UOP Callidus

2013 Flare School

Brian Duck
General Manager of Flare Division

Introductions

UOP Callidus Flare School

November 7-8, 2013
Shanghai, China
© 2013 UOP LLC. All rights reserved.
UOP Callidus Overview

• CALLIDUS (kal’ I dus) adj. (Latin)

• 1. Clever by reason of
experience
• 2. Skillful

• Founded November, 1989

• Acquired by Honeywell December,

2008

• Part of the UOP Equipment Group

within Honeywell

© 2013 UOP LLC. All rights reserved.

 UOP Callidus Overview

• Main Design and

Management Office in
Tulsa, Oklahoma, USA
• 400+ Employees
• 100,000+ ft2
Manufacturing Facility,
Beggs, Oklahoma,
USA
• 3,000+ m²
Manufacturing Facility,
Shanghai, China
• ISO 9001:2008
Certified USA Phone: +1-918-496-7599
Web: www.callidus.com
© 2013 UOP LLC. All rights reserved.
 UOP Callidus Product / Service Portfolio

Process Burner Selective Catalytic Reduction Flare Systems Service & Parts
Systems (SCR)

Thermal Oxidizers CFD Modeling Flare Gas Recovery

© 2013 UOP LLC. All rights reserved.

What UOP Does

UOP creates knowledge via invention &

innovation & applies it to the energy industry

• 1,570 Scientists & engineers • Process Technology

• 2,600 active patents • Catalysts
• Expertise • Adsorbents
• Experience • Equipment
• Services

Petroleum Renewables
Petrochemicals Natural Gas

More than 60% of World’s Gasoline & 85%

Biodegradable Detergents Use UOP Technology
© 2013 UOP LLC. All rights reserved.
Honeywell’s Businesses
• $35-36 billion* in revenues, 50% outside of U.S.
• Nearly 130,000 employees operating in 100 countries
• Morristown, NJ global corporate headquarters
Automation & Performance Transportation
Aerospace
Control Solutions Materials & Systems
Technology

$10.8-11.2B* $14.7-15.1B* $5.0-5.2B* $4.3-4.5B*

*‘11 revenues estimate

© 2013 UOP LLC. All rights reserved.
 UOP Global Locations

Research & Engineering

Development Sales & Service Offices Manufacturing Centers

North America North America Middle East North America Europe North America
Anaheim, CA Des Plaines, IL – Baghdad, Iraq Anaheim, Ca Brimsdown, UK Des Plaines, IL
Des Plaines, IL Headquarters Dubai, UAE Baton Rouge, LA Reggio, Italy Houston, TX
Mobile, AL Houston, TX Dhahran, KSA Beggs, OK Tulsa, Ok
Riverside, IL Mt Laurel, NJ Mumbai, India Catoosa, OK
Shreveport, LA Tulsa, OK Littleton, CO Asia Europe
Asia McCook, IL Hiratsuka, Japan Antwerp, Belgium
Beggs, OK Penang, Malaysia
South America Bangkok, Thailand Mobile, AL
Middle East Rio de Janeiro, Brazil Beijing, China Shreveport, LA Shanghai, China Asia
Dhahran, KSA Delhi, India Tonawanda, NY Yokkaichi, Japan Delhi, India
Europe/Russia Jakarta, Indonesia Kuala Lumpur,
Asia Antwerp, Belgium Kuala Lumpur, Malaysia
Delhi, India Erkrath, Germany Malaysia
Shanghai, China Guildford, UK Seoul, Korea
Milan, Italy Singapore
Hiratsuka, Japan Moscow, Russia Tokyo, Japan
Rolle, Switzerland © 2013 UOP LLC. All rights reserved.
Global Customer Base

© 2013 UOP LLC. All rights reserved.

UOP Callidus Testing and Development

© 2013 UOP LLC. All rights reserved.

UOP Callidus Manufacturing and Test Facility

© 2013 UOP LLC. All rights reserved.

Introductions
•What Is Your Name?
•What Is Your Current Role?
•Where Is Your Home Office?
•How Long Have You Been In The
Industry?

Optional…
•Some Of Your Background?
•One Thing About You That May Be
Unique Or Of Interest?
• Interesting Hobbies, Interests?

© 2013 UOP LLC. All rights reserved.

© 2013 UOP LLC. All rights reserved.
 UOP Callidus
2013 Flare School

Brian Duck
General Manager of Flare Division

Flare Design Basics

UOP Callidus Flare School

November 7-8, 2013
Shanghai, China
© 2013 UOP LLC. All rights reserved.
What is a Flare?

• Flare: A device or system used to safely dispose of

relief fluids in an environmentally compliant manner
through the use of combustion (API 537)

© 2013 UOP LLC. All rights reserved.

Plant Safety is Critical

© 2013 UOP LLC. All rights reserved.

What Does a Flare Do?

• The flare acts as the last point of disposal for waste

exhaust gas

• It must operate with an extremely large turndown ratio

• It must be highly reliable in all climatic conditions

• Often operated outside the design envelope

• Without the flare, most facilities cannot be operated

safely

© 2013 UOP LLC. All rights reserved.

Types of Flares

• Elevated Flares

• Enclosed Ground Flares

• Multipoint (Open) Ground Flares

• Horizontal and Pit Flares

• Offshore

© 2013 UOP LLC. All rights reserved.

Elevated Flares

• Most common type of flare

• Elevated flare tips reduce radiation

at grade

• Elevated flares have the best

dispersion profiles of any flare type

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Major Types

• Guy Supported

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Major Types

• Self Supported

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Major Types

• Derrick Supported

© 2013 UOP LLC. All rights reserved.

Enclosed Ground Flares

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Multipoint (Open) Ground Flares

© 2013 UOP LLC. All rights reserved.

Horizontal and Pit Flares

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Offshore Flares

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Flare Design Parameters

• Hydraulic Capacity

• Radiation Control

• Smokeless Capacity

• Noise

• Environmental Considerations

© 2013 UOP LLC. All rights reserved.

