W R I T I N G O F J O H N Z I N K I N F O R M A T I O N S H A L L B E D I S C L O S E D T O A N Y T H I R D P A R T Y O R R E P R O D U C E D I N W H O L E O R P A R T W I T H O U T T H E P R I O R C O N S E N T I N T H I S I N F O R M A T I O N I S C O N F I D E N T I A L A N D T H E P R O P E R T Y O F J O H N Z I N K A N D I S R E L E A S E D O N C O N D I T I O N T H A T N O N E O F T H E T I T L E S C A L E I S S U E S T A M P K A L D A I R J O B N o . P R O J E C T C L I E N T O R D E R N o . C L I E N T E N G . P R O J . P R O C E S S D E S C R I P T I O N D A T E R E V D R G . N o . A B C D E F G H A B C D E F G H 5 4 3 2 6 1 1 2 3 4 5 6 E N G . N O N E P I P I N G & I N S T R U M E N T A T I O N D I A G R A M 0 2 1 . 1 1 . 0 5 I S S U E D F O R T E N D E R N D P D R N . DRG. No. K E P - 1 0 0 P I L O T I G N I T I O N S Y S T E M N O T E S : 1 . H T C A B L E F O R K E P - 1 0 0 I G N I T I O N & D E T E C T I O N S U P P L I E D B Y J Z 2 . D R A I N A L L L O W P O I N T S . . P R E L I M I N A R Y D o l p h n H o u s e 1 4 0 W i n d m i l l R o a d S u n b u r y - o n - T h a m e s M i d d l e s e x , T W 1 6 7 H T E n g l a n d T e l : ( 0 1 9 3 2 ) 7 6 9 8 3 0 F a x : ( 0 1 9 3 2 ) 7 8 7 4 7 1 D i v i s i o n o f t h e K o c h C h e m i c a l T e c h n o l o g y G r o u p L i m i t e d J O H N Z I N K P I L O T B B A H P I L O T A O N B A L P I L O T B O F F H S H S M A N U A L A U T O / O F F M A N U A L H S H S K E P - 1 0 0 C L I E N T J O H N Z I N K I N L E T P I X A 1 " 1 " N O T E 1 B A H P I L O T B O N O F F P I L O T A B A L I G N I T E P I L O T B P I L O T A M A N U A L I G N I T E P I L O T A P I L O T B P C V P O W E R S U P P L Y 2 4 0 V 1 p h 5 0 H z M A N U A L A U T O / O F F A L A R M C O M M O N P I L O T F A I L C L I E N T J O H N Z I N K N O T E 1 B E B E P I L O T C R E M O T E S T A R T / S T O P C L I E N T J O H N Z I N K " 1 / 2 1 " x x 1 " " 1 / 2 P I L O T I G N I T I O N & D E T E C T I O N P A N E L H P I N L E T 1 0 " 1 5 0 # R F W N 2 x K E P - 1 0 0
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
WRITING OF JOHN ZINK
INFORMATION SHALL BE DISCLOSED TO ANY THIRD PARTY OR REPRODUCED IN WHOLE OR PART WITHOUT THE PRIOR CONSENT IN
THIS INFORMATION IS CONFIDENTIAL AND THE PROPERTY OF JOHN ZINK AND IS RELEASED ON CONDITION THAT NONE OF THE
TITLE
SCALE
ISSUE STAMP
KALDAIR JOB No.
PROJECT
CLIENT ORDER No.
CLIENT
ENG.
PROJ.PROCESSDESCRIPTIONDATEREV
DRG. No.
A B C D E F G H
A B C D E F G H
5
4
3
2
6
1 1
2
3
4
5
6
ENG.
NONE
PIPING & INSTRUMENTATION DIAGRAM
0 21.11.05 ISSUED FOR TENDER NDP
DRN.
DR
G.
No.
KEP-100 PILOT IGNITION SYSTEM
NOTES:
1. HT CABLE FOR KEP-100 IGNITION & DETECTION SUPPLIED BY JZ
2. DRAIN ALL LOW POINTS.
.
PRELIMINARY
Dolphn House
140 Windmill RoadSunbury-on-Thames
Middlesex, TW16 7HTEngland
Tel: (01932) 769830Fax: (01932) 787471
Division of the Koch Chemical
Technology Group Limited
JOHN ZINK
PILOT B
BAH
PILOT AON
BAL
PILOT BOFF
HS HS
MANUAL
AUTO/OFF
MANUAL
HSHS
KEP-100
CLIENT JOHN ZINK
INLET
PI
XA
1"1"
NOTE 1
BAH
PILOT BON
OFFPILOT A
BAL
IGNITE
PILOT BPILOT AMANUAL
IGNITE
PILOT A PILOT B
PCV
POWER SUPPLY240V 1ph 50Hz MANUAL
AUTO/OFF
ALARMCOMMON
PILOT FAIL
CLIENT JOHN ZINK
NOTE 1
BE BE
PILOT C
REMOTESTART/STOP
CLIENT JOHN ZINK
"1/ 21"x x 1""1/ 2
PILOT IGNITION & DETECTION PANEL
HP INLET
10" 150# RFWN
2 x KEP-100
JOHN ZINK®KOCH CHEMICAL TECHNOLOGY GROUP LIMITED
JOHN ZINK ���� TODD COMBUSTION ���� BROWN FINTUBE ���� KALDAIR
VAT No. GB 785 4178 88 � Registered in England � Registration No. 3321082
Sheet 5
The design we have offered presents the opportunity for you to make significant cost
savings both in the sizing of the flare stack, risers and KO drums as well as
eliminating the need for any additional equipment for utility supply. In addition there
is a long term operational saving both in the reduction in utility usage and reduced
maintenance costs.
