AIR LIQUIDE ENGINEERING

Project : HERMES

Equipment : FL5711 – FLARE

P.O. No. : 189563

Page Job. No.

1 OF 7 353

2 10/07/2009 FINAL ISSUE A. Zanata A. Cabiati 1 13/02/2009 CLIENT COMMENTS INCORPORATED A. Zanata A. Cabiati 0 28/11/2008 ISSUE FOR APPROVAL A. Zanata C. Longoni

REV. DATE DESCRIPTION PREP.BY APPROV.

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FILENAME: 353-063-rev.2 p2.vsd

-

AC

AC

CL

CHKD:

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2

1

0

REV-:

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Final issue

General revision

Issue for approval

DESCRIPTION:

-

10/07/09

13/02/09

28/11/08

DATE:

-

AZ

AZ

AZ

BY:

REVISIONS

AIR LIQUIDE ENGINEERING

SOXAL

Hermes Project 51-3282

353

Client:

End-User:

Project:

GBA Ref :

Flare Stack Specification Derrick System

DATA SHEET N°:

353-63Page 2 of 7

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-

-

-

-

-

-

-

-

-

-

-

-

-

-

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-

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30"

78m

12m

Triangular

12m

12m

12m

12m

30"

BS 5950

10

5

GENERALUPPER SET No. / TYPE

MAIN RISER DIAMETER

DESIGN CODESSTRUCTURAL DESIGN CODE

BASIC WIND SPEED

WIND LOADING CODE

SEISMIC ZONE

SEISMIC CODE

AMBIENT TEMP. RANGE

STACK DESIGN PRESSURE

STACK DESIGN TEMP.

STACK DETAILSRISER TYPE

POSITION

FINISH

SHIPPING LENGTHS

END CONNECTIONS

SITE ASSEMBLY

LADDERS & PLATFORMSNo. 360° PLATFORMS

No. REST PLATFORMS

No. LADDERS

MATERIAL / FINISH

SITE ASSEMBLY

GUY WIRESNo. GUY LEVELS

No. ROPES / LEVEL

GUY WIRE TYPE

AIRCRAFT WARNING LIGHTS

MIDDLE SET No. / TYPE

LOWER SET No. / TYPE

DEMOUNTABLE/FIXED

SERVICE SIZE MATERIALEND

CONNECTIONINSULA

TIONTRACE HEAT

SHIP'G LENGTH

SITE ASMBY

COMMENTS

RISERS & SERVICE LINES

Gas Riser/FL5711

Ignitor Gas

Pilot Gas

-

-

-

-

3x1"

3x1"

1x2"

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-

-

-

C.S.

S.S.

S.S.

C.S.

-

-

-

-

150# RFWN B16.47B

150# RFWN B16.5

150# RFWN B16.5

150# RFWN B16.5

-

-

-

-

No

No

No

No

-

-

-

-

No

No

No

No

-

-

-

-

-

-

-

-

Welded

Welded

Welded

Welded

-

-

-

-

10.31THK-API 5L GR.B

SCH 10S A312-TP-316L

SCH 10S A312-TP-316L

SCH. 40-ASTM A 106 GrB

-

-

-

-

HEIGHT

BS

N/A

N/A

+ 19.4 / +35.8 °C

3.5 barg

-3 / +390°C

Fixed

Internal to Structure

As per Doc. No. E-GS-4-2-2

Bevelled/Flanged

Welded / Bolted

5

C.Steel / Hot Dip Galvanized

Bolted

N/A

N/A

N/A

N/A

N/A

N/A

N/A

REMARKS

STRUCTURE TYPESTRUCTURE DETAILS

TYPE OF LEGS

STRUCTURE MATERIAL

STRUCTURE FINISH

DAYLIGHT RED/WHITE BANDING

TYPE CROSS BRACING

Tubular, Flanged

Tubular, Bolted

Carbon Steel

Hot Dip Galvanized

N/A

1) T/C cable and relevant cable tray (AISI304) included.

