FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

Rev 0

page 1 of 10

Rev Date : 25 July 2005

PT. MEDCO E&P INDONESIA

STANDARD SPECIFICATION
FOR
FLARE STACK, FLARE TIP AND FLAME FRONT GENERATOR

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

Rev 0

page 2 of 10

Rev Date : 25 July 2005

TABLE OF CONTENTS
PAGE
1

SCOPE

CODES AND STANDARDS

2.1
2.2

3
4

Applicable Codes and Standards

Applicable COMPANY Specifications

DESIGN

3.1
3.2

4
5

Process Design
Vertical Flare Stack

INSPECTION AND TESTING

DOCUMENTATION

PREPARATION FOR SHIPMENT

GUARANTEE

DATA SHEET

10

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

Rev 0

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Rev Date : 25 July 2005

1

SCOPE
1.1

This specification, together with the project data sheets, drawings, and project
specific requirements, covers the minimum requirements for the engineering,
design, fabrication, inspection and delivery of flare stack, flare tip assemblies
complete with pilots, and remote flame front generators for vertical flare stacks

1.2

VENDOR shall have total unit responsibility for the packages, including:
-

1.3

Project Management, Supervision and Labor

Process Engineering and Design
Structural and Mechanical Engineering and Design
Instrument and Electrical Engineering and Design
Procurement of Materials and Components
Shop Fabrication and Shop Assembly
Shop Testing
Preparation for Shipment
Documentation

VENDOR shall provide a base quotation in compliance with this specification and
referenced COMPANY specifications and drawings. However, the VENDOR may
also submit alternate quotations. Alternate quotations shall be clearly identified as
such, shall be fully described technically and shall be separately priced (as
add/deduct) to the base quotation. VENDORs are encouraged to separately quote
alternatives to the base quotation, provided the alternatives are technically
equivalent to COMPANY specifications.

CODES AND STANDARDS

The latest revision of applicable sections of the Codes, Standards, and Specifications
listed below (including addenda, and documents incorporated by reference) shall be
considered an integral part of this specification. Where two or more references define
requirements for the same subject, the more restrictive reference shall govern.
2.1

Applicable Codes and Standards

ANSI B31.3

Chemical Plant and Petroleum Refinery Piping

ASME Boiler and Pressure Vessel Code

Section II
- Parts A and C Material Specifications
Section V
- Non-Destructive Examinations
Section VIII, Div.1
- Unfired Pressure Vessels
Section IX
- Welding Qualifications

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

Doc. No : MEP-R-ES-007

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Rev 0

page 4 of 10

Rev Date : 25 July 2005

Regulations Applicable to Piping and Pressure Vessels
AISC,

Manual of Steel Construction

AISE and AWS D1.1 Standard for Design and Welding of Structural Steel
API Std - 2510A,

Design and Construction of Installations at Petroleum

Terminals, Natural Gas Processing Plants, Refineries and
Other Industrial Plants

API RP-521,

Guide for Pressure Relief and Depressurizing Systems

API Manual on Disposal of Refinery Wastes, Volume on Atmospheric Emissions,

Chapter 15-Flares

2.2

ISA RP-12.2,

Intrinsically
Safe
Instrumentation

and

Non-Incentive

Electrical

NFPA 70

National Electric Code, Article 500, Hazardous (Classified)

Locations and Article 501, Class I Locations

Applicable COMPANY Specifications

MEP-G-ES-001

General Technical Conditions for Tender and Purchase of

Equipment and Materials

MEP-P-ES-001

Piping Material Specification (Spec. 1B only)

MEP-P-ES-003

Fabricated Piping and Inspection

MEP-P-ES-005

Valve Specification (Spec. 1B only)

MEP-M-ES-017

Standard Specification For Unfired Pressure Vessels

MEP-G-ES-008

Surface Preparation, Painting and Galvanizing

MEP-I-ES-004

Local Instrument Control Panels and Consoles for Outdoor

Installation

DESIGN
3.1

Process Design
VENDOR shall supply a stack of sufficient height to limit the radiation to levels
specified in project data sheets and project specifications. Flare tip, stack, and