For the Sour Service we are concerned about the low LHV. While we consider that
given the current composition a high pressure flare tip could be used, we anticipate
that over time the LHV of the field production will reduce due to inert gas re-injection
and therefore an HP flare tip would become unstable. Therefore for this application
we would offer a utility pipeflare.
For the AP service there is not enough pressure available to take advantage of a
high pressure flare tip design and therefore for this application we would propose a
utility pipeflare.
John Zink are able to offer a comprehensive after sales service package including
assistance with installation, commissioning and training as well as spare parts
holdings. John Zink are an International combustion specialist with over 80 years
experience in supplying flare systems. John Zink have main manufacturing and
service facilities in Tulsa Oklahoma and Luxembourg along with service centres
throughout the world. John Zink employ over 1000 people worldwide. Scope Wellhead Flare Systems Reference Document: Wellhead Flare Functional Specification KM-5000-WP-PR-
DAT-0008 – rev 0 Sour Gas Flare
The current composition of the sour well head gases would be suited to use a KMI
type flare tip but the LHV levels are marginal and would not be high enough to
ensure burner stability for the KMI style flare tip as the field matures. We understand
that the Sour flare will be operated at exploration and early production phase and
therefore would not be subject to future dilution from reinjection. In this case we
would propose to use a high pressure KMI solution.
For this application we propose a KMI-2-12 high pressure flare tip (2 each 12"
Coanda tips) operating at 5 barg. We have included for a 75m high flare stack. Such
a flare would easily meet both the noise and radiation requirements defined in the
VAT No. GB 785 4178 88 � Registered in England � Registration No. 3321082
Sheet 23
2.2.12 Address where to place the order
You are kindly requested to place any order resulting from this offer directly to our
European Headquarters in Luxembourg at the following address:
JOHN ZINK INTERNATIONAL LUXEMBOURG SARL
Zone Industrielle Riedgen
Boîte Postale 83
L - 3401-DUDELANGE
Phone (352) 51.89.91
Fax (352) 51 86 11
Attn: Stephane Tarchala
DATA SHEET No. 103
KMI -2-12WB REV.
DATE
BY
1
2 Amin Buah
3 MAX mmscfd 50 50.0
4 MIN mmscfd
5 g/mole 24.20 23.51
6 °C 0 0
7
8 barg 5.00
9
10 SEE CUSTOMERS DATA SHEET
11
12
13
14
15 Fuel Gas
16 N2
17
18 2 TYPE: KEP-100
19 No TYPE:
20
21
22
23
24
25
26
27
28
29
30 FLAME RETENTION
31 LIFTING LUGS
32
33
34
35
36 PIPE2_1
37
38
39
40 SIZE
41 10 ''
42
43 1 ''
44
45
46
47 dBA 62.5 125 250 500 1K 2K 4K 8K
48 151
49 101.0
50
51
52
53
54
55
56
57
58
59 FILE:PIPE_DS2
ASME16.5 CLASS 150 RFWN
DESCRIPTION
SURFACE FINISH
MATERIALS
AISI 310
NATURAL
The drawing is typical only
2.25 Nm³/hr
UTILITY CONSUMPTION
200803-8213
SPL dB
This offer may not include all items shown above.
NOISE DATA
FREQUENCY COMMENT
AISI 310
PWL dB
SPL dB
PWL dB
Noise at stack base
AISI 310
AISI 310
AISI 310
AISI 310
AISI 310
LOWER BODY
WIND DEFLECTORS
SEAL
PILOT
PILOT NOZZLE AISI 310
FLOW
INLET PRESS.
NDP
TEMPERATURE
SMOKELESS
JZ REF:
PILOTS
PURGE GAS
FUEL GAS / PILOT
2.01 Nm³/hr
3.0m
0.5m
WEIGHT kg 450 kg
LENGTH mm
DIMENSIONS
PILOT GAS INLET
AISI 316LFLARE GAS INLET
MANIFOLD
UPPER BODY
ASME16.5 CLASS 150 RFWN
JOHN ZINK
RATING
QUANTITY
THERMOCOUPLES
TERMINAL POINTS
MATERIAL
WIDTH mm
PURGE
<Ringelmann 1
GAS COMPOSITION
INDAIR SPECIFICATION
M.W.
DESIGN CASES
SOUR FLARE
PARSON KHAZZAN/MAKERAM
GAS STREAM
200803-8213-
REMARKS
0
31-Mar-08PROJECT:CLIENT:
1.85 Nm³/hr
AISI 316L
Sweet Flare
-70
-50
-30
-10
10
30
50
70
-60 -40 -20 0 20 40 60
Distance (m).
Ele
vation (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 31/03/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 KMI-2-12 50 MMSCFD 22.32
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
7 3000.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
9.46
JOHN ZINK
1
2345
67
DATA SHEET No. 104
KMI -2-12WB REV.
DATE
BY
1
2 Max
3 MAX mmscfd 50
4 MIN mmscfd
5 g/mole 22.32
6 °C 0
7
8 barg 5.00
9
10 SEE CUSTOMERS DATA SHEET
11
12
13
14
15 Fuel Gas
16 N2
17
18 2 TYPE: KEP-100
19 No TYPE:
20
21
22
23
24
25
26
27
28
29
30 FLAME RETENTION
31 LIFTING LUGS
32
33
34
35
36 PIPE2_1
37
38
39
40 SIZE
41 8 ''
42
43 1 ''
44
45
46
47 dBA 62.5 125 250 500 1K 2K 4K 8K
48 148
49 96
50
51
52
53
54
55
56
57
58
59 FILE:PIPE_DS2
ASME16.5 CLASS 150 RFWN
DESCRIPTION
SURFACE FINISH
MATERIALS
AISI 310
NATURAL
The drawing is typical only
2.25 Nm³/hr
UTILITY CONSUMPTION
200803-8213
SPL dB
This offer may not include all items shown above.