Hydraulic Capacity

• Flare system must flow the maximum volumetric relief

case without exceeded maximum relief valve
backpressure

• Typically multiple simultaneous relief sources

• Maximum flare tip exit velocity

• Maximum velocity for a stable flame
• Most important on elevated flare tips
• Federal requirements
• USA: 40 CFR 60.18
• Other countries have similar requirements
© 2013 UOP LLC. All rights reserved.
Hydraulic Capacity

• Properly designed flares

can maintain stable flame
as high as 0.8 Mach in pipe-
style flare tips

• HP tips routinely operate at

sonic velocities

• Flame retention tabs help

anchor the flame to the
flare tip exit

• Unstable flame can result in

combustion rumble
© 2013 UOP LLC. All rights reserved.
Hydraulic Capacity—40 CFR 60.18

• Sets maximum exit velocity based on either:

• Hydrogen content (by volume)

• 8% minimum hydrogen requirement

• Waste gas lower heating value

• 200 BTU/scf minimum for unassisted flare
• 300 BTU/scf minimum for air or steam assisted
flare

• These requirements are under detailed review by the

US EPA.
© 2013 UOP LLC. All rights reserved.
Hydraulic Capacity—40 CFR 60.18

• Under hydrogen rules, unassisted flares are capped at

122 ft/s exit velocity

• Under LHV rules, unassisted and steam assisted flares

are capped at 400 ft/s

• Air flares have no velocity cap, but are limited by

practical application

© 2013 UOP LLC. All rights reserved.

 Hydraulic Capacity—40 CFR 60.18
Steam Assisted/Unassisted Flare Tip
Maximum Exit Velocity vs. Waste Gas Lower Heating Value
425

400

375

350

325
Maximum Waste Gas Velocity (ft/s)

300

275

250

225

200 Unassisted

175
Steam Assisted
150

125

100

75

50

25

0
200 300 400 500 600 700 800 900 1,000 1,100 1,200 1,300 1,400 1,500 1,600 1,700 1,800 1,900 2,000
Waste Gas Lower Heating Value (BTU/scf)
© 2013 UOP LLC. All rights reserved.
 Hydraulic Capacity—40 CFR 60.18
Air Assisted Flare Tip
Maximum Exit Velocity vs. Waste Gas Lower Heating Value
500
475
450
425
400
375
Maximum Waste Gas Velocity (ft/s)

350
325
300
Air Assisted
275
250
225
200
175
150
125
100
75
50
25
0
250 500 750 1,000 1,250 1,500 1,750 2,000 2,250 2,500 2,750 3,000 3,250 3,500 3,750 4,000 4,250 4,500 4,750 5,000
Waste Gas Lower Heating Value (BTU/scf)
© 2013 UOP LLC. All rights reserved.
 Hydraulic Capacity—40 CFR 60.18
Unassisted Flare Tip
Maximum Exit Velocity vs. Hydrogen Percentage by Volume
150

125
Maximum Waste Gas Velocity (ft/s)

100 Unassisted Hydrogen Flare

75

50

25

0
8 9 10 11 12 13 14 15 16 17 18 19 20
Hydrogen Percentage by Volume
© 2013 UOP LLC. All rights reserved.
Hydraulic Capacity—40 CFR 60.18

• 40 CFR 60.8(c) states:

• “…nor shall emissions in excess of the level of the
applicable emission limit during periods of startup,
shutdown, and malfunction be considered a violation
of the applicable emission limit unless otherwise
specified in the applicable standard”

• Different states interpret this differently, so check your

local permitting authority

© 2013 UOP LLC. All rights reserved.

Hydraulic Capacity

• Design impact of oversized flare tips:

• Increased capital cost of tip

• Higher radiation levels at grade

• Increased wind loading and structural requirements

• Shorter tip life

© 2013 UOP LLC. All rights reserved.

Hydraulic Capacity—Further Considerations

• Probability of simultaneous
relief valve lifts at the
maximum rate

• High integrity protection

system (HIPS)

• Commercial software
available for detailed relief
system design.
• Unisim
• Hysis Flare operated at roughly
10x the design capacity

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• Two basic types of flame:

• Diffusion flame
• Buoyancy and wind have a large impact on flame
shape
• Typical operating condition for an elevated flare

• Aerated flame
• Momentum has a large impact on flame shape
• Typically observed in high pressure flares

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• Diffusion flames tend to

be more radiant than
aerated flames

• The redder the flame is,

the more it tends to emit
radiation in the infrared
end of the spectrum

© 2013 UOP LLC. All rights reserved.

Flare Radiation

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• Aerated flames tend

more towards clear or
blue flames

• Typically less radiant

than diffusion flames

© 2013 UOP LLC. All rights reserved.

Flare Radiation

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• Flare radiation is heat radiation emitted in the infrared

portion of the spectrum

• Only 0.1% of flare energy is emitted as visible light

• The amount of radiant heat emitted is highly influenced

by the composition of the waste gas

• By cooling the flame and reducing the amount of free

carbon, steam or air assist methods tend to reduce the
amount of infrared radiation emitted

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• API 521 Maximum Exposure Times Summary

Radiation Level Maximum Stay Time

9.46 kW/m2
A few seconds with appropriate clothing
3,000 BTU/(hr∙ft2)
6.31 kW/m2 Up to 30 seconds for emergency actions with
2,000 BTU/(hr∙ft2) appropriate clothing
4.73 kW/m2 Emergency actions lasting from two to three
1,500 BTU/(hr∙ft2) minutes with appropriate clothing
1.58 kW/m2
Continuous exposure with appropriate clothing
500 BTU/(hr∙ft2)
Appropriate clothing consist of a hard hat, long-sleeved shirts, gloves,
pants, and shoes.

© 2013 UOP LLC. All rights reserved.

Flare Radiation

• The most common model for calculating flare radiation

is the API 521 simple approach
• Assumptions:

• Radiation emanates in a spherical manner from a

single point near or within the flame
• The point of interest is far enough from the flame
that the flame can be considered a point source
• Flame length is governed by heat release
• Radiation is equal in all directions
• Vertical velocity is zero at the end of the flame

© 2013 UOP LLC. All rights reserved.

