RELIANCE- REFINERY -JAMNAGAR

GENERAL UNIT DESCRIPTION-FLAR& STACKS

1.0

GENERAL:

Flares are provided to safely combust relief valve discharges and normal process
vents. These discharges and vents may be flammable, toxic or corrosive vapours,
which are converted to less objectionable compounds by means of combustion.
The safety facilities / design of flare system is used to prevent catastrophic equipment
failure. These facilities are designed to prevent over pressure and safe disposal of
discharged vapours, liquids and hydrocarbons during startup and shutdown.
Relieving gases are sent through an elevated stack from a closed collection system
and burnt at the top. The flame generated is open to the atmosphere.
The flame, which reaches the top, is burnt by means of pilot burners, which are at the
top of the flare stack. These burners burn continuously to avoid any vapours to leave
the stack unburned. Flaring takes place by burning the vapours with the help of air.
This air is not allowed to enter the internals of the flare, as pressure of flue gases is
greater than atmospheric pressure.
Flares shall achieve smokeless operation at up to 2 % of their design rates
using steam injection (maximum 40 t/hr of steam).
The scope of this section is restricted to the following Flares:
1.

Main flare

2.

FCC / COKER flare.

In our complex, these two flares receive discharges of different pressure ratings.
Flare

Header

Main

HP
LP
LLP

FCC / COKER

Discharge from PSVs

( kg/cm2g)
Above 9
Between 3.5 to 9
Below 3.5

The pressure break point of 9 Kg/cm2g is recommended, as this is the set point of the
large Xylene fractionation relief load.
These flares include the following equipment:
No.
1
2
3
4
5
6
7

Equipment
Knockout drums
Knockout drum pumps
Liquid seal drums
Flare stacks
Flame front generators
Steam control skid
Pilots per stack

2.0

PRINCIPLE OF OPERATION

2.1

Knock Out Drums & Pumps:

Main Flare
2
2
3
3
1
1
3

FCC/COKER Flare
1
2
2
2
1
1
4

These are located before the flare stack in order to separate any condensate from
relieving vapours as burning of condensate liquid droplets is hazardous. The Pumps
are on auto system and will be activated on High Level Alarm. The condensate is
pumped through the Flare Liquid Cooler (natural cooling) to the Cracked Slop Oil
tank in RTF.
2.2

Liquid Seal Drums:

These are provided to avoid any slop to be discharged into the flare stack. A liquid
seal is provided by a continuous supply of utility water. When the vapours pass
through the water, bubbles are formed carrying any residual slop oil to the surface.
This slop oil is sent to ETP through Oily Water Lift Station.
2.3

Flare Stacks:

FLARE
MAIN
FCC / COKER

NO. OF STACKS
3
2

HEIGHT (m)
150
150

DIA(inches)
60
72

These flare systems are the highest in India as on date. The other feature is the derrick
support structure, which has been introduced for the first time in India.

2.4

Flame Front Generator:

At the time of igniting the pilots, the flame front generator plays a major role. It
contains a special skid to ignite each pilot at a time. LPG is used as ignition gas.
Pilots, which have to burn continuously, are supplied with purge gas after lighting.
2.5

Steam Control Skid:

As per PCB regulations, a smokeless flare is essential for maintaining the ecology.
Smoke formation mainly occurs in fuel-rich systems where a low hydrogen atom
concentration suppresses the smoke. At high temperatures, hydrocarbons crack,
producing free hydrogen and carbon. Hydrogen reacts much faster than carbon.
Unless the carbon particles are burned away, they cool down and form smoke.
Steam addition also assures that the steam separates the hydrocarbon molecules,
thereby minimizing polymerization reactions and forms oxygen compounds that burn
at a reduced rate and temperature so as to prevent cracking.
Steam control skid allows optimum amount of steam to be introduced at the burner tip
to avoid a smoky flame.
3.0