NOISE DATA
FREQUENCY COMMENT
AISI 310
PWL dB
SPL dB
PWL dB
Noise at stack base
AISI 310
AISI 310
AISI 310
AISI 310
AISI 310
LOWER BODY
WIND DEFLECTORS
SEAL
PILOT
PILOT NOZZLE AISI 310
FLOW
INLET PRESS.
NDP
TEMPERATURE
SMOKELESS
JZ REF:
PILOTS
PURGE GAS
FUEL GAS / PILOT
2.01 Nm³/hr
3.0m
0.5m
WEIGHT kg 450 kg
LENGTH mm
DIMENSIONS
PILOT GAS INLET
AISI 316LFLARE GAS INLET
MANIFOLD
UPPER BODY
ASME16.5 CLASS 150 RFWN
JOHN ZINK
RATING
QUANTITY
THERMOCOUPLES
TERMINAL POINTS
MATERIAL
WIDTH mm
PURGE
<Ringelmann 1
GAS COMPOSITION
INDAIR SPECIFICATION
M.W.
DESIGN CASES
SWEET FLARE
PARSON KHAZZAN/MAKERAM
GAS STREAM
200803-8213-
REMARKS
0
31-Mar-08PROJECT:CLIENT:
1.85 Nm³/hr
AISI 316L
HP Flare Composition
-80
-60
-40
-20
0
20
40
60
80
-60 -10 40
Distance (m).
Ele
va
tio
n (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 31/03/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 KMI-9-12 280 MMSCFD 19.08
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
7 3000.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
9.46
JOHN ZINK
12
3
44
4
5
5
5
6
6
7
DATA SHEET No. 105
KMI -9-12WB REV.
DATE
BY
1
2 Max Cont
3 MAX mmscfd 280 200.0
4 MIN mmscfd
5 g/mole 19.08 19.08
6 °C 23-60 23-60
7
8 barg 5.00 3.25
9
10 SEE CUSTOMERS DATA SHEET
11
12
13
14
15 Fuel Gas
16 N2
17
18 3 TYPE: KEP-100
19 No TYPE:
20
21
22
23
24
25
26
27
28
29
30 FLAME RETENTION
31 LIFTING LUGS
32
33
34
35
36 PIPE2_1
37
38
39
40 SIZE
41 18 ''
42
43 1 ''
44
45
46
47 dBA 62.5 125 250 500 1K 2K 4K 8K
48 159
49 114
50
51
52
53
54
55
56
57
58
59 FILE:PIPE_DS2
ASME16.5 CLASS 150 RFWN
DESCRIPTION
SURFACE FINISH
MATERIALS
AISI 310
NATURAL
The drawing is typical only
8.22 Nm³/hr
UTILITY CONSUMPTION
200803-8213
SPL dB
This offer may not include all items shown above.
NOISE DATA
FREQUENCY COMMENT
AISI 310
PWL dB
SPL dB
PWL dB
Noise at stack base
AISI 310
AISI 310
AISI 310
AISI 310
AISI 310
LOWER BODY
WIND DEFLECTORS
SEAL
PILOT
PILOT NOZZLE AISI 310
FLOW
INLET PRESS.
NDP
TEMPERATURE
SMOKELESS
JZ REF:
PILOTS
PURGE GAS
FUEL GAS / PILOT
9.05 Nm³/hr
3.0m
1.4m
WEIGHT kg 1800 kg
LENGTH mm
DIMENSIONS
PILOT GAS INLET
AISI 316LFLARE GAS INLET
MANIFOLD
UPPER BODY
ASME16.5 CLASS 150 RFWN
JOHN ZINK
RATING
QUANTITY
THERMOCOUPLES
TERMINAL POINTS
MATERIAL
WIDTH mm
PURGE
<Ringelmann 1
GAS COMPOSITION
INDAIR SPECIFICATION
M.W.
DESIGN CASES
HP FLARE X-171
PARSON KHAZZAN/MAKERAM
GAS STREAM
200803-8213-
REMARKS
0
31-Mar-08PROJECT:CLIENT:
1.85 Nm³/hr
AISI 316L
LP Flare Composition
-70
-50
-30
-10
10
30
50
70
-60 -40 -20 0 20 40 60
Distance (m).
Ele
vation (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 31/03/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 KMI-2-12 22 MMSCFD 33.93
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
7 3000.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
9.46
JOHN ZINK
1
23
4
5
67
LP Flare Composition
-70
-50
-30
-10
10
30
50
70
-60 -40 -20 0 20 40 60
Distance (m).
Ele
vation (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 31/03/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 KMI-2-12 22 MMSCFD 33.93
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
7 3000.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
9.46
JOHN ZINK
1
23
4
5
67
DATA SHEET No. 107
EEF-U- 42 REV.
DATE
BY
1
2 Max Cont
3 MAX MMSCFD 28.00 20
4 MIN MMSCFD
5 g/mole 35.16 35.16
6 °C 20-120 20-120
7
8 mbar 0.17
9
10 SEE CUSTOMERS DATA SHEET
11
12
13
14
15 Fuel Gas
16 N2
17
18 3 TYPE: KEP
19 TYPE: Cr/Al
20
21 3.00m 1.35m
22 1500kg
23
24
25
26
27
28
29
30
31
32
33
34
35
36 PIPE2_1
37
38
39
40 SIZE
41 42 ''
42 1"
43
44
45
46
47 dBA 62.5 125 250 500 1K 2K 4K 8K
48
49 <85
50
51
52
53
54
55
56
57
58
59 FILE:PIPE_DS2
39.00 Nm³/hr
NDP
FREQUENCY COMMENT
Noise level at 0m from flare
ANSI CLASS 150 RF FLANGE
PWL dB
SPL dB
NOISE DATA
AISI 316
LIFTING LUGS
WIND DEFLECTORS
AISI 316
AISI 310
AISI 310
AISI 316
AISI 310
AISI 310
AISI 310
AISI 316
PILOT NOZZLE
PILOT MANIFOLD
IGNITION MANIFOLD
SURFACE FINISH
This offer may not include all items shown above.
