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PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

PROJECT:

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T T

SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

:

Technical Specification for Flare Stacks and Flare Ignition

SHEET NO. 1 of 12

:

REV.:

B03

DOCUMENT NO

:

SYME-MEBASC-ENME-SPEQ-0210-B03

Technical Specification for Flare Stacks and Flare Ignition Panel

B03

4-Feb-2014

issued for Design

M.Zabihi

M.Zabihi

A.Bodaghi

B02

5-Jan-2014

issued for Design

M.Zabihi

M.Zabihi

A.Bodaghi

B01

30-Sep-2013

Issued For Comment

M.Zabihi

M.Zabihi

A.Bodaghi

Rev.

Date

Description

Prepared

Checked

Approved

 

SAZ. POI :

IFD1

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT DOCUMENT TITLE : Technical Specification for Flare Stacks
PROJECT:
SOUTH YARAN OIL FIELD
DEVELOPMENT PROJECT
DOCUMENT TITLE
:
Technical Specification for Flare Stacks and Flare Ignition
:
REV.:
DOCUMENT NO
:
SYME-MEBASC-ENME-SPEQ-0210-B03
SHEET NO.
2 of 12
B03
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PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

:

Technical Specification for Flare Stacks and Flare Ignition

SHEET NO. 3 of 12

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Table of Contents

I. INTRODUCTION

4

II. Definitions

4

III. APPLICABLE DOCUMENTS

4

IV. CODES AND STANDARDS

4

V. Clarification

6

VI. GUIDELINE

7

VII. AMENDMENTS/SUPPLEMENTS TO IPS-G-ME-210(2)

7

1. Conflicting Requirements

7

2. References

7

3. Units

7

4. Design

8

4.1 General

8

4.2 Type

of Flare

8

4.3 Flare Tip

8

4.4 Structure

8

4.5 Piping

8

4.6 Aircraft Warning Lights

8

5. Instrumentation

8

6. Flame Front Generators

9

7. Fabrication Requirements

9

7.1 Piping

9

7.2 Welding

9

7.3 Painting

9

7.4 Explosion Precautions

9

7.5 Fabrication Tolerance

9

8. Inspection

10

9. TESTING

11

10. Preparation

for Shipment

11

11. Guarantees

and Warranties

11

12. SPARE PARTS

11

12.1 Flare Assembly

12

12.2 Ignition Package

12

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DOCUMENT TITLE

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Technical Specification for Flare Stacks and Flare Ignition

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I. INTRODUCTION

South Yaran oil field is located in Kuzestan province 120KM west of Ahwaz with 20Km length and 2.5Km width at south part of Yaran oil field. 24 No wells considered at this area consisting of 14 No Sarvak wells, 8 No Fahlian & Gadvan wells and 2 No appraisal wells for sarvak and fahlian & Gadvan layers with total estimated output between 50,000 to 60,000 STB/Day. Flow of wells is transferred to the 2 phase separation unit (Cluster) for separation of gas from liquids and dehydrating of gas. The dehydrated gas is transferred to NGL 3200 and the liquids are transferred to Karoon production plant for further processing.

II. Definitions

OWNER CLIENT CONSULTING ENGINEER PROJECT

: NIOC : Petroleum Engineering and development Co. (PEDEC) : Sazeh Consultants : South Yaran Petroleum Filed Development (Basic

LOCATION

Engineering) : Khuzestan Province-120Km west of AHWAZ

APPROVED

: Approved by Client

III. APPLICABLE DOCUMENTS

Flare packages (PK-006) shall be designed in accordance with IPS-G-ME-210(2). It is intended that the design be to Iranian Petroleum Standards, however, when doubtful or conflicting interpretations arise, precedence shall be determined as follows, unless agreed to by Purchaser:

Data sheets (or specification sheets) and drawings, if any.

This job specification.

Other codes and standards mentioned in Section III.

IV. CODES AND STANDARDS

The applicable provisions of the latest editions of the following codes, standards and specifications that are in effect at the date of the Contract together with codes and standards referred to in IPS-G-ME-210(2), Second edition, February 2010 General Standard For Flare Details For General Refinery And Petrochemical Service” shall form part of this specification to the extent specified herein.

