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/ 37
IPS-E-PR-460
ENGINEERING STANDARD
FOR
PROCESS DESIGN OF FLARE AND BLOWDOWN SYSTEMS
ORIGINAL EDITION
JULY 1994
This standard specification is reviewed and
updated by the relevant technical committee on
June 1999. The approved modifications are
included in the present issue of IPS.
This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum. IRS oe
IPS-E-PR-460
CONTENTS
0. INTRODUCTION.
1. SCOPE
2. REFERENCES
3. DEFINITIONS & TERMINOLOGY
4, SYMBOLS AND ABBREVIATIONS
5. UNITS,
6. SELECTION OF BLOWDOWN SYSTEMS
6.1 General
6.2 Blowdown System for Vapor Relief Stream
6.3 Blowdown System for Liquid Relief Stream.
7. DESIGN OF DISPOSAL SYSTEM COMPONENTS
7.4 Piping
7.2 Sizing a Knock-out Drum
7.3 Quench Drum
7.4 Sizing a Seal Drum.
7.5 Flares.
7.6 Burning Pits.
TABLES
TABLE 1 TYPICAL Kf VALUES FOR PIPE FITTINGS
TABLE 2 TYPICAL FRICTION FACTORS AND CONVERSION FACTORS
FOR CLEAN STEEL PIPE.
TABLE 4 RADIATION FROM GASEOUS DIFFUSION FLAMES
PAGE No,
10
15
15
18
18
25
"
n
19
TABLE § RECOMMENDED DESIGN FLARE RADIATION LEVELS EXCLUDING SOLAR
RADIATION. 21
TABLE 6 EXPOSURE TIMES NECESSARY TO REACH THE PAIN THRESHOLD. 21
TABLE 3. OPTIMIZING THE SIZE OF HORIZONTAL KNOCK-OUT
DRUM (SI UNITS) 31
FIGURES
FIGURE 1 DRAIN POT 13
FIGURE 2 DETERMINATION OF DRAG COEFFICIENT. 18
FIGURE 3 FLARE KNOCK-OUT DRUM 16
FIGURE 4 QUENCH DRUM 7
FIGURE § HEAT RELEASE, 22
WATTS FLAME LENGTH VERSUS HEAT RELEASE: 22 IPS uly 1084 IPS-E-PR-460
INDUSTRIAL SIZE AND RELEASES
FIGURE 6 APPROXIMATE FLAME DISTORTION DUE TO LATERAL WIND
ON JET VELOCITY FROM FLARE STACKS.
FIGURE 7 FLARE STACK SEAL DRUM
FIGURE 8 TYPICAL BURNING PIT.
FIGURE 9 DIMENSINONAL REFERENCES FOR SIZING A FLARE STACK
APPENDICES :
APPENDIX A VAPOR RELIEF HEADER SIZING
APPENDIX 8 SIZING A KNOCK.OUT DRUM
APPENDIX C DETERMINATION OF LIQUID LEVEL IN A HORIZONTAL VESSEL
‘APPENDIX D_ SAMPLE CALCULATION FOR SIZING A FLARE STACK
22
23
24
6
36
28
29
33
34 IPS July 1994 IPS-E-PR-460
0. INTRODUCTION
“Process Design of Safeguarding Systems for Oil, Gas and Petrochemical (OGP) Processes” are
broad and contain variable subjects of paramount importance. Therefore a group of process
engineering standards are prepared to cover the subject.
This group includes the following Standards:
STANDARD CODE STANDARD TITLE
IPS-E-PR-450 "Process Design of Pressure Relieving Systems
Inclusive Safety Relief Valves”
IPS-£.PR-460 “Process Design of Flare and Blowdown Systems”
IPs.
R470 "Process Design of Emergency Measures’
‘This Standard covers:
“PROCESS DESIGN OF FLARE AND BLOWDOWN SYSTEMS”
In designing safeguarding systems for process plants, facilities should be provided for handling,
directing and ultimately disposal of voluntary and involuntary gases and liquids. There are several
options available to the process design engineer as to the selection of disposal systems. Once a
specific disposal system is selected detail design is then undertaken. Irs July 1994 IPS-E-PR-460
1. SCOPE
‘This Standard covers process design and evaluation and selection of relief systems for Oil, Gas and
Petrochemical (OGP) process plants
It includes network and related ancillary installations which are to handle and direct fluids
discharged due to overpressure andlor operational requirements to a safe disposal system,
This Standard is primarily concerned with selection of disposal system, sizing of relief headers,
sizing of flare systems and burning pits.