NATURAL
FLOW
INLET PRESS.
PURGE
PILOTS
PURGE GAS
FUEL GAS / PILOT
TEMPERATURE
GAS COMPOSITION
FLARE GAS INLET
QUANTITY
THERMOCOUPLES
FLAME STABILIZER
PURGE SEAL
MATERIALS
BODY UPPER
BODY LOWER
PILOT
TERMINAL POINTS
DESCRIPTION RATING MATERIAL
DIMENSIONS
LENGTH(LA):
APPROX. WT.:
WIDTH(LB):
PILOT INLET
AISI 316ANSI CLASS 150 RF FLANGE
30.11 Nm³/hr
UTILITY CONSUMPTION
JZ REF:
200803-8213JOHN ZINK
PIPE FLARE SPECIFICATION
M.W.
PROCESS DATA
AP FLARE X-193
Workey Parsons Khazzan/Makarem
GAS STREAM
200803-8213-
REMARKS
0
1-Apr-08PROJECT:CLIENT:
1.85 Nm³/hr
AISI 316
AP Flare
-70
-50
-30
-10
10
30
50
70
90
110
-60 -40 -20 0 20 40 60
Distance (m).
Ele
vation (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 04/01/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 EEF-U-42 33.4 MMSCFD 35.16
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
JOHN ZINK
12
34
56
Sour Flare Buah Composition
-80
-60
-40
-20
0
20
40
60
80
-60 -40 -20 0 20 40 60
Distance (m).
Ele
vation (
m).
RADIATION PLOT
RFQ: 2008-8213 By: Nigel Philpott
Rev: 0Doc: 31/03/2008
Wind Speed: 17.1 m/s
Wind Direction: 0 degrees
Flare and contour key
Flare Flow Mol.
Wt.1 KMI-2-12 50 MMSCFD 23.51
Btu/hr.ft2
1 500.00
2 700.00
3 900.00
4 1100.00
5 1500.00
6 2200.00
7 3000.00
KW/m2
1.58
2.21
2.84
3.47
4.73
6.94
9.46
JOHN ZINK
1
2
3
4
567
JOHN ZINK® KOCH CHEMICAL TECHNOLOGY GROUP LIMITED
HIGH PRESSURE FLARES INTRODUCTION The use of flare tips operating at high pressure has become very much normal practice in petrochemical operations. The use of high pressure systems enables the operator to minimise line, vessel and relief valve sizes in order to save on capital cost and weight. The use of a high pressure flare does not only provide advantages in terms of capital cost but also in terms of improved flare tip performance. Typically a high pressure flare will deliver high capacity, improved efficiency, better dispersion and lower radiation. It will do this by utilising the Kinetic energy in the high pressure gas as it exits the tip, to entrain more air and create turbulence to mix that air with the flare gas. Improved aeration and mixing results in a more efficient flame which burns with a shorter and cooler flame. The result is a reduction in unburned elements in the combustion products, an increase in the proportion of entrained air allowing for improved atmospheric dispersion, and a reduction in the temperature and surface area of the flame to improve radiation levels. The art of designing the optimum flare tip is to maximise the surface area of gas exposed to air. John Zink and Kaldair have been the two world leaders in flare technology for a quarter of a century. The merger of the two companies in 2001 has yielded a range of flare tips and new technologies which is unique in the industry.
THE JOHN ZINK KSP FLARE TIP The KSP single point sonic pipeflare is the simplest form of high pressure flare tip. The KSP, originally developed by Kaldair, has been integrated into the John Zink range in its single nozzle form. The tip operates by allowing flare gas to accelerate to sonic velocity at the tip exit. For low capacity applications burning light hydrocarbon gases, this is a low cost and efficient solution for smokeless operation and reduced radiation. Single nozzle sonic flares have limitations. This type of tip is suitable for burning light hydrocarbons smokelessly, but as the hydrocarbons become heavier then more and more smoke will result at lower flows as the kinetic energy reduces and more air is required to burn heavier hydrocarbons. In addition there is a size limitation. As tip capacities increase then the exit diameter increases. As the flame envelop increases then it is more difficult for air to penetrate to the centre of the envelope. This results in unburned hydrocarbons at the centre of the flame ultimately producing smoke.
Small Diameter Nozzle Large Diameter Nozzle
Aspirated AirAspirated AirAspirated AirAspirated Air
Unb
urne
d H
ydro
carb
ons
THE JOHN ZINK HYDRA FLARE TIP To overcome the limitations of single nozzle flare tips, designers have sought to configure the tip to increase the the gas / air surface area. Designers of conventional flares have achieved this by passing the flare gas at high velocity through multiple nozzles rather than one large tip. This has the effect of increasing the surface area of gas exposed to the air and also reducing the effective diameter of the flare gas envelope allowing air to penetrate to its centre. The highly successful John Zink Hydra flare tip operates on this principle. It is a single point flare tip with multiple sonic nozzles.
The Hydra flare tip achieves a highly aerated, stiff and stable flame inspiriting significantly more air than a conventional sonic pipeflare which in turn reduces heat radiation. This stable flame is highly resistant to wind effects and flame pull down. The flame is initiated above the tip metal surface contributing to extended tip life. The Hydra is proven in service worldwide since 1989.
The phenomenon of flame lift off is common in high pressure flare tips. The unique John Zink technology used in the Hydra flare tip incorporates a small central burner which stabilises the flame and roots it to the flare tip resulting in a tip where lift off has been eliminated.