Basic Flare Radiation Equation

τ • F •Q
D=
4π • K
• The API 521 simple approach
calculates the spherical radiation
emanation from a single point using
the following variables:
• τ = the amount of radiation
transmitted through the atmosphere
• F = the fraction of the total heat
release that is emitted as infrared
radiation
• Q = total flare heat release
• K = the target radiant heat intensity
© 2013 UOP LLC. All rights reserved.
Radiant Fraction

• Not all heat released by the flare is emitted as infrared

radiation

• The radiant fraction (F) represents the fraction emitted

in the infrared spectrum

• Often referred to as “emissivity”, although this is not

technically accurate

• Determined experimentally

• Varies with gas composition and tip design

© 2013 UOP LLC. All rights reserved.

API 521 Location of Emissive Point

• Uses flame length calculation

based on heat release

• Uses flame lean calculation 0.4 Mach

based on values of cross wind
velocity and waste gas exit
velocity
• Higher waste gas velocity,
less flame lean
• Not validated at extremely
high wind velocities

0.1 Mach

© 2013 UOP LLC. All rights reserved.

Radiation Calculation Accuracy

• Point of interest should be two to three flame lengths

from the flame in order for the point source
approximation to be valid

• API 521 assumes flame length is only governed by heat

release in low velocity diffusion flames. High velocity
waste gas can change both the flame length and the
flame shape

• Highly dependent on the radiation fraction selected

© 2013 UOP LLC. All rights reserved.

Other Radiation Models

• Brzustowski’s and Sommer’s method

• Also found in API 521
• Changes the method for calculating the emissive
point
• Very similar to the simple approach
• Shell-Thornton
• Gas Processors Suppliers Association
• Various multiple point of interest flame models
• Proprietary, unpublished vendor methods

• UOP Callidus typically uses the API 521 simple

approach or the B&S method

© 2013 UOP LLC. All rights reserved.

Smokeless Capacity

• Smoke is the release of cooled, unburned free carbon

outside of the flame bundle

• Results from localized or bulk fuel-rich areas within the

combustion zone

• Eliminated by ensuring sufficient oxygen within the

combustion zone

• The tendency of the waste gas to smoke varies based

on composition

© 2013 UOP LLC. All rights reserved.

Smokeless Capacity

PROPANE: EASY

PROPYLENE:
MORE DIFFICULT

© 2013 UOP LLC. All rights reserved.

Smokeless Capacity

BENZENE:
DIFFICULT

© 2013 UOP LLC. All rights reserved.

Smoke Suppression Methods

• Must combine oxygen with the waste gas

• Steam or gas injection

• LP or HP air injection

• Self-inspirating HP flares

• Assist method selected based on a variety of criteria

© 2013 UOP LLC. All rights reserved.

Ringelmann Scale

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Ringelmann Scale

• Commonly used to define the level of flare smoking

• Ranges from zero to five

• Zero is 20% opaque; five is 100% opaque

• Measured visually

• Ringelmann one and lower is normally considered

smokeless

• UOP Callidus normally designs for Ringelmann zero

© 2013 UOP LLC. All rights reserved.
Ringelmann Scale—Ringelmann Five

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Ringelmann Scale—Best Judgment

© 2013 UOP LLC. All rights reserved.

Ringelmann Scale—Best Judgment

© 2013 UOP LLC. All rights reserved.

EPA Test Method 22

• US method of measuring smoke density

• Defines the procedure for measuring smoke emissions

• Condensed water vapor is not smoke

• Smoke within the flame is not considered a violation

© 2013 UOP LLC. All rights reserved.

Smoke Suppression Methods

• Must combine oxygen with the waste gas

• Steam or gas injection

• LP or HP air injection

• Self-inspirating HP flares

• Assist method selected based on a variety of criteria

© 2013 UOP LLC. All rights reserved.

Flare Noise Sources

• Combustion noise (often calculated using the thermo-

acoustic efficiency factor)

• Combustion rumble due to flame instability

• Waste gas jet noise

• Steam injection noise

• Air assist blower noise

© 2013 UOP LLC. All rights reserved.

Noise Considerations

• Allowable noise
often a function of
the facility location

• Residential
locations are
extremely sensitive
to nighttime noise
emissions

© 2013 UOP LLC. All rights reserved.

Flare Noise Control Methods Discussion

• Combustion noise

• Combustion rumble due to flame instability

• Waste gas jet noise

• Steam injection noise

• Air assist blower noise

© 2013 UOP LLC. All rights reserved.

Environmental Concerns

• 40 CFR 60.18 originally written to improve destruction

efficiency of flares

• Current research is ongoing to revise flare requirements

• Oversteaming and overuse of air assist currently a

major concern

• EPA criteria are being revised

© 2013 UOP LLC. All rights reserved.

© 2013 UOP LLC. All rights reserved.
 UOP Callidus
2013 Flare School

Brian Duck
General Manager of Flare Division

Elevated Flare Structures, Elevated Flare Tips

UOP Callidus Flare School

November 7-8, 2013
Shanghai, China
© 2013 UOP LLC. All rights reserved.
Elevated Flares

• Most common type of flare

• Elevated flare tips reduce radiation

at grade

• Elevated flares have the best

dispersion profiles

• Major support types

• Guy wire stabilized
• Self supported
• Derrick supported

© 2013 UOP LLC. All rights reserved.

 Elevated Flares—Guy Wire Stabilized

• Typically least expensive

of the tall flare options

• Largest plot area due to

guy wire radius (~75% of
stack height)

• Very common design

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Guy Wire Stabilized

• Typically erected in
sections with elevated
welds

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Guy Wire Stabilized

• Guy supported may be

erected in a single piece,
but steel weight
increases significantly

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Guy Wire Stabilized
• Guy wires are typically
arranged with 120° separation
around the flare stack

• Guy wire design typically

assumes the deadmen
locations are level

• Unlevel deadmen, asymmetric

orientation, or large
temperature changes may
significantly increase
calculational complexity

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Self Supported

Barge shipping a self-support flare and piggyback from

South Korea to Sakhalin Island, Russia
© 2013 UOP LLC. All rights reserved.
Elevated Flares—Self Supported

• Self supported stacks

may be less expensive
that guy wire supported
stacks for short stack
heights

• Often field welded at

grade and lifted as a
single piece

• Liquid seals or knockout

drums are often
integrated into the base

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Self Supported

• Self support typically has less

elevated field welds than a
guy wire stack

• Self support total installed

cost is normally less than a
derrick if the overall height is
less than 250’

• Self support installation time

may be much shorter than a
derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Derrick Supported

• Derrick supported will be

the low-plot space
solution for very tall stack
heights

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Derrick Supported

• Derricks typically
arrive at the site in
pieces for field
assembly

© 2013 UOP LLC. All rights reserved.