AMERICAN PETROLEUM INSTITUTE (API)

API STD 537,

API RP 520,

API STD 521,

API RP 551,

"Flare Details for General Refinery and Petrochemical Service"

"Sizing, Selection and Installation of Pressure-relieving Devices in Refineries"

"Sizing and Selection"

Part 1

"Installation"

Part 2

"Guide for Pressure-relieving and De-pressuring Systems"

"Process Measurement Instrumentation"

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

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Technical Specification for Flare Stacks and Flare Ignition

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API RP 552,

API RP 553,

API RP 554,

"Transmission Systems"

"Refinery

Instrumented Systems"

and

Valves

Accessories

"Process Control Systems"

IRANIAN PETROLEUM STANDARDS (IPS)

For

Control

And

Safety

IPS-G-ME-210(2),

IPS-E-PR-460,

IPS-E-SF-860,

IPS-G-SF-860,

IPS-E-GN-100,

IPS-G-SF-900,

"General Standard For Flare Details For General Refinery And Petrochemical Service "

"Engineering Standard For Process Design Of Flare And Blow down Systems"

"Engineering Standard for Air Pollution Control"

"General Standard for Air Pollution Control"

"Engineering Standards for Units"

General Standard For Noise Control And Vibration“

ASME (AMERICAN SOCIETY OF MECHANICAL ENGINEERS)

Boiler and Pressure Vessel Code, Section II

Boiler and Pressure Vessel Code, Section V

Boiler and Pressure Vessel Code, Section VIII Division 1

Boiler and Pressure Vessel Code, Section IX

B16.5

B16.9

B16.28

B16.47B

"Pipe Flanges and Flanged Fittings"

"Factory-Made Wrought Steel Butt welding fitting"

"Wrought Steel Butt welding Short Radius Elbows and Returns"

"Large Diameter Steel Flanges NPS 26 through NPS 60"

"Process Piping"

"Welded and Seamless Wrought Steel Pipe"

"Metallic Gaskets for Pipe Flanges: Ring Joint, Spiral-Wound and Jacketed"

B31.3

B36.10

B16.20

ASTM S(AMERICAN SOCIETY FOR TESTING AND MATERIAL)

A312 (TP 304,309, 321) "Standard Specification for Seamless and Welded Austenitic Stainless Still Pipes"

AWS(AMERICAN WELDING SOCIETY)

D1.1

"Structural Welding Code"

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

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Technical Specification for Flare Stacks and Flare Ignition

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PROJECT SPECIFICATIONS

Following referenced specifications shall be considered as part of this specification.

SYME-PRBASC-ENPS-BSDE-9005 South Yaran Process Design Basis

SYME-PRBASC-ENPS-DIPF-0001

Legend

And

Symbols

Process

Flow

Diagram

SYME-INBASC-ENIN-SPDE-0001

SYME-INBASC-ENIN-SPDE-0004

Specification For General Instrumentation

Specification For Instrument And Control Of Package Unit System (PU)

Electrical Legend And Symbols

Electrical Design Criteria

SYME-ELBASC-ENEL-LILS-0001

SYME-ELBASC-ENEL-CIDE-0001

SYME-INBASC-ENIN-DWIC-0001 Instrument Installation Drawing

SYME-PIBASC-ENPI-CIDE-0001

SYCV-CVBASC-ENCV-DCDS-0001

SYCV-STBASC-ENSO-CIDE-0001

Piping Design Criteria

Civil Design Criteria

Job

Specification

for

Structural

design

SYME-PIBASC-ENPI-SPPA-0001

SYME-PIBASC-ENPI-SPDE-0001

criteria

Painting Specification

Insulation Specification

 SYME-PIBASC-ENPS-PHDS-0001 Relief Venting and Flare Philosophy B03  SYME-PIBASC-ENPI-DSPR-0003 Process Data Sheet
 SYME-PIBASC-ENPS-PHDS-0001 Relief Venting and Flare Philosophy
B03
 SYME-PIBASC-ENPI-DSPR-0003 Process Data Sheet for Flare Stack
V.
Clarification

For site location and conditions reference shall be made to “SOUTH YARAN PROCESS DESIGN BASIS” Doc no.”SYME-PRBASC-ENPS-BSDE-9005”.