Due to its high flame stability the Hydra tip can be operated at higher pressures than other sonic flare tips. The Hydra is recommended for flaring low to medium weight saturated hydrocarbons between 1 and 15 barg. Even at high pressures the central burner holds the flame onto the centre of the tip. As many countries now are seeking to tax Emissions, there has been a trend in recent times to operate flare tips without pilots. This practice is not recommended by API as flare tips require pilot to remain stable. Most open pipe and multi nozzle flare tips will become unstable when operating without pilots. The central burner on the Hydra acts in place of the pilots to maintain stability. Although this type of flare tip has superior operational characteristics over single point flare tips, it still does not provide for smokeless flaring of heavier hydrocarbon gases at low pressure low flowrates.
Coanda Technology THE JOHN ZINK INDAIR FLARE TIP The INDAIR flare has been developed to provide a safe and reliable high efficiency flare tip to produce a smokeless, low radiation flare design without the need for outside assist media such as forced air or steam. The INDAIR flare is a pressure-assisted flare design which utilizes the internal energy within high-pressure gas streams to produce a highly aerated, turbulent flame.
The INDAIR flare utilizes the “Coanda Effect” to entrain and mix air into the hydrocarbon gas stream. High-pressure gas is ejected radially from the annular slot at the base of the INDAIR tulip. Instead of continuing horizontally, the gas adheres to the Coanda profile and is diverted through 90 degrees, entraining up to 20 times its own volume of air in the process.
The pre-mix air/gas mixture creates very efficient, 100% smokeless combustion of the flare gases. The flame produced by this efficient pre-mixed combustion is a very low radiation, low luminance flame. The flame length is less than half of that produced by a conventional flare tip. The flame is also a thin, stiff, pencil shape that is not easily distorted by crosswinds.
Flame initiation always takes place near the maximum diameter of the tulip, insuring reliable ignition of the gas by external pilots, even on sudden venting and under high wind conditions. Smokeless, low radiative combustion is achieved without the need for ancillaries such as steam, compressed air or fuel gas. Unlike other flare tips, the flame propagates from the outside and there is always a protective film of hydrocarbon gas insulating the Coanda tip. This avoids overheating of the flare tip and allows it to be manufactured from conventional alloy steels, using normal welding procedures, without the need for sophisticated materials such as ceramics.
Advantages and Operating Characteristics of the INDAIR Flare
High Pressure Operation
Since the INDAIR flare operates at elevated pressure when burning HP gas (rather than near atmospheric pressure as with a conventional flare), significant savings in header size and knock-out vessel size may be made. The primary design consideration in sizing relief headers and liquid knockout vessels is the velocity of the gas. Maintaining a high backpressure at the flare tip keeps the gas compressed in the upstream flare header. This reduces the velocity of the gas for a given relief flow rate of gas.
Efficient Air Entrainment and Mixing
The efficiency of any combustion process is largely a function of the efficiency of the fuel/air mixing. Conventional low-pressure pipeflares emit a cylinder of hydrocarbon gases that rely totally on natural diffusion of air into the flame. This produces relatively low combustion efficiency. Multi-point sonic pipeflare tip designs improve the efficiency by splitting the flow between smaller, separated cylinders of hydrocarbon gases and creating some air entrainment into the flame due to the sonic jet nozzles which are used. The unique INDAIR flare tip, based on the Coanda Effect, forms a thin film of hydrocarbon which entrains and pre-mixes air prior to combustion. The INDAIR flare, in most cases, produces combustion efficiencies in excess of 99.9%.
Smokeless Operation
INDAIR flares will provide smokeless combustion of high-pressure gas over their specified operating range. Conventional multi-point sonic flare tip designs can produce smoke when flaring heavy hydrocarbon gases, unsaturated hydrocarbon gases, or gas streams containing liquid droplets. The INDAIR flare tip, due to its unique pre-mixed turbulent flame, high air entrainment rate, and thin film combustion technique, will produce smokeless flaring of any hydrocarbon gas stream.
Low Radiation The INDAIR flare produces a highly aerated turbulent diffusion flame that radiates far less heat than the equivalent flame produced by the conventional pipeflare. The reduction in radiation is achieved without the use of ancillaries such as steam, compressed air or fuel gas. The Fraction of Heat Radiated (F), which is also often termed flame Emissivity (e), is the portion of a flame’s gross heat release that is emitted as radiation from the flame. The F-factor (or Emissivity) of INDAIR flares has been measured for a wide range of operating conditions. The value of F for INDAIR flares varies from 0.08 to 0.10. A value for F of 0.20 to 0.25 is used for an API-type pipe flare. A value for F of 0.12 to 0.15 is produced by conventional multi-point sonic flare tip designs.
Flame Length The turbulent INDAIR diffusion flame with its increased combustion intensity is far shorter than that of an equivalent conventional flare. The flame length produced by an INDAIR flare is less than half that produced by a conventional API-type pipeflare
Flame Stability In contrast to the wind sensitive flame produced by a conventional flare, the INDAIR flare produces a flame with a high directional stability which is not easily distorted by cross-winds. The flame is extremely stable; in fact, INDAIR flares have been operating successfully in the North Sea in wind speeds in excess of 100 mph.
Liquid Carry-Over Even with the best run production/separation installations, liquid carry-over to the flare line can take place. With conventional pipeflares or multi-point sonic flare tips this can be a serious potential hazard giving rise to 'flaming rain' falling and pollution affecting a wide area.
The intense shear in the INDAIR slot region ensures efficient atomization of liquids, aiding vaporization and combustion. The INDAIR flare is capable of burning 25% by weight of liquid carry-over without any fall-out or smoke production whatsoever. The INDAIR flare tip can effectively atomize liquid particles with size in excess of 1200 microns. This feature means that, in many cases, the flare may be operated without a liquid knockout drum in the HP flare line.