 Elevated Flares—Derrick Supported

• Modules are
assembled on
the ground and
lifted into place
as necessary

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Derrick Supported

• Two main types of derricks:

• Fixed-Riser Derricks

• Demountable Riser Derricks (Demountables)

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Fixed Riser Derrick

• Typically one riser, but may have

multiple risers

• May have liquid seal or knockout

drum in the base of the riser

• Common worldwide

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

• Special purpose derrick design

• Allows for multiple risers co-

located on the same derrick

• Allows the flare tip to be brought

to grade without a large crane

• Often used when

• Plot space is restricted
• Multiple plant relief systems
with different shutdown
schedules on a single derrick
structure
© 2013 UOP LLC. All rights reserved.
Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

General Sequence Of Events – Demounting

1. Lowest Riser section secured.
2. Remaining sections secured at base of lowest remaining
riser and unflanged from lowest section.
3. Upper section raised via winches and pulley for
clearance.
4. Lowest section rotated from vertical to horizontal at tilting
table for placement on transfer table.
5. Lowest section moved off transfer table, remaining
sections lowered to tilting table.
6. Cables detached and attached in appropriate locations for
subsequent iterations of riser relocation from stack to
transfer table.
7. Repeat steps 1-6 until flare tip is moved to transfer table.

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick

© 2013 UOP LLC. All rights reserved.

Elevated Flares—Demountable Derrick
• Three Winches

• Lifting

• Tilting

• Braking

• Hydraulically powered

• Common electric motor

and pump assembly

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners

• Removable burner
assembly located at the
top of a flare stack

• Designed for long life

under incredibly harsh
conditions

• Main styles
• Unassisted
• Unassisted high
pressure
• Steam assisted
• Air assisted
© 2013 UOP LLC. All rights reserved.
 Elevated Flare Burners

• Type of flare tip selected will be

based on a number of criteria

• Waste gas composition

• Local permitting requirements

• Smokeless requirement
• Velocity requirement
• Noise

• Available utilities

• Cost
© 2013 UOP LLC. All rights reserved.
Elevated Flare Burners—Unassisted

• Pipe Flare
• Used for gases that do not
smoke or where smoke
suppression is not required
• Designed to ensure ignition,
flame stability and extended
life
• Simplest design available
• Suitable for exit velocities up
to MACH 1.0 dependent upon
the gas being flared
• Typically limited to 0.8 Mach

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Unassisted

• High pressure
• Various burner geometries
available
• High velocity gas jet entrains
air, eliminating smoke
• Typically fixed orifice size
resulting in limited turndown
• Often used offshore
• Suitable for exit velocities up
to MACH 1.0 dependent
upon the gas being flared

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Unassisted

• Variable Orifice (Hemisflare)

• Generally high pressure

• Variable orifice opens with

waste gas pressure

• High velocity gas jet entrains

air, eliminating smoke

• Suitable for exit velocities up

to MACH 1.0 dependent upon
the gas being flared
© 2013 UOP LLC. All rights reserved.
Elevated Flare Burners—Unassisted

• Variable Orifice (Hemisflare)

• Orifice exit geometry

distributes waste gas as a
thin film

• This thin film curves around

the distribution head,
entraining air for smokeless
operation

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Steam Assisted

• Uses steam energy to force

air into the combustion zone,
reduction or eliminating
smoke

• Cools flame and reduces

radiation

• Typical steam pressure 100-

150 PSIG

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Steam Assisted
• Major Types:

• Upper Steam (US)

• Inner Steam
• Sonic Steam (IS)
• Subsonic Steam (IS3)

• Center Cooling Steam (C)

• Steam Hybrid
• MP4-S
• Steam Hemisflare
© 2013 UOP LLC. All rights reserved.
Elevated Flare Burners—Upper Steam
• Uses ring to inject steam
into the combustion zone

• Advanced nozzle design

minimizes noise while
maximizing air entrainment

• Relatively inexpensive
when compared to more
advanced designs

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Upper Steam

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Upper Steam
• Generally an unlined
flare tip

• Refractory lining is
available at customer
request, but isn’t
recommended

• Large sizes (24” and

larger) should include
center steam

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Upper Steam

• Geometric limitations will determine the maximum

allowable size of an upper steam flare tip

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam
• Inner steam flare
systems use a
lower steam
injection manifold
• More steam
efficient than upper
steam
• Steam injection
nozzles are out of
the flame zone and
are shrouded to
reduce high
frequency noise

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam

• Steam spiders are directed

into either a 6” or an 8”
venturi to maximize air
induction

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam
• IS Burners use a straight
drilled, investment cast
sonic steam nozzle

• IS3 Burners use a De Laval

nozzle design that allows
supersonic flow rates

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam

• Each steam tube

is reinforced with
a pressed-in and
welded CK20
reinforcement
casting

• Greatly increases
the strength of
steam-air tubes

• Prevents tube
deformation

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Steam

• Deformed,
unreinforced steam/air
tubes

• Not a UOP Callidus

flare tip

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Inner Steam

• An additional upper
steam ring may be
added to improve
smokeless performance

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Inner Steam

• UOP Callidus proprietary inner steam features

• Steam tubes reinforced at exit with casting
• Steam tubes supported internally to combat vibration
damage
• True inlet venturi for each steam tube
• Multi-port supersonic steam injection nozzle
• Muffler with ceramic fiber insulation and flow-through
design concept

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Center Steam

• Center steam is an “add-on”

steam system

• Acts as cooling steam for

the flare tip shell

• Reduces burnback

• Not intended to be a
significant contributor to
overall smokeless
performance

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Steam Hybrids
• Some steam assisted flare burners
are steam/pressure hybrids