NORMAL OPERATING CONDITIONS

Design conditions(Main flare)
Emergency flow rate per stack

11,00,189 kg/hr

Total emergency flow rate

22,00,378 kg/hr

Smokeless flow rate per stack

66,678 kg/hr

Total smokeless flow rate

1,33,356 kg/hr

LHV of flare gas

31,984 Kcal/Nm3

Molecular weight

72.93

Temperature at inlet

185 0C

Available pressure

0.35 kg/cm2 g

Flare stacks (Main flare)

Temperature at inlet

185 0C

Available pressure

0.35 kg/cm2 g

Purge gas flow per stack

180 Nm3/hr

Pilot gas flow per stack for 3 pilots

5.22 Nm3/hr @ 1.05 kg/cm2 g

FFG fuel gas flow

2.95 Nm3/hr @ 1.41 kg/cm2 g

FFG ignition air flow

29.5 Nm3/hr @ 1.41 kg/cm2 g

Upper steam flow per stack

8,900 kg/hr @ 8.15 kg/cm2 g

Center steam flow per stack

1,100 kg/hr @ 8.15 kg/cm2 g

Utility requirements

4.0
4.1

Purge gas flow per stack

180 Nm3/hr

Total purge gas flow for 3 stacks

540 Nm3/hr

Pilot Gas Flow Per Pilot

1.74 Nm3/hr @ 1.05 kg/cm2 g

Pilot gas flow per stack for 3 pilots

5.22 Nm3/hr @ 1.05 kg/cm2 g

Total pilot gas flow for 9 pilots

15.66 Nm3/hr @ 1.05 kg/cm2 g

FFG fuel gas flow

2.95 Nm3/hr @ 1.41 kg/cm2 g

FFG ignition air flow

29.5 Nm3/hr @ 1.41 kg/cm2 g

Upper steam flow per stack

8,900 kg/hr @ 8.15 kg/cm2 g

Total upper steam flow for 2 stacks

17,800 kg/hr @ 8.15 kg/cm2 g

Center steam flow per stack

1,100 kg/hr @ 8.15 kg/cm2 g

Total center steam flow for 2 stacks

2,200 kg/hr @ 8.15 kg/cm2 g

TROUBLE SHOOTING
Flare Tips:

Problem
Smoky operation

Shell overheating

4.2

Solution(s)
Check vent gas composition to
see if it contains heavy and/or
unsaturated hydrocarbons

Lack of Steam flow

Check the ports on the Steam

Tips and check the Steam ring
and risers for possible plugging.
Clean as necessary.

Lack of Steam flow

Check the ports on the Center

Steam Tip for possible plugging.
Clean as necessary.

Loss of Refractory lining

Check the Refractory lining in

the Flare Tip and replace as
necessary.

Pilots:

Problem
Pilot will not
light

4.3

Possible cause(s)
Fuel consumption

Possible cause(s)
Lack of Fuel

Solution(s)
Fuel is not being delivered to the pilots due
to a break in the Fuel Gas piping or a
plugged pilot mixer orifice. Check the Pilot
Fuel Gas piping for proper routing and any
open drain valves. Also check the pilot
mixer orifice for possible plugging.

Fuel Gas pressure too

low

Check the Fuel Gas pressure supplied to

the pilots. The pilots require 1.05 kg/cm2 g
at their gas inlet for proper operation.

No Ignition source

Check the ignition line piping for proper

routing and check that there are no open
drain lines. Check for presence of a spark
when depressing the ignition button.

Thermocouple failure

Check the thermocouple for proper

operation. If the thermocouples are not
correctly installed or wired to the DCS
properly, the pilot may be lit but it is not
registering.

Flame Front Generator:

Problem

Possible cause(s)

Solution(s)

Pilot will not

light

No spark in
Ignition
chamber

Pilot status
will not
register

4.4

Lack of spark

Check for presence of a spark when

depressing the Ignition button. Contact the
Electrical department if no spark is
observed through the Ignition chamber
sight glass.

Improper Fuel/Air
mixture

Check that the Air and Fuel pressure are set

as stated in this manual. It may be
necessary to adjust Fuel and Air setting to
obtain a proper combustible mixture.

Insufficient Ignition
trail spacing

Due to length of utility piping and Fuel/Air

pressure settings at the Ignition chamber,
the time between ignition attempts may
need to be lengthened.