Stiff Directional Flame
The unique geometry and stiff directional flame allow the Indair to be mounted at an angle without any detrimental effect on the tip operation or life. This feature is particularly useful in offshore application where the flame can be angled away from the platform or FPSO in order to reduce radiation on deck.
Unique Metallurgical Design
Extensive research and development has led to recent advances in the metallurgical design of INDAIR flare tips. Flaring is a unique high temperature service in that the metal is often exposed to extreme temperature differentials across the periphery of the flare tip, thermal shock during a sudden blowdown condition, and very high temperatures during low to moderate flow rates. Conventional high nickel alloys used in many flare designs can withstand very high temperatures, but can be subject to cracking and failure when exposed to repeated cycles of thermal shock and high temperature differentials.
The INDAIR flare tip uses a special high-nickel alloy that combines high temperature strength and high ductility. All of the metal surfaces that have contact with the flame (i.e. the entire “tulip” assembly) are fabricated with this alloy. This unique design enables the INDAIR flare to easily withstand a vast array of harsh operating conditions. The unique INDAIR flare tip design can provide long, maintenance-free service life.
Reliable Ignition The INDAIR flame always initiates near the maximum tip diameter so that reliable ignition of the INDAIR flame is achieved, even on sudden venting and under high wind conditions.
Flare Capacities In general, the volumetric gas flow rate (Q) through a sonic flare tip is a function of the absolute gas pressure (P) at the exit area (A) and the specific gravity and absolute temperature of the gas (Sg, T). The multiplier K is a function of flare design and to a lesser extent gas composition.
Q = KPA (T x Sg)-0.5
For conventional sonic flare tips, the outlet area A is fixed, and turndown is largely governed by the ratio of operating pressures:
Turndown = P available/ P minimum
Where P minimum is normally around 10 psig.
With the unique variable slot (VS) INDAIR design, the area varies linearly with pressure. Much larger turndown ratios can be achieved since:
Turndown = (P available x A max) / (P min x A min)
THE FIXED SLOT INDAIR Few other devices in engineering are required to perform satisfactorily over such a wide range of operation as the flare tip. It must be able to handle all flow conditions from purge to full relief. This it can do but it is fair to say that it handles some conditions better than others. Essentially at high flow the flame is more controlled and burns away from the flare tip. Under this condition metal temperatures are low and the tip would last an almost indefinite period. However under low flow conditions flame control is lost. It burns around the tip or even inside it, metal temperatures are high and cyclical. This is the situation that burns out flare tips and unfortunately it is
the one commonly encountered on modern platforms that export or re-inject their gas. The fixed slot version of the Indair is most susceptible to damage due to continued operation at low pressures and therefore should only be considered where high flows are anticipated or where continuous purging is with nitrogen.. The tip is recommended for venting applications where high air entrainment and dilution are required to aid dispersion. It is a physical fact that the shape of the flow/pressure curve of an orifice discharging to atmosphere is such that relatively high flows are achieved at low upstream pressures i.e. if an orifice were designed to pass 23 MMSM³/D at 5 barg then it would still pass 2.8 MMSM³/D at only 0.1 barg. In flaring terms this latter pressure is not enough to produce a turbulent, stiff flame and the result is a laminar diffusion flame (like a pipeflare). The region that a Coanda flare will give good performance starts at about 0.2 barg is fully developed by 0.8 barg and carries on to 5 barg or above. So, in the case of our 23 MMSM³/D flare, this will give it's best performance from 6.5 to 23 MMSM³/D, give improving performance from 2.8 to 6.5 MMSM³/D and pipeflare like flames below 2.8 MMSM³/D. Thus in the area where it's performance is worst is just where it will operate most of the time. HL Indair A variant of the Indair is the HL which allows a separate LP case to be passed through the centre of the Indair Tulip. The efficiency of the Indair in entraining air is such that when HP and LP are firing simultaneously there is enough air entrained to allow both LP and HP streams to operate smokelessly.
Flare TipFlow vs Pressure Curve
0.00
5.00
10.00
15.00
20.00
25.00
0.0 1.0 2.0 3.0 4.0 5.0 6.0
Pressure barg
Flo
w M
M S
m3/
d
MW= 17.00 Temp= 15.0°C
VARIABLE SLOT INDAIR The only solution for providing reasonable smokeless turndown with a conventional sonic flare tip is to provide an elaborate multi-flare tip design with many flare stages separated by control valves. This type of design is therefore very expensive to install and maintain There is another way to "stage" a flare, that is to say to modify it's flow/pressure curve so that it operates at higher pressures at lower flows. This can only be done by varying the discharge flow area of the flare tip itself. The INDAIR flare lends itself to this very well. It is apparent that the gas slot area can be changed by raising or lowering the tulip assembly within the flare tip body.
The whole tulip and inner stack is allowed to move up and down in response to applied flare gas pressure. In effect we have a force balance with the tulip weight, Coanda thrust and spring force all acting downwards being opposed by the upward force caused by the internal gas pressure. The rating of the springs determines the opening characteristic which is normally to start opening at 0.7 barg and be fully open by 2.0 barg
The slot width (which determines the tip outlet area) remains at a small size during low gas flow rates and increases proportional with increase in gas flow. This design provides near infinite smokeless turndown design while maintaining high maximum flow capacities. This variable slot INDAIR design, therefore, produces 100% smokeless flaring from minimum (purge) to maximum design flow rates.
The unique variable slot INDAIR flare tip provides infinite smokeless turndown without the need for these elaborate staged multi-flare designs. A single INDAIR flare tip provides 100% smokeless flaring and high flaring capacity with a very low radiation flame. The spring-loaded mechanism is extremely reliable, with a design similar to that used in safety relief valves.