Flare stacks and related auxiliary equipment shall conform to IPS-G-ME-210(2), , " General Standard For Flare Details For General Refinery And Petrochemical Service ", modified, substituted, deleted and/or added by this specification and the Codes and Standard specified section III of this specification.

DIN, BS or any other international standard materials equivalent or superior to ASME/ASTM materials specified in Section III of this specification could be used when approved by the purchaser / Owner (but certification is needed.)

Vendor shall follow design requirements in his design, such as this specification, other engineering specification, codes and standards mentioned in Sections III, data sheets and other requirements in requisition. When vendor has any difficulty to conform his design to the design requirement, vendor shall offer his alternative design consideration for purchaser’s approval.

Vendor shall submit his drawings and documents to purchaser, which are mentioned in Purchaser’s requisition.

The plant life time of a minimum of 30 years shall be considered by vendor.

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

:

Technical Specification for Flare Stacks and Flare Ignition

SHEET NO. 7 of 12

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B03

Flare System shall be designed in accordance with “Relief Venting and Flare Philosophy” Doc. no. SYME-PIBASC-ENPS-PHDS-0001 and “Process Data Sheet for Flare Stack” Doc no. SYME-PIBASC-ENPI-DSPR-0003.

VI. GUIDELINE

The following annotations, as specified hereunder, have been used at the end of each clause or paragraph to indicate the type of change made to the equivalent clause or paragraph of reference standard.

Sub. (Substitution)

"The clause in IPS-G-ME-210(2) shall be deleted and replaced by the new clause in this specification".

Del. (Deletion)

"The clause in IPS-G-ME-210(2) shall be deleted without any replacement".

Add. (Addition)

"The new clause with the new number shall be added to the relevant section of IPS-G-ME-210(2) ".

Mod. (Modification) "Part of the clause or paragraph in IPS-G-ME-210(2) shall be modified and/or the new description and/or statement shall be added to that clause or paragraph as given in this Specification".

VII. AMENDMENTS/SUPPLEMENTS TO IPS-G-ME-210(2)

This engineering specification gives the amendments and supplements to IPS-G-ME- 210(2), Second edition, February 2010 “General Standard for Flare Details for General Refinery and Petrochemical Service".

It is intended that IPS-G-ME-210(2) together with this specification shall be used for design and supply of Flare Stacks

For ease of reference, the clause or section numbering of IPS-G-ME-210(2) Second edition, February 2010 has been used throughout this document. Clauses in IPS-G-ME- 210(2) that are not mentioned remain unaltered.

1. Conflicting Requirements

Refer to item V of this specification "Order of Precedence".

2. References

Refer to Section IV of this Specification.

3. Units

(Sub.)

(Sub.)

This Standard is based on International System of Units (SI), in accordance with IPS-E- GN-100 except for tube and piping sizes, pressure and temperature whose units shall be in Inch, Bar and Degree Celsius respectively. (Mod)

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

DOCUMENT TITLE

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Technical Specification for Flare Stacks and Flare Ignition

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4. Design

4.1

General

4.1.1

Suitable lifting lugs shall be provided on each component.

(Add.)

4.1.2

The Igniter Package with flare system will be subject to HAZOP meeting. The vendor

shall incorporate all HAZOP comments as required for safe and reliable operation and maintenance of the Package. The vendor is expected to participate in Project HAZOP

meeting.

(Add.)

4.1.3

Vendor shall be responsible for ensuring that the supplied equipment and services meet

all applicable regulations on health, safety and environmental issues.

(Add.)

4.2

Type of Flare

4.2.1

Flare Type Classification Based on Flare Structure

Type of Flare Stacks shall be as per "Data Sheet for Flare Stacks and Flare Ignition

Panel.

(Mod.)

4.3

Flare Tip

The top 4 meters of the flare tip shall be fabricated from stainless steel. Type/Grade of material shall be specified on "Data Sheet for Flare Stacks and Flare Ignition Panel”. (Mod.)