M. Seal DrainT

34 m/s

REFER TO G.A.Doc. 353/01

(AL doc. n° 51-3282-U2G-554-001)

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AC

AC

CL

CHKD:

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2

1

0

REV-:

-

Final issue

General revision

Issue for approval

DESCRIPTION:

-

10/07/09

13/02/09

28/11/08

DATE:

-

AZ

AZ

AZ

BY:

REVISIONS


SOXAL


353

Client:

End-User:

Project:

GBA Ref :

Flare Tip Specification PF-36

MX5711

DATA SHEET N°:

353-63Page 3 of 7

5 Nm3/hr

Hydrocarbon case 6

196,400 Nm3/hr

Purge

11.69

300 °C

< 0.3 barg

<= Ringelmann N° 1

As per client data sheet

GAS STREAM

FLOW MAXIMUM

FLOW MINIMUM

MOLECULAR WEIGHT

GAS TEMPERATURE

OVERALL PRESSURE LOSS

SMOKELESS CAPACITY

GAS COMPOSITION

PROCESS DATA

DIMENSIONS (approx)LENGTH WIDTH

WEIGHT

MATERIALS (2)

SURFACE FINISH (1)ALLOY STEEL

CARBON STEEL

DESCRIPTION SIZE RATING MATERIAL

UTILITIES

PILOTS

REMARKS

3,000 mm 1,200 mm

1,200 kg

NATURAL

High Temp Aluminium Paint

TERMINAL POINTS

GAS INLET

PILOT GAS INLET

IGNITION INLET

36"

3 x 1"

3 x 1"

150# ANSI RFWN B16.47B

150# ANSI RFWN B16.5


ASTM A182F316L Stainless Steel

ASTM A182-F316L Stainless Steel

ASTM A182-F316L Stainless Steel

PILOT FUEL GAS

PURGE GAS

2.5 Nm3/hr per pilot

QUANTITY

THERMOCOUPLES3

2/pilot

TYPE

TYPE

G-100

K/Single

UPPER BODY (2 m)

LOWER BODY (1m)

PILOT

PILOT NOZZLE

PILOT MANIFOLD

LIFTING LUGS

WIND SHIELD

PURGE SEAL

FLAME STABILISER LUGS

IGNITION MANIFOLD

310 S

310 S

310 S

Cast 25 / 12 Cr / Ni Alloy

N/A

N/A

310 S

N/A

310 S

310 S

InspiratorAssembly

IgnitionInlet1"

(3-off)

Pilot Gas Inlet 1"

(3-off)

Wind Deflectors

Gas Inlet36"

PilotNozzle

Flame Retention Lugs

(1) Flare tip will be pickled & passivated.

(2) For further information, refer to flare tip drawing

(AL doc. 51-3282-U2G-514-003).

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CHKD:

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2

1

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REV-:

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Final issue

General revision

Issue for approval

DESCRIPTION:

-

10/07/09

13/02/09

28/11/08

DATE:

-

AZ

AZ

AZ

BY:

REVISIONS


SOXAL


353

Client:

End-User:

Project:

GBA Ref :

Molecular Seal SpecificationMS-36/30

DATA SHEET N°:

353-63Page 4 of 7

Hydrocarbon case 6

196,400 Nm3/hr

Purge

11.69

300 °C

< 0.3 barg

5 Nm3/hr

PROCESS DATAGAS STREAM

FLOW MAXIMUM

FLOW MINIMUM

MOLECULAR WEIGHT

GAS TEMPERATURE

PRESSURE LOSS

UTILITIESPURGE GAS

DIMENSIONS (approx)LENGTH DIAMETER

WEIGHT

MATERIALS (1)MAIN BODY

INTERNALS

DRAIN NOZZLE(S)

BRACKETS

SURFACE FINISHALLOY STEEL

CARBON STEEL

GAS INLET

DRAIN

TERMINAL POINTS

GAS OUTLET

DESCRIPTION SIZE RATING MATERIAL

REMARKS

4,000 mm 2,060 mm

4,100 kg

A516 Gr. 70

A516 Gr. 70

A105N

A516 Gr. 70

N/A

As client specification

36"

30"

2"

ASTM A105N Carbon Steel






2" Drain

Inlet30"

Outlet36"

Hand Hole8"

1) Refer to 353/05 (AL doc. 51-3282-U2G-396-341).