Tulip Bowl
Tulip Cone
Annular Slot(maximum width)
CoandaProfile
Tulip Bowl
Tulip Cone
Annular Slot(minimum width)
CoandaProfile
Flare TipFlow vs Pressure Curve
0.00
5.00
10.00
15.00
20.00
25.00
0.0 1.0 2.0 3.0 4.0 5.0 6.0
Pressure barg
Flow
MM
Sm
3/d
MW= 17.00 Temp= 15.0°C
THE JOHN ZINK KMI FLARE TIP The KMI is a Hybrid of the Hydra and Indair Variable slot technology. The concept of multiple Indair tips being located in an array has been used for many years however John Zink have developed a multi-nozzle flare tip which is a single point tip with multiple Indair Nozzles. This not only has provided the multi-arm advantages of the Hydra, increasing the flare gas surface area exposed to the air, but also employs the infinite turndown features of the Variable Slot Indair. In addition the turndown flexibility can be enhanced further by varying the spring rates on the individual nozzles such that the flare tip can act as a staged system in itself. Thus the tip can be set up to bring nozzles online in turn such that at low flows only one or two nozzles will have their slots open while all the others are closed. As the pressure and flow increase then slots can open in sequence until at full flow all slots are fully open. KMI Advantages
The KMI benefits from all of the advantages of single tulip Indair’s described above, but also has some key advantages:
• The large Indair tulips are a two part construction with a pressed bowl and a fabricated cone. These parts are welded together. In operation this construction does have an inherent weakness in the welds which over time can reduce the life of the tip. The small Indair tulips used in the KMI are investment cast single part construction and very robust. The ratio of bowl diameter to wall thickness is much higher for the smaller tulip and therefore the tulip is extremely stable.
• As the KMI tulips are very small they
are easily man handled. Therefore in the event that any tulips require changing, it can be done without the use of crane a crane. In addition the replacement of an investment cast small tulip is not expensive where the manufacturing cost of a large tulip is relatively high.
• The KMI design allows much more
flexibility than the single point tip. The springs on the KMI can be set at different ratios to allow slots on some arms to open earlier than slots on others. This can be used to effectively stage the flare. In this way at low flows it is possible to operate with one 1 or 2 slots open thus optimizing the pressures and saving wear and tear on other nozzles.
• The spring system is maintenance free and will give many years of trouble free
operation. Often there are concerns over the possibility of the springs failing and the tip not opening. The mechanism has a fail safe, i.e. fail open, arrangement. Our experience has been that we have not, in 30 years of supplying Indair’s, had a report of a spring failure with tips operating within their design criteria.
• Over a 20 year flare life all types of flare tip will require a certain extent of
refurbishment. For the single point Indair tip this would mean a new tulip on average every 5 to 7 years. For the multipoint we would expect this period to be much longer and only a few of the tulips may need changing if at all. Maintenance costs and down time will be reduced.
Tulip Bowl
Tulip Cone
SpringAdjustment
Port
Annular Slot(maximum width)
CoandaProfile
Spring Assembly(Bellville Washers)In CompressedState
Fixed (Welded)Support Brackets
Non-Fixed (Guide Tube)Support Brackets
MainBodyMainBody
The Variable Slot Indair has been installed in over 300 installations worldwide for nearly 30 years.
With smokeless flaring being a more important design feature in recent years the variable slot INDAIR has become the choice of most major oil and gas producers.
Advantages of angling flare tips The unique geometry and stiff directional flame allow the Indair to be mounted at an angle without any detrimental effect on the tip operation or life. This feature is particularly useful in offshore application where the flame can be angled away from the platform or FPSO in order to reduce radiation on deck. The following radiation isopleths demonstrates how the deck level radiation is reduced for a boom mounted Indair flare tip CONDAIR FLARE TIP The CONDAIR flare tip is a variation of the Indair tip which utilises the superb liquid handling ability of the Coanda effect. The CONDAIR tip can burn gases smokelessly with up to 75% entrained liquids and without liquid fall out. These flare tips are often used in well test applications where high pressure is available or in burn pit applications.
Angled TipVertical Tip
Wind Speed = 65 ft/s
MARDIAR FLARE TIP A derivative of the INDAIR, again based on the 'Coanda Effect' is the MARDAIR flare. The cross-section, shown of the MARDAIR shows the gas exiting from the slot over a Coanda surface on the inside of the flare tip drawing air from beneath the flare. The MARDAIR flare tip has many of the attributes of the INDAIR tips but the MARDAIR flare is intrinsically more efficient than the INDAIR, producing lower radiation and a less luminous flame. Even greater air entrainment is achieved by an “inwardly curved” Coanda profile. The MARDAIR, with its unique “trumpet shape” entrains air at a rate up to 25 times the gas flow rate The MARDAIR is also the quietest of all flares that operate within the sonic flow regime. Its unique low noise feature is achieved by virtue of all high velocity gases being contained within the body of the flare.
A special low noise version of the MARDAIR M-400, has been developed. With this the normally plain slot profile is replaced by a 'Shark Tooth' design which effectively reduces sonic jet noise by increasing the gas/air contact interface in exactly the same manner as low noise trim valves. This version gives a useful 3-4 dB drop in jet noise.
The low radiation characteristic of the Mardair is compared to other flare tip designs in the example below The radiation for the Indair tip can less than half that of a conventional low pressure pipeflare. The Mardair can offer radiation levels of up to half of that again.
JOHN ZINK u TODD COMBUSTION u BROWN FINTUBE u KALDAIRu KEU Registered Address: Dolphin House w 140 Windmill Road w Sunbury-on-Thames w Middx TW16 7HT w England
KEP-100 Automatic Electronic Ignition Control System
John Zink are committed to the principle of pilot ignition for flares. The use of a continuous pilot is the only reliable method to guarantee flare ignition and stability. It is proven that flare tips and pilots work as a system and pilotless flare tips have a tendency to instability.