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

Rev 0

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Rev Date : 25 July 2005

seal drum sizing shall be determined by VENDOR to meet the design gas flare
rate within the maximum allowable pressure drop specified in the project data
sheets and project specifications.
3.2

Vertical Flare Stacks

3.2.1

The Flare Stack System shall consist of self supporting or guyed stack,
as specified in the project data sheets and project specific
specifications, complete with pilots, ignitors, flame failure
thermocouples, and molecular seal, all provided by VENDOR. Seal
drums and/or knock-out drums shall be furnished by VENDOR when
specified in project data sheets and project specifications.

3.2.2

The Flare Stack and Accessories shall conform to API RP521 and the
API Manual on Disposal of Refinery Wastes, Volume on Atmospheric
Emissions, Chapter 15 - Flares, unless specifically modified herein. The
Flare Assembly shall be complete with all auxiliary equipment and
accessories required to operate satisfactorily. VENDOR shall specify
minimum purge gas rate in the quotation.

3.2.3

The Flare Tip Assembly furnished by VENDOR shall consist of the main
flare tip, pilots, and ignitors. The flare tip shall be designed to flange to
the stack. As a minimum, the top 10 ft. of flare tip, pilot, and ignitor
piping shall be 310 S.S. This top 10 ft. section shall be flanged (ANSI
150 RFWN) to permit removal for maintenance. The top 10 ft sections
of 310 S.S. pilot and ignitor piping shall terminate with 3000# socket
weld unions or ANSI 150 RFSW flanges.

3.2.4

The VENDOR shall furnish all pilot gas, ignitor, and gas seal piping from
flare tip assembly down to 15 ft. from stack base. Molecular seal drain
piping to base of stack shall also be furnished by VENDOR. Drain
piping shall terminate with valve at stack base. Piping shall be carbon
steel A106B in accordance with MEP-P-ES-001, Piping Spec (Spec. 1B)
and MEP-P-ES-003, Fabricated piping. All piping shall be attached by
clips to the individual stack sections. Valves shall comply with
MEP-P-ES-005, Valve specification

3.2.5

Main flare stack piping shall be carbon steel, A-106B or API 5L GRB
(ERW or Seamless) in compliance with MEP-P-ES-001, Piping Material
Specification (Spec. 1B) and MEP-P-ES-003, Standard Specification for
Fabricated Piping, except that corrosion allowance shall be increased
from 1/16" to 1/8". Flare stack minimum design pressure shall be 150
PSIG at 150oF. Individual sections of the flare stack shall be flanged
(ANSI 150 RFWN) and individual flanged sections shall not exceed 30
ft. length, in order to facilitate shipment and field erection. VENDOR

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

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Rev Date : 25 July 2005

may shop hydrotest the individual stack sections or full x-ray all welds,
at his option. VENDOR shall furnish all required gaskets and bolting in
accordance with MEP-P-ES-001, Piping Material Specification.
3.2.6

When specified in the project data sheets and project specifications,

VENDOR shall also supply water seal drums and/or knock-out drums.
Mechanical design, fabrication, inspection, testing, and documentation
of drums shall comply with ASME Section VIII Div.1 and,
MEP-M-ES-017, Unfired Pressure Vessel, and requirements. Minimum
mechanical design pressure of drums shall be 150 PSIG at 150oF. No
ASME Code stamp is required. Mechanical construction of water seal
and knock-out drums shall comply with the project data sheets.
Process sizing and process design of drum internals (weirs, baffles,
deflectors, etc.) shall be VENDOR's responsibility.

3.2.7

The VENDOR shall supply caged ladders, 180 degree intermediate

platforms at 30 ft. maximum intervals, and a 360 degree top platform for
access to the flare tip and ignitor area. Ladders, platforms shall be
galvanized in accordance with MEP-G-ES-008, Surface Preparation,
Painting and Galvanizing, and shall be shop assembled and clipped to
each 30 ft. section of flare stack, prior to shipment.