Presence of moisture

Only dry air should be supplied to the FFG

rack, as it is vulnerable to moisture in
piping. It is necessary to flow air through
the system to thoroughly dry the piping
before ignition is possible.
Check to ensure proper power supply is
attached to the correct terminals on the
Ignition Transformer.

No power to
Transformer
Broken spark plug

Check the spark plug in the Ignition

chamber for possible damage. Change if
necessary.

Improper connection
to DCS

The Pilot Status Indication panel does not

monitor the pilots. The signal for a pilot
failure comes from the DCS. Check the
wiring for proper connection.

Status lamp burned

out

Check for a burned out lamp. Depress the

Lamp Test button to see if all lamps light.

Steam Control Skid:

Problem

Possible cause(s)

Solution(s)

Smoky Flare
Tip operation

Overheating
of Flare Tip
shell

Heat damage
to idle Flare
Tip Steam
Tips

4.5

Lack of Upper Steam

flow

Check the isolation valves on the skid

leading to the smoky Flare Tip to ensure
they are fully open. Also check to ensure
all drain valves in the steam piping leading
to the Flare Tip are closed.

Low Upper Steam

flow

Check the movement of the Control valves

on the skid to ensure proper steam flow is
being metered to the Flare Tip.

Lack of Center Steam

flow

Check the isolation valves on the skid

leading to the smoky Flare Tip to ensure
they are fully open. Also check to ensure
all drain valves in the steam piping leading
to the Flare Tip are closed.

Low Center Steam

flow

Check the movement of the Control valves

on the skid to ensure proper steam flow is
being metered to the Flare Tip.

Lack of Cooling
Steam flow

Check the isolation valves on the skid

leading to the concerned Flare Tip to
ensure they are partially open to allow
some Cooling Steam flow to the Steam
Tips. Also check to ensure all drain valves
in the steam piping leading to the Flare Tip
are closed.

Knockout Drum and pumps:

Problem
High level
buildup

Pump not
developing
pressure

Possible cause(s)
High amount of
condensation of HC

Solution(s)
Ensure that the pump starts on Auto. If not,
start manually.

Pump not working

Check for power supply. If pump is not

picking up in Auto, start pump manually.

Pressure gauge
faulty

Check calibration of pressure gauge.

Suction strainer
choked

Clean the suction strainer.

Suction valve closed

Open the valve.

Improper priming of
pump

Prime it properly.

Pump rotating in

Check direction.

reverse direction

HC leakage
from seal

Oil leakage
from oil seal

4.6

Air leakage into

suction piping

Check flanges and other tapings such as

drains and vents for leakage.

Improper adjustment
of mechanical seal

Check and adjust

Damaged
mechanical seal

Check and replace

Damaged oil seal

Check and replace

Liquid Seal Drums:

Problem
High level in
drum

Low level in
drum

Possible cause(s)
Overflow valve
closed

Solution(s)
Open overflow valve.

High amount of
condensation of HC

Stop Utility Water and watch for decrease

in level through overflow line.

Utility Water valve

closed

Open Utility Water valve.

5.0

SALIENT FEATURES:

1.

Derrick structure for flare stack support.

2.

Largest diameter header in the refinery site (102) for the main flare system.

3.

Capacity of Main flare 2200 t/hr

4.

Capacity of FCC / Coker flare 1350 t/hr

5.

Aircraft warning lights with three heights at three levels (40m, 95m and
140m). Bulb life is 18000 hrs.

6.

6.0

Guaranteed noise level is 90-dB (A) at the perimeter of the sterile area.

INTER PLANT RELATIONSHIP:

Main flare is a recipient of flue gases from various suppliers in the complex as listed:
1.

Aromatics

2.

Crude Train 1

3.

Crude Train 2

4.

FCC

5.

n-Butane(future)

6.

Fuel Gas/Hydrogen

7.

LNUU

8.

Merox

9.

Propylene Recovery

10.

SHP/TAME

11.

Ethylene Recovery(future)

12.

RTF/RRTF