Work Pack Title:

HP Flare (K-FX-043001)

Client : In Salah Gas Ltd.

Asset : In Salah Gas (REG)

Doc. No. : ISG/IMS/WP/16-050

Title : High Pressure Flare (K-FX-043001)

Issue Date : 12th April 2016

Revision Date Comment Prepared Reviewed Approved

00 12/04/2016 Issued for Use AS KS VH

FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

  Amendment Record

Issue Revision Section Page Detail Date

 Distribution List

Copy No Recipient Location

01 ISG Site In Salah Gas - Algeria

02 AIE – File Copy AIE – Sharjah, UAE

 Contact List

Name Designation Phone Email ID

Virginia Hutchinson Integrity Team +971 6 5741933 virginia.hutchinson@aiegroup.org

Leader +971 529465379
Kishore Shriyan Senior Integrity +971 526513722 kishore.shriyan@aiegroup.org
Engineer
Ayoub Sheriff Senior Inspection +971505038140 ayoub.sheriff@aiegroup.org
Engineer

FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 Abbreviation / Definition

AIE - Asset Integrity Engineering (Integrity Service Contractor)

API - American Petroleum Institute

CS - Carbon Steel

CVI - Close Visual Inspection

DPI - Dye Penetrant Inspection

ENACT - National Company of Survey and Technical Control

FRA - Failure Risk Assesment

GVI - General Visual Inspection

HET - Hostile Environment Training

HSE - Health Safety & Environment

IRIS - Internal Rotary Inspection System

RBI - Risk Based Inspection

RFET - Remote Field Electromagnetic Test

TAR - Turnaround (plant periodic shutdown)

UT - Ultrasonic Testing

WSE - Written Scheme of Examination

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 Table of Contents

1. INTRODUCTION .................................................................................................................................... 5
1.1 SUMMARY OF FLARE TIP DESIGN DATA AND INSPECTION HISTORY .............................................................................................5
1.2 INSPECTION AND ASSESSMENT PROCEDURES ........................................................................................................................5
1.3 JOB HAZARDS AND RISK MANAGEMENT ..............................................................................................................................5
2. SCOPE OF WORK .................................................................................................................................. 6
2.1 INSPECTION ACTIVITIES.....................................................................................................................................................6
2.2 DEGRADATION MECHANISMS AND INSPECTIONS ...................................................................................................................6
2.3 GENERAL INSTRUCTIONS FOR INSPECTION ............................................................................................................................7
3. REPORTING ...................................................................................................................................... 7

APPENDIX I - Written Scheme of Examination

APPENDIX II - Pre-Inspection Preparation Sheet
APPENDIX III - Equipment Inspection Drawings
APPENDIX IV - P&ID’s
APPENDIX V - Previous Inspection Reports
APPENDIX VI - Work Scope Modifications Sheet
APPENDIX VII - Time Logging Sheet – 3rd Party Contractor
APPENDIX VIII - New / Amended Drawings
APPENDIX IX - Completed Inspection / Anomaly Reports

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 1. Introduction

In Salah Gas (ISG) intends to inspect the HP and LP flare stacks at various fields during their
respective shutdown opportunity.
This work pack details the inspection requirements for the high pressure flare stack (K-FX-
043001) at REG. Section 1.1 summarises the design data and inspection hiistory of the flare
stacks, while section 2.2 gives a brief description of the applicable degradation mechanisms.

1.1 Summary of Flare Tip design data and Inspection History

 The high pressure flare (Zeeco Model UFX flare tip) is designed to dispose off a flammable
waste gas stream during normal or emergency plant operations. The flare is equipped with a
stability tip to provide a low pressure zone, which ensures ignition of the flare gas and flame
stability at high exit velocities.
 The type of the flare tip assembly is UFX-20 Sonic - HP flare with stack height of 44m and
stack riser diameter of 20 inches.
 The flare tip is fitted with two stainless steel Zeeco model HSLF-A2T/C pilots mounted 1800
apart.
 The maximum thermal radiation at the boundary of the restricted access zone (coincident with
parts of the surrounding fence line) is 4.73 kW/m² (1500 Btu/ft²/hr) and includes 1.01 kW/m²
(300 Btu/ft²/hr) solar radiation.
 Top half of the flare tip is constructed of stainless steel confirming to the specification 310 while
the bottom half is constructed of carbon steel confirming to the specification A 516-70N.
 The HP flare stack has been in service since the plant was commissioned in 2004. Since then,
the HP flare stack has undergone five inspections.The intial three inspections were for the flare
tip with original design while the later two inspections were for the flare tip with a modified
design.
 During 2010 inspection, severe cracking was noted on the edge of the flare tip and an
anomaly was raised for the remedial work. (ISG-REG-10-ANOM-009)
 During 2014 TAR, the flare tip was replaced with new design flare tip with a deflector unit.
 No anomalous findings have been reported since 2014 inspection, post replacement of the
flare tip. Both the inspections post flare tip replacement have been performed remotely utilising
a high performance camera.

1.2 Inspection and Assessment Procedures

The following Inspection and Integrity procedures apply to this workbook:

 API 510 – In-Service Inspection of Pressure Vessel.
 API 570 - In-Service Inspection of Pressure Piping.
 BP GP 32-30 Guidance Practice for Inspection and Testing of Equipment In-Service.
 UU00-A-OOAQ-000-0007 Anomaly Management Procedure.
 ISG/UT/01 Ultrasonic Thickness Measurement Procedure.