Note:
This standard specification is reviewed and updated by the relevant technical committee on
June 1999. The approved modifications by T.C. were sent to IPS users as amendment No. 4
by circular No. 82 on June 1999. These modifications are included in the present issue of
IPs,
2. REFERENCES,
Throughout this Standard the following dated and undated standardsicodes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard, For dated
references, the edition cited applies. The applicabilty of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.
IPS (IRANIAN PETROLEUM STANDARDS)
IPS-E-GN-100 “Units”
IPS-E-PR-440 "Process Design of Piping Systems (Process Piping &
Pipelines)", Pars 1-4
IPS-E-PR-725, "Process Design of Plant Waste Water Sewer Systems".
API (AMERICAN PETROLEUM INSTITUTE)
"API Manual on Disposal of Refinery Wastes, Volume on
‘Atmospheric Emissions"
3. DEFINITIONS & TERMINOLOGY
For extensive description reference can be made to API RP 521
3.4 Atmospheric Discharge
Is the release of vapors and gases from pressure-relieving and depressuring devices to the
atmosphere.
3.2 Autorefrigeration
Is the reduction in temperature as a result of pressure drop and subsequent flashing of light
hydrocarbon liquids, Irs July 1994 IPS-E-PR-460
3.3 Back Pressure
Is the pressure that exists at the outlet of a pressure relief device as a result of pressure in the
discharge system
3.4 Balanced Safety/Relief Valve
Is a safetyirelief vaive that incorporates means for minimizing the effect of back pressure on the
performance characteristics- opening pressure, closing pressure, it, and relieving capacity
3.5 Built-up Back Pressure
Is the pressure in the discharge header which develops as a result of flow after the safety-relief
valve opens.
3.6 Closed Disposal System
Is a disposal system that is capable of containing pressures different from atmospheric pressure
without leakage.
3.7 Conventional Safety/Relief Valve
Is a closed-bonnet pressure relief valve whose bonnet is vented to the discharge side of the valve
The valves performance characteristics-opening pressure, closing pressure, lift, and relieving
capacity are directly affected by changes of the back pressure on the valve,
3.8 Critical Pressure Ratio
Is the result of the following relationship:
3.9 Flare
Is a means of safe disposal of waste gases by combustion. With an elevated flare, the combustion
is carried out at the top of a pipe or stack where the burner and igniter are located. A ground flare is,
similarly equipped, except combustion is carried out at or near ground level. A burn pit differs from a
flare in that itis primarily designed to handle liquids.
3.10 Flare Blow OffiFlame Lift-up
Is the lifting of fame front from the flare tip.
3.11 Flare Blow Out
|s the extinguishing of flare flame.
3.12 Mach Number
Is the ratio of vapor velocity to sonic velocity in that vapor at flowing conditions.
3.13 Open Disposal System
Is a disposal system that discharges directly from the relieving device to the atmosphere with no
containment other than a short tail pipe
PeF
AS a ecke aye” (Eq.
po ent tH (Ea) IrS
3.14 Quenching
Is the cooling of a hot vapor by mixing it with another fluid or by partially vaporizing another liquid
uly 1994 IPS-E-PR-460
3.18 Super Imposed Back Pressure
Is the static pressure that exists at the outlet of a pressure relief device at the time the device is
required to operate. Itis the result of pressure in the discharge system coming from other sources
and may be constant or variable.
3.16 Vent Stack
Is the elevated vertical termination of a disposal system that discharges vapors into the atmosphere
without combustion or conversion of the relieved fluid
4, SYMBOLS AND ABBREVIATIONS
A
Au
Au
Cross-sectional area, in (m*)
‘Vessel segment area occupied by slops and drain, in (m”),
‘Vessel segment area occupied by condensed liquid, in (m°),
Pit area required to vaporize and burn liquid, in (m2).
Total vessel cross-sectional area, in (m’)
\Vessel cross-section area available for vapor flow, in (m’)
Drag coetficient
Diameter ofthe inlet gas pipe, in (m)
Inside diameter of the line, in (m).
Particle diameter, in (m)
Moody Friction Factor, f=f
Friction Factor
‘Acceleration due to gravity, in (9.8 mis”)
Design mass flow, in (kg/s. m’).