• Steam is injected for smokeless

performance at low rates. At high
rates, high pressure waste gas
provides the necessary mixing energy

• Commonly used in ground flares

• MP4-S

• Steam Hemisflare
© 2013 UOP LLC. All rights reserved.
 Elevated Flare Burners—Air Flares
• Air from a blower is used
reduce smoke production

• Air is routed to the flare tip

using the stack or a duct
system

• Typically sized using 25-35% of

stoichiometric air from the
blower

• Air velocity at tip is function of

gas being burned and
manufacturers flare tip design
© 2013 UOP LLC. All rights reserved.
 Elevated Flare Burners—Air Flares
• Used for smokeless rates up to
500,000 lbs/hr smokeless dependent
upon gas type

• Horsepower required varies from 1.0

to 3.0 per 1000 lbs/hr of gas being
burned

• Developed initially for cold climates

where steam freezing was a
problem. Often used where steam
availability is limited (deserts)

• Complex flare tip geometry due to Not a Callidus Flare

low available mixing energy
© 2013 UOP LLC. All rights reserved.
 Elevated Flare Burners—Air Flares
• Staged air flare stacks, cold climate
• 1,000 blower horsepower per stack

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Air Flares

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Air Flares

• Air assisted flare stacks use low

pressure forced air to provide
sufficient O2 in the combustion zone
to prevent smoke

Waste
• Custom geometries are required to Gas
ensure adequate mixing at the flare tip
Air

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Blower Speed Change

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Basic

• Advantages: most basic, least

expensive, low pressure drop

• Disadvantages: limited capacity,

not good for difficult gases

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Basic

• Advantages: most basic, least

expensive, low pressure drop

• Disadvantages: limited capacity,

not good for difficult gases

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Vane Style
• Advantages: More smokeless capacity than previous
styles, less pressure drop

• Disadvantages: Must be properly designed or will

have a shortened lifespan

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Vane Style

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Air

• Advantages: Highest
capacity of any air tip, long
life

• Disadvantages: Highest cost

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inner Air

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Inlet Snorkel

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Vaneaxial Blowers

• Most air flares use

vaneaxial blowers

• Inexpensive

• Straight-through air
design is very efficient

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Vaneaxial Blowers

• No inlet filters needed

• TEAO design for long

service life with limited
maintenance; excellent
motor cooling

• API 560 does not apply to

vaneaxial blowers

• Generally for low total

pressure applications

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Centrifugal Blowers

• More expensive than

vaneaxial

• Less efficient than

vaneaxial largely due to air
flow path

• Suitable for higher total

pressure applications

© 2013 UOP LLC. All rights reserved.

Elevated Flare Burners—Centrifugal Blowers

• Less cooling air flow over

motor

• API 560 may apply

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Air Flares

• Inlet snorkels often

used to raise blower
intake above snow or
sand

• May be lined with

fiber blanket to
reduce blower noise

© 2013 UOP LLC. All rights reserved.

 Elevated Flare Burners—Liquids
• Elevated flare tips typically cannot survive flammable liquid
carryover

© 2013 UOP LLC. All rights reserved.

© 2013 UOP LLC. All rights reserved.
 UOP Callidus
2013 Flare School

Brian Duck
General Manager of Flare Division

Ground Flares

UOP Callidus Flare School

November 7-8, 2013
Shanghai, China
© 2013 UOP LLC. All rights reserved.
 Multipoint Ground Flares (MPGF)

• Often referred to
as “Open Ground
Flares”

Saudi Arabia

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flares

Saudi Arabia

Venezuela

© 2013 UOP LLC. All rights reserved.

Multipoint Staging

© 2013 UOP LLC. All rights reserved.

Basic Smokeless Requirements
• Smoke is cooled, unburned carbon particles

• Elimination depends upon combination with oxygen

while the carbon is in an excited state

• Multipoint burners convert pressure to velocity

through the burner orifices.

• This velocity results in mixing between the waste gas

and the surrounding air, ensuring sufficient air in the
combustion zone.

© 2013 UOP LLC. All rights reserved.

Basic Smokeless Requirements (cont’d)

Propylene Under Propylene After

Pressure Depressurization

© 2013 UOP LLC. All rights reserved.

 Basic Smokeless Requirements (cont’d)

• Different waste gas compositions have different

requirements to burn smokelessly

• The difference between various gasses is evident in the

burner orifice sizing and required burner pressure

• More difficult gasses require higher burner tip

pressures. Most systems are designed for 15 Psig (1
Bar) or higher at the manifold inlet flange.

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flare Burners

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flare Burners

Note: Tracing
‘particles’ released
from the fuel gas
ports. The central re-
circulation zone
formed with the fuel
from the ignition ports
is evident.

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flare Burners

Note: Velocities in the

central ‘core’ are well
above the (laminar)
flame speed for
methane. Turbulent
flame speeds are
higher; however the
combustion appears
to occur at the
diffusion boundary for
these cases.

© 2013 UOP LLC. All rights reserved.

Basic Smokeless Requirements

• Most multipoint systems have a low-pressure first

stage to manage operation at reduced relief
system pressures

• Steam-assisted first stage

• Air-assisted first stage

• Gas-injection is occasionally used

• Variable-orifice designs such as the Hemisflare

• Cycling staging valve/blowdown

© 2013 UOP LLC. All rights reserved.

MPGF First Stage Air Assist Burners
Saudi Arabia

Burner Tip Fabrication

Air Ducting

© 2013 UOP LLC. All rights reserved.

MPGF First Stage Steam Assist Burners

Steam Burner
Test

Steam-Assisted Stage After ~15 Years of

Service (Texas)

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flares

• Multipoint ground flares are

designed for very high smokeless
capacity. As additional smokeless
capacity is needed, additional
stages are added

Saudi Arabia

Prior to Heat Shield/Gravel Installation

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flares

• Multipoint ground flares are staged systems, meaning

that not all of the burners are on service at any given
time.

Staging and Bypass Valves, Saudi Arabia

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flares

• Burner spacing set to ensure sufficient air flow to

burners.
• Burner rows are 7-12 meters apart
• Fence is 10-15 meters from burners

© 2013 UOP LLC. All rights reserved.