DATA SHEET No.:Manual type F.F.G. Ignition & Control Panel

X5711353-63

Page 5 of 7REV.

DATE

BY

CHKD

0

28/11/08

AZ

CL

1

13/02/09

AZ

AC

2

10/07/09

AZ

AC

PROJECT:AIR LIQUIDE

ENGINEERING

CLIENT:

SOXAL

End-User:Hermes Project

51-3282-00

GBA REF: 353

yes/3

3 - off

1

GENERAL DETAILSMOUNTING

LOCATION

AREA CLASSIFICATION

ENCLOSURE SPEC

ENCLOSURE MATERIAL

PAINT SPEC

IGNITION METHOD

FLARE SERVED

No. PILOTS PER FLARE

UTILITY REQUIREMENTSPILOT GAS

IGNITOR GAS

IGNITOR AIR

PURGE GAS

POWER

DIMENSIONS & WEIGHTDIMENSIONS (APPROX)

WEIGHT (APPROX)

PANEL FEATURESELECTRIC IGNITION (F.F.G. type)

PIEZO BACK UP

AUTO RE-IGNITION GAS / AIR REGULATORS

PILOT GAS TAKE OFF /No.

PURGE GAS TAKE OFF / No.

PILOT GAS FLOWMETERS FITTED

LPG BACK UP SYSTEM

FUEL GAS LOW PRESSURE ALARM

PILOT FLAME MONITORING

REMOTE ALARM CONTACTS

POWER ISOLATOR

SUN SHADE / RAIN CANOPY

AUDIBLE ALARM

MATERIAL OF CONSTRUCTION

PIPING (2)

FRAME / BACKPLATE

REMARKS

Free-standing

Outdoor within derrick footprint

IP65

EExd IIC T3

As per client specs

F.F.G.

2.5 Nm3/hr each

4 Nm3/hr

40 Nm3/hr

N/A

2,000 mm x 700 mm x 1,800 mm

800 kg

yes

no

no

yes/yes

no

no

(1)

no

yes

yes

yes

yes

no

Carbon Steel

Stainless Steel / Carbon Steel

Aluminium

230V 1 ph / 50Hz

1) Provision will be left for future installation.

Ignition Control Box(Enclosure)

(2)

Control Piping(2)

Fuel Gas/Air Supplies 3-off

ignitors

Sun Shield

LD

H

Earth Boss

Cable Tray

3-off pilot lines

Thermocouples signals 3-off

IgnitionControl Box

2) Refer to 353/38 for panel details (AL doc. n°51-3282-U2G-554-010)

To Flare

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2

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Issue for approval

DESCRIPTION:

-

10/07/09

13/02/09

28/11/08

DATE:

-

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AZ

AZ

BY:

REVISIONS


SOXAL


353

Client:

End-User:

Project:

GBA Ref :

Knock Out Drum SpecificationV5711

DATA SHEET N°:

353-63Page 6 of 7

150# RFWN B16.5

4,150 / 1,700 mm

6,500 / 3,750 mm

32"

30"

-3 / +390°C

Liquid In

-

Flare Gas Out

-

Drain

Filling Water in

LT

LG B

LG A

Manhole

Skirt Vent

Skirt Access

Flare Gas In

GENERAL (2:1 ELLIPTICAL)

DIAMETER (INTERNAL)