3.2.8

Aviation obstruction lights shall be supplied by VENDOR when specified

in the project data sheets and project specifications.

3.2.9

When guyed stacks are specified in the project data sheets and project
specifications, the VENDOR shall supply:
-

All guy wires

Turnbuckles
All shackles, hooks
All cable clamps, thimbles
All miscellaneous hardware required to field install the guy wire
assemblies.

Guy wires and guy wire installation hardware shall be galvanized per
MEP-G-ES-008, Surface Preparation, Painting, Galvanizing.
3.2.10

The pilot flame shall remain lit, even under adverse conditions of high
wind and heavy rain. Wind velocities of up to 80 mph and rainfall rates
of up to 2 inches per hour are possible. Three (3) flare pilots and flame
front ignitors spaced 120 degrees apart shall be furnished to ensure the
flare will stay lit regardless of wind direction.

MEP-R-ES-007, Flare Stack, Flare Tip And Flame Front Generator, rev 0, 25 July 2005
Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

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Rev Date : 25 July 2005

3.2.11

The flame front generator shall be designed to initiate and

maintain a pilot flame. The pilot gas shall be ignited with an
electric spark and the flame transported to the ignitor tip through
closed conduit. At the tip, the flame will ignite the pilot gas.
The flame front generator ignition system will be located not
more than 250 feet from the base of the stack. VENDOR shall
supply the flame front generator complete with valves, gauges,
regulators, ignition housing and ignition transformer system
mounted in a panel.
All panel components shall be suitable for NEC Class I, Div. 2
Group D service.
Panel enclosure shall be NEMA 4X.
Alternately, VENDOR may supply NEC Class I, Div. 1, Group D
(explosion proof) panel enclosure. In any case, inert gas purge
of panel enclosure to achieve compliance with NEC Div. 2
requirements is not acceptable.

3.2.12

The flame front ignition system shall be equipped with automatic

pilot relight capability in case of flameout. If a relight attempt
does not give a rising pilot flame temperature within a time
period in seconds as specified by the VENDOR, an alarm signal
shall be transmitted to the ignition panel.
VENDOR shall
provide a contact for remote alarm of pilot flame failure.

3.2.13

VENDOR shall supply all pilot thermocouples, thermowells,

extension cable, and fittings. Pilot thermocouples shall be
chrome-alumel sealed in a high temperature corrosion resistant
sheath connected into an explosion proof/ weatherproof junction
box located on the top platform of the flare stack, pilot
thermocouples shall be located in high temperature (310 SS or
equal) thermowells. VENDOR shall also supply multi-pair
extension cable for the pilot thermocouples. Extension cable
shall terminate in a VENDOR furnished explosion proof junction
box mounted at base of stack. Extension cable shall, as a
minimum, be 304 SS braided, Teflon insulated color coded
chrome-alumel cable. VENDOR shall provide Teflon wrap locks
for field attachment by others to pilot gas piping.
Thermocouples shall be shop tested by VENDOR prior to
shipment

MEP-R-ES-007, Corrugated Plate Intercept Separator, rev 0, 25 July 2005

Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

Rev 0

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Rev Date : 25 July 2005

4

INSPECTION AND TESTING

In addition to the equipment inspection requirements listed in Specification
MEP-G-ES-001, General Technical Conditions For Tender And Purchase
Equipment And Materials, and the additional referenced COMPANY specifications,
the following items shall be required as a minimum.

4.1

A Field Performance Test shall be conducted by COMPANY upon

completion of installation. This test shall be satisfactorily passed before
final acceptance of the system. VENDOR may, at his cost, designated a
representative to witness the field performance test.

4.2

A review of documentation to assure that the equipment complies with all

applicable codes and with ordinances of the governing agencies where the
unit is to be installed. Refer to Specification MEP-G-ES-001, General
Technical Conditions For Tender And Purchase Equipment And Materials,
for detailed requirements including resolution of any conflicts in regulations.