Multipoint Components

• Multipoint Burners

• Burner center hub and burner castings may be a

single piece casting or be a welded assembly

• Long life

• Various types of stainless steel available

• Custom drilled for each application

© 2013 UOP LLC. All rights reserved.

Multipoint Components

• Burner Risers

• Normally 304 stainless steel, although half-

carbon, half-stainless installations have been in
service for decades.

• Callidus proprietary offset design for better air

access to burners.

• Riser is assembled to burner casting in Callidus

China. Callidus has assembled thousands of
burner/riser assemblies

© 2013 UOP LLC. All rights reserved.

 Burners and Risers

Cal-China Cal-China

Saudi Arabia
Cal-China

© 2013 UOP LLC. All rights reserved.

Multipoint Components
• Burner Runners

• Waste gas distribution to burner risers

• Downstream of staging valves

• Weld-o-lets used for solid, strong connections

• Diameter typically gets smaller from the beginning

to the end

• Mounting point for heat shields, pilot gas piping,

ignition system conduit and wiring, and
thermocouples
© 2013 UOP LLC. All rights reserved.
 Burner Runners

Cal-China Cal-China

Saudi Arabia

© 2013 UOP LLC. All rights reserved.

Burner Runners

Turkey
Cal-China

Cal-China

Cal-China

© 2013 UOP LLC. All rights reserved.

Multipoint Components

• Runner and Foundation Shielding

• To protect the runners from direction exposure to flame
radiation, heat protection is required
• Runners can be covered in gravel (roughly 18”) as protection
• Thermal stresses for piping in gravel can be high
• Runners may also be covered by stainless steel heat shields
• All concrete inside the flare field should be covered by gravel for
heat protection
• If gravel is used for runner shielding, Callidus typically provides
a hybrid design, providing heat shielding where the runner
penetrates the fence and heat shielding where the pilot gas
piping would penetrate the gravel vertically
• Heat shielding is normally fabricated in Callidus China

© 2013 UOP LLC. All rights reserved.

Runner Shielding

Texas-Gravel
Covered Runner

Saudi Arabia-
Shielded Runner
© 2013 UOP LLC. All rights reserved.
Foundation Shielding

Saudi Arabia

© 2013 UOP LLC. All rights reserved.

 Multipoint Components
• Multipoint Fence
• Galvanized carbon steel fence
• Stainless steel or other high temperature material sometimes used
• Emergency vs. continuous usage.
• Radiation shielding
• No visible flame is a special case
• Safe area for maintenance
• Blocks personnel maintenance to flare area
• Can be hot during operation.
• Callidus proprietary double-fence design
• Better air access
• Chain link may be added
• Single-fence design with shielded legs

© 2013 UOP LLC. All rights reserved.

Multipoint Fence

Double Fence
Saudi Arabia

© 2013 UOP LLC. All rights reserved.

Multipoint Fence

Fence with Leg

Fencing

© 2013 UOP LLC. All rights reserved.

Multipoint Fence

Fence Panel Preparation for

Shipping, Cal China

© 2013 UOP LLC. All rights reserved.

Multipoint Components
• Staging and Bypass Valve Assembly
• Staging valves control which runners are on service based on
pressure in the relief system.
• Bypass valves are designed to open mechanically should the system
overpressure due to a staging valve or logic failure
• Possible to operate safely without a bypass valve on every stage because
some smal stages may be for smooth transition from stage to stage and
may not be included in the total flow rate
• Relay-based system is also available to open the staging valves
in case of PLC failure but prior to bypass valve operation.
• Major types of ASME-recognized pin actuated bypass valves
• Small Pin
• Large Pin
• Pilot-Operated
• Shear Pin
• Rupture disk can be used instead of bypass valves—some
drawbacks

© 2013 UOP LLC. All rights reserved.

Small-Pin Style

Saudi Arabia

Saudi Arabia

© 2013 UOP LLC. All rights reserved.

Large-Pin Style

Singapore

18” Large Pin Style, Oklahoma City

© 2013 UOP LLC. All rights reserved.

 Multipoint Components
• Main Manifold
• Transition between the relief header and the staging valves
• Normally where the pressure transmitters are located
• May have a manual or automatic liquid drain system
• Unique structural requirements due to runner layout
• May require multiple inlets to provide enough piping flexibility.
• Coordination between client structural engineering and Callidus
structural engineering often needed
• Maintenance access inside manifold required
• Stepover ladders
• Stepover stairs
• Full-length access platform

© 2013 UOP LLC. All rights reserved.

Main Manifold

Saudi Arabia, Full-Length Platform

© 2013 UOP LLC. All rights reserved.

Multipoint Components

• Nitrogen Purge System

• Post Purge
• After a staging valve closes, the runner is still full of combustible
hydrocarbon
• As the system depressurizes, the hydrocarbon will smoke
• Post purge system is designed to sweep the combustible mixture from
the runner (preventing flashback) and forces the hydrocarbon from the
runner (reducing the duration of smoke while the row is at low pressure)
• Typically lasts +/- two minutes
• Continuous Purge
• Normal plant purge commonly provides sufficient purge for the first stage
• Flare gas recovery unit may require additional purge
• Other stages may or may not have a continuous purge
• Customer choice
• Provides some protection against valve leakage
• All nitrogen purge racks are assembled Oklahoma, USA
© 2013 UOP LLC. All rights reserved.
MPGF Piping and Instrument Diagram

Multipoint
P&ID

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flare Advantages
• Lowest operating cost

• Easiest maintenance. Most maintenance items are accessible from

outside the flare fence

• Lower radiation

• Lower noise

• Largest smokeless capacity

• Longest life

• Less visibility to the surrounding community

© 2013 UOP LLC. All rights reserved.

Multipoint Ground Flare Disadvantages

• Higher installed cost

• Improper operation can produce damage. Follow

the operating instructions

• Liquids will destroy the flare

© 2013 UOP LLC. All rights reserved.

 Totally Enclosed Ground Flare (TEGF)

• Cylindrical, refractory lined

combustion chamber

• Burners located in the

base of the unit

• May be steam or air

assisted (similar to a
MPGF)

• Side fired or bottom fired.