4.4

Structure

4.4.1

All structural Steel including platforms and ladders shall be designed and fabricated in accordance with "Job Specification for Structural design criteria" No. SYCV-STBASC- ENSO-CIDE-0001 and "Specification for Structural Steel Design, Fabrication and Erection” No. SYCV-STBASC-ENSO-SPDE-0001. (Mod.)

4.4.2

These criteria shall be considered for selecting the type of flare stack support unless

otherwise specified on "Data Sheet for Flare Stacks and Flare Ignition Panel”.

(Mod.)

4.4.3

Pockets or depressions, which would hold water, shall have drain holes or be otherwise

protected.

(Add.)

4.5

Piping

All piping and pipe fittings shall be designed in accordance with "Piping Design Criteria" No.: SYME-PIBASC-ENPI-CIDE-0001 and “Piping Material Specification” No.: SYME-

PIBASC-ENPI-SPMT-0001.

(Mod.)

4.6

Aircraft Warning Lights

(Add.)

Aircraft warning lights shall be supplied and installed on flare stack in accordance with ANSI/API STD 537 when requested in data sheet.

5.

Instrumentation

All instrumentation shall be in accordance with the requirements of "Specification for Instrument and Control of Package Unit System (PU)" No.: SYME-INBASC-ENIN-

SPDE-0004.

(Mod.)

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Technical Specification for Flare Stacks and Flare Ignition

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6. Flame Front Generators

(Add.)

Flame front generators shall be the type that does not require a connection to an external electrical supply, and shall be certified as flame-proof.

The flame front generator shall be designed to light the pilots during wind speeds of up

to 50 meters/second (m/s).

The flame front generator panel shall be fully protected against the effects of dust storms, rain storms, ambient and sun-temperature extremes.

A suitable shield shall be fitted around the flame front generator panel to protect

operators from the weather extremes described above.

7. Fabrication Requirements

7.1

Piping

 

All piping shall be assembled and hydrostatically tested prior to being put to operation. Requirements of ANSI/API STD 537 shall be met by vendor. (Mod.)

7.2

Welding

7.2.1

Edge preparation shall be in accordance with following paragraph of ASME Section VIII. :

 

(Add.)

 

UW-31 for fitting and alignment

UW-32 for cleaning of surfaces to be welded

7.2.2

All joints in riser shell shall be full penetration. For Joints inaccessible from the inside, the fabricator shall submit for approval an alternative method where full fusion weld can

be

achieved from one side.

(Add.)

7.2.3

When required, preheat and PWHT shall be as per ASME B31.3. (Add.)

7.3

Painting

 

All support brackets, etc shall be painted in accordance with the requirements of "Painting Specification" No.: SYME-PIBASC-ENPI-SPPA-0001. Surfaces which are inaccessible afterwards shall be painted before installation with fully specified paint system, plant-mounted instruments and stainless steel impulse lines shall not be

 

painted.

(Mod.)

7.4

Explosion Precautions

All electric/electronic instruments shall comply with “Electrical Design Criteria” No.:

SYME-ELBASC-ENEL-CIDE-0001.

(Mod.)

7.5

Fabrication Tolerance

(Add.)

Fabrication Tolerance for stack shall be as follows;

Out of Roundness shall be in accordance with ASME Section VIII Division1 Paragraph UG-80

Out of Straightness shall not be in excess of 3mm in 3m

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

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8.

Inspection

As a minimum, supplier of Inspection and Test Plan shall cover following requirements

for shop welds. Inspection and Test plan shall be submitted to purchaser for review and

approval.

(Add.)

After removal of fit-up lugs or strong backs welded to P-4, P-5 or P-6 group alloys (if any), the weld area shall be dressed and examined by magnetic particle method.

The final pass of attachment welds to P-4, P-5 or P-6 group alloys (if any), shall be magnetic particle examined after final post-weld heat treatment.

Welded joints belonging to Categories A and B of Paragraph UW-3 of ASME Code Section VIII division1shall not be positioned to pass under a reinforcing pad, where possible. If this is unavoidable, the joint under the pad shall be ground smooth and radiographed for its entire hidden length plus 40 mm on each side.