Critical mass flow, in (kgis.m'.
Depth (maximum distance, thatthe inlet pipe is submerged), in (m).
Flare stack height. in ().
Vessel depth occupied by stops and drain, in (m)
Vessel depth occupied by condensed liquid, in (m)
Vertical space for vapor flow, in (em)
Ralio of specific heats, C,/C, forthe vapor being relieved
Dimensional constant equal to 0.078 men/min.
Unit conversion factor equal to 60,000
forte, fe
-anning Friction Factor, f D=Darcy
Factor representing tctional resistance fo fow. (dimensionless).
Equivalent length of line, in (m).
Flare knock-out drum length, in (rm),
Flame length, in (m).
Flare knockout drum minimum length required, in (m) uy 0% IPS-E-PR-460
Pe
Py
Poo
Por =
pL (rho)
pv(rho)
p (muy
(Gama)
atmosphere
© (phiy
Y (psi)
@ (theta)
7 (pi)
Molecular mass (weight) of the vapor or gas.
Line resistance factor, (dimensionless).
Polytropic exponent.
Upstream pressure, in (kPa absolute)
Pressure in the pipe at the exit or at any point or distance |
downstream from the source, in (kPa absolute)
Pressure in reservoir into which pipe discharges, in (101 kPa (absolute)
with atmospheric discharge}.
Critical-flow pressure, in (kPa absolute).
Pressure of the vapor just inside the flare tip, in (kPa absolute)
Rate of vaporization and burning of liquid, in (kg/s) (selected as equal to
the rate of lashed liquid entering the pit)
‘Steam flow rate, in (kg/s).
Vapor relief rate, in (kg/s).
Heat required to vaporize liquid, in (ki/kg)
Radius.
‘Surface distance from the center of flare stack to the object under
consideration, in (m),
Relative humidity, in (percent)
Minimum distance from the midpoint of the flame to the object under
consideration, in (m),
Linear regression rate of liquid surface in (mmimin)
Upstream temperature, in (K)
Temperature of the vapor just inside the flare tip in (K).
Particle dropout velocity, in (mv).
Exit gas velocity, in (ris).
Vapor velocity, in (rvs)
Lateral wind velocity, in (mis)
Greek Letters
= Density of liquid at operating conditions, in (kgim*)
= Density of vapor at operating conditions, in (kgim*)
= Viscosity of gas, in (¢P=1m Pa. s);
= Fraction of heat intensity transmitted through the
= Heat release (LHV), in (kW).
= Allowable radiation level, in (kWim?)
Liquid particle dropout time, in (s).
Constant figure equal to 3.1416. Irs ily 1984, IPS-E-PR-460
5. UNITS
This standard is based on International System of Units, (SI) except where otherwise specified
6. SELECTION OF BLOWDOWN SYSTEMS
6.4 General
While the various systems for the disposal of voluntary or involuntary vapor oF liquid are mentioned
below, the actual selection of a disposal system shall be conducted in accordance with the
expected frequency, duration of operation, required capacity and fluid properties,
6.2 Blowdown System for Vapor Relief Stream
‘Systems forthe disposal for voluntary and involuntary vapor discharges are:
41) To atmosphere
2) To lower pressure process vessel or system
3) To closed pressure relief system and flare
4) Acid gas fare
6.2.1 Vapor discharge to atmosphere
Vapor relief streams shall be vented directly to atmosphere if all of the following conditions are
satisfied (for a complete discussion on the subject see API RP 21):
1) Such disposal is not in confict with the present regulations concerning pollution and
noise.
2) The vapor is effectively non-toxic and non-corrosive.
3) Vapor which is lighter than air or vapor of any molecular mass that is non-flammable,
non-hazardous and non-condensable,
4) There is no risk of condensation of flammable or corrosive materials.
'5) There is no chance of simultaneous release of liquid, apart from water.
6) Relief of flammable hydrocarbons direct to the atmosphere should be restricted to cases
where it can be assured that they will be diluted with air to below the lower flammable limit.
‘This should occur well before they can come in contact with any source of ignition
‘The above condition can most easily be met if the vapors to be released have a density less than
that of air. However, with proper design of the relief vent adequate dilution with air can be obtained
in certain cases with higher density vapors. Methods of calculation are given in API RP 521 section
43.
Exceptions:
41) Vapor from depressuring valves shall be discharged to a closed pressure relief system
2) Vapor which contains 1% H2S or more by volume, shall be discharged to a closed
pressure relief system.