The Kaldair model KEP-100 automatic electronic pilot ignition control system is proprietary design providing many operational benefits over conventional flare pilot ignition control systems which use flame front generation for ignition or thermocouples to detect the flame. The KEP offers the following features
• Proven and reliable pilot monitoring technology
• Instantaneous recognition of pilot failure
• Fast, reliable pilot ignition / re-ignition
• Easy and flexible installation
• Simple hassle free operation
• Low capital cost
The KEP pilot draws in air with the fuel gas fed to the pilot to create a combustible mixture that is fed into the pilot burner nozzle. The burner nozzle includes a high voltage electrode that terminates directly in the burner nozzle. Upon energizing the electrode with a high AC voltage potential, a high-voltage arc is discharged creating a spark that ignites the fuel/air mixture in the burner nozzle.
The direct spark ignition achieved with the KEP-100 electronic pilot is far more reliable than conventional flame front generator ignition systems, which require a long purge of the flame front lines followed by the remote ignition of the flame front at the remote location.
InspiratorAssembly
Pilot Inlet
IgnitionInlet
PilotNozzle
CeramicRod
(Electrode)
The electrode used in the pilot nozzle is a rugged Kanthal rod design. The rod is insulated along the entire length of the pilot by a high temperature ceramic rod. The ceramic rod/electrode assembly is protected in a ½” 316 SS pipe. The electrical connection is made in a stainless steel connector box at the base of the pilot. The high voltage cable termination is made at this point using a spark plug boot-type connection to the Kanthal rod.
The specially developed KEP ignition cable has one core and a single cable is used for both ignition and monitoring.
How does Ionization Detection Work ?
In the ignition monitoring mode, the electrode is energized with a small AC potential applied between the electrode and ground. The AC current flow between the electrode and ground is then monitored by the control system.
If no flame is present, there is no path for current flow between the electrode and ground (for example, an open circuit is detected). However, if a flame is present, the pilot nozzle will contain a cloud of ionized gases in the burning flame (referred to as “Flame Ionization”). These ionized gases create a path for current flow between the electrode and ground (for example, a closed circuit is detected).
Open Circuit =Flame Out
Closed Circuit =Flame On
+-
-
- -
--
+
--
-
-+
++
++ +-+
-+
++
+
+ +
Ceramic Rod
Kanthal Electrode(Pilot Nozzle End)
Kanthal Electrode(Cable End)
Locking Nut(Pilot Nozzle End)
Locking Nut(Cable End)
The method of flame ionization monitoring is a very reliable pilot flame monitoring technique. The instant that the flame is lost, the loss is detected by the control system, allowing the control system to immediately switch to the re-ignition mode to attempt to re-ignite the pilot. Conventional pilot monitoring techniques rely on thermocouple measurements that create a considerable response time delay as the thermocouple sheath cools to the alarm set point. Thermocouples can take up to 15 minutes to recognize flame failure. Cold venting of hazardous flare gas for this period of time could be fatal.
If the first attempt is unsuccessful than the purge delay cycle is started once again. These considerable response time delays with an FFG ignition system can often leave the pilots unlit for an unacceptable, dangerous time period. The KEP system, however, provides immediate indication of pilot flame loss and nearly instantaneous re-ignition via direct spark in the pilot nozzle.
Conventional pilot monitoring systems use a thermocouple mounted in the pilot nozzle. The extreme temperature of the pilot flame makes the long-term reliability of this technique very poor. In fact it is common to burn up the thermocouple junctions upon initial startup of the pilots. When designs are modified to protect the thermocouple, response time upon loss of flame becomes very slow.
With the KEP-100 pilot ignition system all of the electronics to control the ignition and flame monitoring are housed in a remote control panel. A single high voltage cable connection is made between the control panel and each of the pilots. The standard control panel can be easily installed up to 300m from the pilots and as far as 1000 m with special modifications.
The control panel includes the high voltage transformer (6 kVA) used for pilot ignition and all of the monitoring and control electronics. The panel includes automatic mode selector, manual ignite pushbutton, flame on & flame off indicator lights for each of the pilots. Each pilot has its own dedicated monitoring and control circuits and ignition transformer for truly independent operation of each of the pilots.
PILOT ON
PILOT OFF
MAN/OFF/AUTOSELECTOR
PILOT #2
TOPILOTS
AC POWER INREMOTEALARMS
PILOT ON
PILOT OFF
MAN/OFF/AUTOSELECTOR
PILOT #3
PILOT ON
PILOT OFF
MAN/OFF/AUTOSELECTOR
PILOT #1
The Kaldair KEP-100 ignition control system has been in use for many years and has proven highly successful in hundreds of flaring applications from the rugged Arctic conditions of the North Slope of Alaska to the extremely high winds of the North Sea in the Atlantic. The direct spark ignition coupled with the unique flame ionization monitoring technique provides a system far more reliable than conventional flame front ignition or thermocouple monitoring systems.
Through continuous improvement and experience the KEP system has evolved over the years. Many improvements have been made to the pilot to improve its reliability and operational life. The latest pilots include high integrity systems to eliminate heat damage to the KEP cables.
The latest KEP pilot incorporates the unique technology of the KEP ignition and monitoring system into the advanced John Zink Windproof pilot which, not only reduces gas consumption by up to 50%, but also operates in winds of 160 mph and rainfall equivalent to 20 inches per hour, and will also reliably reignite in these conditions.
The KEP system can be supplied for both safe and hazardous areas. The system is certified to most international standards including ATEX. The individual requirements of most Oil and Gas Operators and Contractors specifications can be accommodated.
JOHN ZINK u TODD COMBUSTION u BROWN FINTUBE u KALDAIR Registered Address: Dolphin House w 140 Windmill Road w Sunbury-on-Thames w Middx TW16 7HT w England