HEIGHT (TL-TL) 8,000mm

3,300 mm

DESIGN CODESDESIGN CODE

DESIGN PRESSURE

DESIGN TEMPERATURE

OPERATING PRESSURE

OPERATING TEMPERATURE

AMBIENT TEMP. RANGE

CORROSION ALLOWANCE

DRUM DETAILSTYPE

POSITION

CLOSED DRAIN

LIQUID DROPLET SIZE

MIN. THICKNESS INCL. CA

EXTERNALFINISH

INSULATION

As per client specs

N/A

ACCESSORIESLEVEL GAUGE

PRESSURE INDICATOR

LEVEL TRANSMITTER

INST & MANWAY ACCESS PLATFORM

Yes

No

Yes

Yes

TEMP. TRANSMITTER No

TEMPERATURE INDICATOR No

TRACING

ASME VIII Div 1

3.5 barg

0.3 barg

+40° / +380°C

+19.4 / +35.8 °C

10 mm

VerticalFree Standing, internally derrick

Yes

600 micron

3 mm

-

-

4"

1½”2x1½"

2x1½"

2x1½"

24"4x4"

-

-

-

ASTM A105 N

ASTM A105 N

ASTM A105 N

ASTM A105 N

ASTM A105 N

ASTM A105 N

-

-

-

150# RFLWN B16.5

150# RFLWN B16.5

150# RFWN

-

-12,700mm

-780mm

5,800mm5,800 / 2,000

mm

5,100mm

1,100mm

-

B1

-

D1

A3

L1-L2GB1-GB2

GA1-GA2

H1

SV

-Connection with FL4711

-c/w mating loose flange in CS (1)

c/w mating loose flange in CS (1)

c/w Blind mating flange in CS



c/w Blind + Davit

-

ELECTRIC HEATER No

MATERIALSSHELL

HEADS

MAIN NOZZLES NECKS

INTERNALS

VALVES

TESTINGNDE of WELDS

HYDROTEST

IMPACT TEST

A516-Gr 70

A516-Gr 70

A105

A516-Gr 70

-

To Code

As per ASME VIII Div.1

-

2x24" - - 700mm SA -

SERVICE SIZE MATERIALEND

CONNECTIONELEV. COMMENTS

NOZZLE NO.

NOZZLE SCHEDULE

3" ASTM A105 5,100mm A2 c/w mating loose flange in SS ASTM-A.182.F.316L (1)

ASTM A105 N 5,500mm A1 c/w mating loose flange in CS (1)

-

No

-

No

No

No

No

No

No

-

-

No

No

INSULATION

150# RFLWN B16.5

150# RFWN B16.5

150# RFLWN B16.5

-

150# RFWN B16.47B

REMARKS1) Thickness of flange neck to be in accordance to Air Liquide piping specification.

Connections

supports for personal protection

Refer To Layout Sketch page 7 of 7Refer to 353/36 (AL doc. n° 51-3282-U2G-396-342)Refer to 353/37 (AL doc. n° 51-3282-U2G-393-343)

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CL

CHKD:

-

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1

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REV-:

-

Final issue

General revision

Issue for approval

DESCRIPTION:

-

10/07/09

13/02/09

28/11/08

DATE:

-

AZ

AZ

AZ

BY:

REVISIONS


SOXAL


353

Client:

End-User:

Project:

GBA Ref :

Knock Out Drum SpecificationV5711

DATA SHEET N°:

353-63Page 7 of 7

32" 150# B16.47B

Flare Gas InletA1

(5,500 mm)

24" 150# Manway H15100mm

1 ½” #150Level Inst. GA16500mm

1 ½” #150Level Inst. L15800mm

4" 150# Drain D1780 mm

3" 150# Liquid Inlet A2(5,100 mm)

1 ½” #150 Filling Water in A35800mm

1 ½” #150Level Inst. L22000mm

1 ½” #150Level Inst. GB21700mm

HL (5,000 mm)

NL (3,800 mm)

9800 mm

Protruding nozzle

24" Skirt Access SA700mm

4" Skirt Vent SV1100mm

30" Flare Gas OutletB1

12,700 mm

1 ½” #150Level Inst. GA23750mm

1 ½” #150Level Inst. GB14150mm

gba flare system installation operating and maintenance manual

Documents

maintenance instructions

gba equipment

hermes equipment

instruction manual

present manual

basic gba instructions

handling instructions

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