6.2.2 Vapor discharge to lower pressure process vessel or system
Individual safety/relief valves may discharge to a lower pressure process system or vessel capable
of handling the discharge, Irs July 1004 IPS-E-PR-460
‘Atthough this type is rarely used, itis effective for discharges that contain materials which must be
recovered
6.2.3 Vapor discharge to closed pressure reliof system and flare
In all cases where the atmospheric discharge or release of vapor to a lower pressure system is not
permissible or practicable, vapor shall be collected in a closed pressure relief system which
terminates in a flare, namely flare system, Where the concentration of HS is such that
‘condensation of acid gas is probable, provision for a separate line, heat traced, shall be considered
In all cases, the installation of a closed pressure relief system shall result in a minimum of air
pollution and the release of combustion products.
6.2.4 Acid gas flare
In process plants where HS free and H,S containing stream are to be flared, consideration should
be given to the installation of a separate header and flare stack assembly for the H2S containing
streams. The following provisions should be studied for the acid gas flare assembly
41) Automatic injection of fuel gas down stream of H2S pot in order to make the combustion
stable
2) Steam injection for smokeless operation shall not be considered for H,S flare tp.
'3) A.common pilot igniter shall be used to ignite all flare stacks including the acid flare.
4) The HS flare header and subheaders may be heat traced in order to prevent the
condensation acid gas.
6.3 Blowdown System for Liquid Relief Stream
Systems for the disposal of voluntary and involuntary liquid discharges are:
1) To onsite liquid blowdown drum.
2) To lower pressure process vessel or system,
3) To oily water sewers only if the material will not cause hazardous conditions.
4) To pump suction if pump will not overheat or can withstand the expected temperature
tise.
5) To burning pit
6) To vaporizer
Thermal expansion relief valves may discharge small quantities of volatile liquid or vapor into the
atmosphere, provided the valve outlet is in a safe location.
6.3.1 Liquid discharge to onsite liquid blowdown drum
The liquid shall be discharged to an onsite liquid blowdown drum which is capable of retaining the
liquid discharged at the required liquid relief rate for a period of 20 minutes. This drum shall have a
vapor discharge line to the closed pressure relief system.
6.3.2 Liquid discharge to lower pressure process vessel or system
‘The liquid shall be discharged to @ lower pressure process vessel or system which is capable of
handling the required liquid relief rate plus any flashed vapor.
6.3.3 Liquid discharge to oily water sewer
Liquid discharge to an oily water sewer shall be nonvolatile and nontoxic. The required liquid relief IreS July 1994 IPS-E-PR-460
rate shall be within the oil removal capabilty ofthe oily water treating system.
6.3.4 Liquid discharge to pump suction
Required liquid relief shall discharge to an upstream liquid reservoir from which the pump takes
suction. The liquid relief may discharge directly to the pump suction line if sufficient cooling is
provided to prevent a temperature rise of the liquid recycled through the pump when the safety/reliof
valve opens or when a constant displacement pump is used,
6.3.8 Liquid discharge to burning pit
Liquid relief or voluntary liquid blowdown which need not be retumed to the process or discharged
to an cily water sewer, shall be discharged to a burning pit, if environmentally accepted.
6.3.6 Liquid discharge to vaporizer
The liquid shall be discharged to a vaporizer which is capable of vaporizing a liquid relief of no more
than 5,000 kg/h,
7. DESIGN OF DISPOSAL SYSTEM COMPONENTS
Depending on the process plant under consideration, a disposal system could consists of a
combination of the following items: piping, knock-out drum, quench drum, seal drum, flare stack,
ignition system, flare tip, and burning pit.
7.4 Piping
7.4.4 General
In general, the design of disposal piping should conform to the requirements of ANSI / ASME 831.3
Installation details should conform to those specified in API Recommended Practice 520, Part Il
7.4.2 Inlet piping
The design of inlet piping should be in accordance with API-RP-521, Section 5.4.1
7.4.3 Vapor relief header
The sizing should be in accordance with API-RP-521, Section 5.4.1.2 in conjunction with Appendix
‘Aas a supplement to the above; and API-RP-520, Pait |, Section 7 and Appendix C therein. ul
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In determination of back pressure the following shall be taken into consideration
41) Flashing of liquid at reietsafety valve discharge or along the network due to pressure