Bottom fired typically used
for less difficult conditions

© 2013 UOP LLC. All rights reserved.

Totally Enclosed Ground Flare (TEGF)

• Currently up to 150 ton/hr

waste gas flow

• Used where no direct view

of the flame is acceptable

• Used in densely
populated areas since the
1960s

• Stack draft induces

extremely high air flow

© 2013 UOP LLC. All rights reserved.

 Totally Enclosed Ground Flare (TEGF)

• Staging method is similar

to a MPGF

• Less waste gas pressure is

required because a TEGF
generates more stack draft

• Refractory lining is
castable refractory or fiber

© 2013 UOP LLC. All rights reserved.

Totally Enclosed Ground Flare (TEGF)

© 2013 UOP LLC. All rights reserved.

 TEGF Typical Applications

• First stage of refinery or chemical plant flare system

to minimize daily noise / light

• Landfill gas disposal

• Truck or barge vapor disposal from loading

operations

• FPSO applications to minimize impact on the

operating personnel

• In any environmentally sensitive area

© 2013 UOP LLC. All rights reserved.

TEGF Advantages
• Advantages similar to a MPGF

• Easiest maintenance. Most maintenance items are

accessible from outside the flare fence

• Reduced radiation

• Reduced noise

• Minimum visibility to the surrounding community

• Emissions control

© 2013 UOP LLC. All rights reserved.

TEGF Disadvantages
• Highest cost per unit of flow of any flare system

• Limited capacity

© 2013 UOP LLC. All rights reserved.

 TEGF Burner Layout Options

• Bottom fired
typically less than
10 meter diameter

• Easier applications

• Physically
constrained by the
amount of
combustion air that
can reach the
center of the
equipment

© 2013 UOP LLC. All rights reserved.

 TEGF Burner Layout Options

• Side fired typically larger

than 10 meter diameter

• Difficult applications

• Less susceptible to
liquid hydrocarbon
carryover

© 2013 UOP LLC. All rights reserved.

TEGF Burner Layout and Staging

• Side fired higher

capacity

• Better aeration of
the waste gas

• Easier maintenance

© 2013 UOP LLC. All rights reserved.

TEGF Burner Layout and Staging

• It can be more difficult

to provide sufficient
combustion air to the
center of a bottom fired
unit

© 2013 UOP LLC. All rights reserved.

TEGF Enclosure Types
Cylindrical Modular

© 2013 UOP LLC. All rights reserved.

Benefits of Modular Construction

© 2013 UOP LLC. All rights reserved.

TEGF Installation and Insulation
• Modular construction allows
faster insulation with less
skilled field labor and reduce
field welds

• The majority of the insulation is

shop installed on the modular
panels

© 2013 UOP LLC. All rights reserved.

CONFIDENTIAL—NOT FOR DISTRIBUTION OUTSIDE OF HONEYWELL
Oil and Gas Production TEGFs

• 95% shop preassembled

• Solar powered if electricity

is unavailable

• Simple installation

• Bottom Fired

© 2013 UOP LLC. All rights reserved.

Multipoint CFD Modeling

•Complete In-House CFD Modeling Capability

•Access to Honeywell Aerospace’s Computing
Capacity for Large Projects

Iso-surface of 1770 K

© 2013 UOP LLC. All rights reserved.

Multipoint CFD Modeling

© 2013 UOP LLC. All rights reserved.

Multipoint CFD Modeling

© 2013 UOP LLC. All rights reserved.

CFD Modeling

CO ppm

© 2013 UOP LLC. All rights reserved.

Q&A

© 2013 UOP LLC. All rights reserved.

 UOP Callidus
2013 Flare School

Brian Duck
General Manager of Flare Division

Pilots and Auxiliary Equipment

UOP Callidus Flare School

November 7-8, 2013
Shanghai, China
© 2013 UOP LLC. All rights reserved.
 Flare Auxiliary Equipment

• Pilots

• Ignition Systems

• Purge Reduction Devices

• Knock-out Drums

• Liquid seals

© 2013 UOP LLC. All rights reserved.

 Pilots

• Flare flames are inherently unstable without re-ignition

• The consequences of unlit vents are serious

• Periodic re-ignition leads to pollution

• Mandatory on most US installations

© 2013 UOP LLC. All rights reserved.

Pilots

• UOP Callidus
elevated flare pilot
system

© 2013 UOP LLC. All rights reserved.

 Pilots

• MUST be reliable
• Not affected by high wind
and rain
• Should have primary
aeration > LEL
• Most pilots have natural
draft air entrainment
• Long service life
• Proof of operation

© 2013 UOP LLC. All rights reserved.

Pilot Thermocouple

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 Pilots

• Flame Front Generator

• Direct spark ignitors

• Pyrotechnic (open and enclosed)

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 Flame Front Generator
• Mixes air and fuel gas, fills a line with this combustible
mixture up to each pilot

• Ignites the mixture at grade using an electrically

generated spark

• A “ball of fire” travels up the pipe to the pilot

• Rugged, with all moving parts at grade for easy repair

• Not particularly easy to use

© 2013 UOP LLC. All rights reserved.

Flame Front Generator

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Flame Front Generator
Flammable
Mixture to Pilot

Fuel Gas

Air

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Flame Front Generator

© 2013 UOP LLC. All rights reserved.

Direct Spark Ignition
• High Energy Electric
Spark (HEI)

• Ignites the pilot directly

• Fast

• Must survive hostile

environment

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Exterior Spark

• Flame Rod/Flame Ionization Detector

• Uses an electric spark to light the pilot
• Sends a current through the ionized pilot flame to
verify the pilot is lit
• Not normally for flares, but an excellent design for
burners

© 2013 UOP LLC. All rights reserved.