The extents of non destructive examination shall be as follows as a minimum:

i. Flare Tip:

ii. Gas Steal:

iii. Riser:

iv. Utility Piping:

Radiograph

requirements.

sensibility

shall

RT 10% of Butt Weld/PT 100%

RT 10% of Butt Weld/PT 100%

RT 10% of Butt Weld/PT 100%

RT 10% of Butt Weld/PT 100%

meet

ASME

Code

Section

VIII

Division1

Each spot radiograph shall be minimum 150 mm in length and in accordance with ASME Section VIII Division 1. All welds to be covered by nozzle reinforcing pads and at least one weld intersection shall be included. Non-radiograph-able welds shall be examined by magnetic particle.

When stack drawings or supplementary specifications call for magnetic particle or Liquid Penetrate inspection of welds, this procedure shall be applied to the back- chipped surface of root pass welds before proceeding to weld on the opposite side unless preheating over 144˚C is required.

When magnetic particle or Liquid Penetrate inspection is specified, machining or grinding of the weld surface will not be required other than to remove excessive irregularities which would interface with proper interpretation of results.

When full radiography is required, any non-radiograph-able welds of non- austenitic stainless steel shall be inspected by magnetic particle and/or ultrasonic methods. Magnetic particle examination, other than above is recommended on all welds of non-austenitic steel liable to crack (particularly after heat treatment). Such inspection, intended to assertion surface appearing defects, shall be made in such a way so as to avoid any damage to the material.

On all welds of stainless steel stacks, liquid Penetrate examination shall be made of the weld surfaces both inside and outside.

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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9. TESTING

(Add.)

Vendor shall notify, as per conditions set in general procurement conditions, of specific test dates.

Acceptance of shop tests does not constitute a waiver of requirements to meet field performance under specified operating conditions, nor does inspection relieve Vendor of his responsibilities.

Fuel and ignition piping shall be tested hydrostatically with liquid at a minimum of 1.5 times the maximum allowable working pressure, but not less than 1.5 bar gage. Test shall be considered satisfactory when no leaks are observed for a minimum of 30 minute.

10. Preparation for Shipment

The equipment shall be given a coat as per requirements of "Painting Specification" No.:

SYME-PIBASC-ENPI-SPPA-0001 shall be met. Exterior machined surfaces shall be coated with a suitable rust preventive compound.

11. Guarantees and Warranties

As a minimum, followings shall be guaranteed by vendor:

a) Flaring Capacity

b) Smokeless Operating Capacity

c) Pressure Drop

d) Radiation Level

e) Noise Level

f) Utility Consumption

g) Material Compliance with Specification

h) Mechanical Integrity

12. SPARE PARTS

(Add.)

Spare parts for erection, pre-commissioning, commissioning, and start up shall be shall be recommended by vendor.

Vendor shall submit 2 years spare parts list with unit price during bid stage and this price shall be valid for 6 months after purchases order.

Two years operational spare parts shall be ordered together with main equipment / package.

PROJECT: SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT D O C U M E N T

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SOUTH YARAN OIL FIELD DEVELOPMENT PROJECT

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Technical Specification for Flare Stacks and Flare Ignition

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12.1 Flare Assembly

Spare Parts for Erection, Pre-commissioning, Commissioning & Start-up shall include but not limited to those mentioned in table 1:

Table 1

Commodity

Required Quantity of Spare Parts

Flange Gasket within the vendors scope

Min. 200% of each type

Stud Bolt / Nut for pipe flange

Min. 10% of each type

Bolt / Nut / Washer for field assembly of structure

Min. 10% of each type

Welding rod for field welding (if any)

Min. 100% for welding of pressure parts

Min. 10% for welding of structure

Pilot Thermocouple

1 Set

12.2 Ignition Package

Spare Parts for Erection, Pre-commissioning, Commissioning & Start-up shall include but not limited to those mentioned in table 2:

Table 2

Commodity

Required Quantity of Spare Parts

Sight Port Glass

1

Panel Lamp

1 Set

Fuses

2 Set

Spark Plug

1 Set

Pressure Gauge

1 Set