DOCUMENTATION
COMPANY requires VENDOR to supply project data books (5) sets, which shall,
as a minimum, include the following, in accordance with specification
MEP-G-ES-001, General Technical Conditions For Tender And Purchase
Equipment And Materials:
5.1

As built drawings.

5.2

Process, mechanical, and structural calculations.

5.3

Mill Test Certificates for all fabricated pressure retaining components,

bolting materials, including guy wires.

5.4

Welding procedure, welder qualification procedure, welder certification

documents.

5.5

Copies of Hydrotest Recording (pressure vs time).

5.6

Nameplate rubbing.

5.7

Report of NDT testing fabrication.

5.8

Operating and maintenance procedures.

MEP-R-ES-007, Corrugated Plate Intercept Separator, rev 0, 25 July 2005

Custodian: Surface Engineering

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Doc. No : MEP-R-ES-007

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Rev Date : 25 July 2005

6

PREPARATION FOR SHIPMENT

All external carbon steel which is not galvanized, shall be prepared and coated
according to specification MEP-G-ES-008, Surface Preparation, Painting, and
Galvanizing. Stainless steel materials shall not be painted.
All openings shall be covered and sealed with plywood, thin gauge sheet metal
and/or screwed plugs.
Components shall be tagged and properly identified to expedite reassembly at the
site, as applicable.

GUARANTEE
The VENDOR shall guarantee that the composite unit and all of the components
are in accordance with specification MEP-G-ES-001, General Technical Conditions
for Tender and Purchase of Equipment and Materials. The VENDOR shall also
provide process performance guarantees as stated in the project specifications.

MEP-R-ES-007, Corrugated Plate Intercept Separator, rev 0, 25 July 2005

Custodian: Surface Engineering

Doc. No : MEP-R-ES-007

FLARE STACK, FLARE TIP AND FLAME

FRONT GENERATOR

Rev 0

page 10 of 10

Rev Date : 25 July 2005

MEDCO E&P Typical Datasheet.
VERTICAL FLARE STACK
DATA SHEET
Page 1 of

AFE No. :
MR No. :
Tag No. :

Prepared by
Revision/Date
Service

:
:
:

SITE CONDITIONS
Location
Grade Elevation (M) :
o
:
Temperature ( F)
Rel Humidity

:
Min :

Seismic Zone
Wind Speed
Precipitation
Elec. Area Class

Max.:

:
:
:
:

PROCESS CONDITIONS
Waste Gas Composition
:
Capacity (MMSCFD)
:
Moleculat Weight
:
Lower Heating Valve (BTU/LB)
Temperature (oF)
:
Inlet Pressure (PSIA)
:

Min :

Max :

Max. Pressure Drop (PSI) :

Water Seal Drum
:
Knock-out Drum
:

:
Min :

Max :

UTILITIES AT SITE
Instrument Air Press. (PSIG) :
(PSIG) :
Utility Water Pressure (PSIG) :
Electric Power
:

Min :

Max

Min :
Volts,

Max
Phase,

:
:
Hertz

Pilot Gas Supply Pressure

Pilot Gas Composition
Pilot Gas L H V (BTU/LB)

:
:

MECHANICAL CONDITIONS
Flare type
:
( )
Base Diameter (MM)
:
Base Height (M)
:
Base W.T. (MM)
:
Stack Diameter (MM)
:
Stack Height (M)
:
Stack W.T. (MM)
:
Stack
:
()
Lifting Davit on Stack
:
()
Heaviest Lift (Kg)
:
Highest Lift (M)
:
Flame Front Generator Ignitor

Vertical Stack;

( ) Horizontal Burn Pit

Self Supporting; ( ) Guyed

Yes;
( ) No

()

Transformer;

( ) Piezoelectric

NOTES:
MEP-R-ES-007, Corrugated Plate Intercept Separator, rev 0, 25 July 2005
Custodian: Surface Engineering