Open Pyrotechnic

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Open Pyrotechnic

• Pyrotechnic flare
ignition doesn’t have to
be particularly
complicated

Popular Mechanics (April 1960)

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Enclosed Pyrotechnic

• Ballistic ignition

• Uses a projectile air-

launched through a guide
tube

• Strikes target near flare tip

and explodes in a shower of
sparks

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Purge Reduction Devices (not Seals)
• Velocity “seal” devices (diode type) require purge
rate of >0.035ft/sec to protect the flare stack from
flashback

• Density “seal” devices (labyrinth or molecular

type) require purge rates of ~0.01ft/sec to protect
the flare stack from flashback

• Flare stacks with no purge reduction device

required purge rates of 0.5 to 1.0ft/sec., but could
be higher if equipment protection (or hydrogen) is
an issue

© 2013 UOP LLC. All rights reserved.

Velocity Seal

• O2 < 6% at 20 ft below the seal

• Simple cone-shaped design

mounted in flare tip

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Density Seal

• O2 < 0.1% at 20 ft below the seal

• Requires ¼ to ½ the amount of purge gas

as a VS

• Also referred to as gas, buoyancy,

labyrinth, molecular, mole seal

Drain

© 2013 UOP LLC. All rights reserved.

Density Seal

• Demountable Flare
with Density Seal

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Density Seal

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Knockout Drums
• Removes liquid hydrocarbon

• Critical to protect flare system

• Horizontal
• Generally free standing
• Liquid separates by gravity

• Vertical
• Often in base of stack
• Liquid separates by centrifugal action
© 2013 UOP LLC. All rights reserved.
Liquid Seals
• Hold small positive pressure in flare header to prevent
oxygen ingress and possible flashback

• Can be used as a switching mechanism

• Provides necessary backpressure for flare gas recovery

compressors

• Also horizontal and vertical orientations

© 2013 UOP LLC. All rights reserved.

Liquid Seals

• Advanced distribution internals

allow for smooth transition from low
flow to high flow without surging

© 2013 UOP LLC. All rights reserved.

© 2013 UOP LLC. All rights reserved.
© 2013 UOP LLC. All rights reserved.
Flare Gas Recovery
 Flaring Gas

2 UOP - CONFIDENTIAL File Number

 Flare Reduction

• Options to reduce flaring emissions

- Advanced process controls
- Process unit utilization
- Flare Gas Recovery
- Other solutions

3 UOP - CONFIDENTIAL File Number

 What is Flare Gas Recovery?
• Captures waste gas from flare header

• Compresses gas to usable pressure

• Recycles gas back into facility

4 UOP - CONFIDENTIAL File Number

 Why Flare Gas Recovery?
• Save the environment
- Reduced facility emissions
• Save the flare tip
- Extended flare tip life
• Save money
- Reduced purchase gas requirements and/or increased
salable gas
- Reduced utility (steam) consumption

5 UOP - CONFIDENTIAL File Number

 Typical Applications

• Refining
• Petrochemical
• Storage Tanks

6 UOP - CONFIDENTIAL File Number

 FGRS Critical Components

7 UOP - CONFIDENTIAL File Number

 FGRS Critical Components

The liquid level in the liquid

seal drum imposes a
positive backpressure in the
flare header, ensuring that
air is not drawn into the flare
system.

8 UOP - CONFIDENTIAL File Number

 FGRS Critical Components

The compressor extracts

hydrocarbon vapor from the
flare header and
compresses vapor to desired
discharge pressure.

9 UOP - CONFIDENTIAL File Number

 Compressor Types

Liquid Ring Compressors

• Robust design
• Good with temperature variations

Ejector Compressors
• Simple design
• Can achieve high pressure

Screw Compressors
• Wet and dry types
• Maintenance

Picture sources:
• Nash compressors (gdnash.com).
10 UOP - CONFIDENTIAL • Venturi Pumps (venturipumps.com). File Number
• Wikipedia
 Liquid Ring Compressor

• Ensures nearly iso-

thermal compression
• Intrinsically explosion-
proof operation
• Handles a wide variation
in flow rate
• Accommodates:
- Variable gas mixtures
- Dirty gas
- Liquid slugs
- Solids
- Temperature variations

11 UOP - CONFIDENTIAL File Number

Image courtesy of Sihi.
 FGRS Critical Components

Multiphase separator
separates two phase flow
(seal fluid + hydrocarbon)
into condensate and
hydrocarbon vapors.

13 UOP - CONFIDENTIAL File Number

 FGRS Critical Components

The seal fluid cooler is a heat

exchanger that removes the
heat of compression from the
seal fluid. Seal fluid then
returns to the liquid ring
compressor.

14 UOP - CONFIDENTIAL File Number

 FGRS Critical Components

In case of a reduction in
suction pressure, a
compressor spillback valve will
open to recirculate
compressed gas back to
compressor suction.

To: From:
Compressor Inlet Separator Drum

15 UOP - CONFIDENTIAL File Number

 Case Study

• SECCO
- Caojing, China
• HP-1 multipoint flare
system
- Designed for 1,800 t/hr
flow
 Highest noted release was
580 t/hr
- 70-80% of normal flow
less than 4 t/hr

25 UOP - CONFIDENTIAL File Number

 Case Study - Design

• System designed to
recover 4 t/hr of flare
gas
• Material and design
considerations due to
gas temperature
• System installed with
flare unit still online
(“hot tapped”)
- Could not modify liquid
seal design

26 UOP - CONFIDENTIAL File Number

 Case Study - Results

• After installation, customer updated overall system

to separate hydrogen as product
- This decreased overall flare/FGR capacity
• Based on new normal flow, FGRS handling 1,200
kg/hr of gas
- Recovered gas is sent to fuel gas network and
then distributed to each customer within the site

27 UOP - CONFIDENTIAL File Number

 Case Study

• Estimated emission savings

- CO: 100 mtons/year
- NOx: 18.75 mtons/year
- CO2: 41,000 mtons/year

28 UOP - CONFIDENTIAL File Number

 Case Study - Results

• Based on updated capacity and utilization, payback

period for FGRS is 1.75 years
• Expected savings over 10 year time period > $6M

Value
$7,000,000.00
$6,000,000
$5,000,000.00

$3,000,000.00

$1,000,000.00

0 1 2 3 4 5 6 7 8 9 10
$(1,000,000.00)

$(3,000,000.00)

$(5,000,000.00)
Years

29 UOP - CONFIDENTIAL File Number