1.3 Job Hazards and Risk Management

The following specific measures shall be observed during the execution of the work:
 Hazards covered in HET and site induction are to be taken care during the site activities.
 Personnel carrying out inspection shall comply with the ISG permit to work system and
prevailing golden rules at site.

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 2. Scope of Work
2.1 Inspection Activities
Part / Scope /
Activity Description
Area Action
 GVI/CVI of the flare tip from the No.5 Platform
(+EL 39700) (feasibility of scaffolding from the top
platform to be considered).
Flare tip and Visual
 Visual inspection of the flare tip using a high ISG Team
auxiliary Inspection
performance camera equipped with telephoto lens.
 Utilising remotely operated drone to get an aerial
view of the flare tip (operation phase).
Visual  General visual inspection of ignition and pilot gas
Pilot Assembly ISG Team
Inspection pipework, support and fixtures.
 CVI of gas seal unit internal through the
Visual observation port.
Gas Seal Unit ISG Team
Inspection  CVI of the gas seal unit external condition.
 CVI of the drain line external condition.
 General visual inspection of the stack riser to
Visual
identify signs of coating damage and corrosion. ISG Team
Stack Riser Inspection
 CVI of accessible welds.
(20” Pipe)
Ultrasonic  UT of flare gas piping at accessible locations (+EL
ISG Team
Testing 9000, +EL 18000 etc.).
Structural  GVI of the access ladder / platforms / handrails to
Visual
Supports identify any physical damages to the structural ISG Team
Inspection
components.
Flare Base  Close visual inspection of visible welds, concrete
Visual
(Foundation foundation, anchor blocks, skirt pipe, earthing ISG Team
Inspection
/Skirt pipe) connection.
 General visual inspection to check for rope
Visual tensioning and elongation.
Guy Wires ISG Team
Inspection  Binoculars or telephoto lens camera could be
utilised to have a closer look at the rope strands.
Deadman Visual  Close visual inspection to identify any signs of
ISG Team
Anchors Inspection damage or detachment.

2.2 Degradation Mechanisms and Inspections

Historic Observations /
Degradation Mechanisms Applicable Inspections
Findings
 High Temperature  Cracking observed during
Corrosion

 Visual inspection
Internal

Cracking the 2010 visual inspection

 No corrosion found during
 CO2 Corrosion  UT of stack riser
the previous inspections
Corrosion
External

 Atmospheric  Coating breakdown seen at

 CVI of stack riser
Corrosion few locations

 CVI of flanged connections, bolts  Corrosion products found

Crevice corrosion
and supports. on fasteners
 CVI of piping supports  No fatigue issues found
Mechanical Fatigue
 Vibration surveillance during the past inspections

Note: Refer to Integrity review section on the WSE document: ISG/IMS/WSE/16-046 attached in the
Appendix 1.
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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 2.3 General Instructions for Inspection

All inspection work shall be conducted in accordance with the relevant procedures that are listed in
Section 1.2. The following however, constitute a series of additional measures that shall be
undertaken as part of the inspection program:
 Photographic evidence of corrosion indications, damage, cracks or any other anomalous
observations shall be captured and compiled. Additional photographs showing the general
view of the vessel, vessel internals, nozzles and other areas of interest shall also be captured.
 Condition assessments shall be ascertained using appropriate tools, such as measurement
tape, depth gauges, profile gauges etc. These shall be utilised where necessary for the
gauging/assessment of anomalies.
 The NDT methods which are recommended herein were based on the assessed integrity
threats and on the findings from previous inspections. However, the use of supplemental
and/or alternative NDT methods may be required dependent on the findings from this latest
planned inspection; the choice of supplemental and/or alternative NDT method(s) shall be
finalised following direct consultation with the site Inspection Engineer / AIE Senior Inspection
Engineer.

3. Reporting
The following steps shall be followed for the completion of the full scope of the work pack:
 All accompanying documentation shall be completed in full. A quality check shall also be
performed by site Inspection Engineer prior to the issue of the inspection documentation.
 Any changes to the pre-defined work scope shall be fully documented on the accompanying
work scope modification sheet (see Appendix V).
 Anomalies observed during the inspections shall be recorded and reported in accordance with
the ISG anomaly management procedure (listed in Section 1.2).
 The completed work pack shall be subject to review and sanctioning for issue by the site
Inspection Engineer.
 The completed work pack, once formally endorsed, shall thereafter be issued to AIE through
the “iback up” shared folder.
 Upon receipt of the workbook a detailed review of the inspection findings shall be completed
by the AIE Senior Integrity Engineer. A review sheet shall be utilized detailing the major
findings from the inspections. Previous inspection results should also be reviewed alongside
recent findings. The inspection data shall thereafter be utilised for the revision and updating of
the risk assessments and risk-based inspection schedules; this shall be conducted in
accordance with the pressure systems FRA procedure (as listed in Section 1.2). The revision
and updating of the risk assessments and risk-based inspection schedules may result in
changes to the scheduling of the future inspections; such changes shall warrant ISG review
and approval.
 The AIE review sheet, once completed and authorised for use by the AIE Integrity Team
Leader, shall be issued to the ISG Integrity Team Leader. This shall serve as a formal record
of the inspection and any follow-on and/or additional measures, if any, which may be deemed
necessary going forward.
 The work pack shall be stored in a central database which is maintained by AIE on behalf of
ISG.
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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - I

Written Scheme of Examination

 Refer attached WSE :ISG/IMS/WSE/16-046.

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - II

Pre-Inspection Preparation Sheet

 Refer attached pre inspection preperation sheet: ISG/IMS/PP/16-046.

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - III

Equipment Inspection Drawings

 Refer attached Drawing: PMB001-0122 (general arrangement drawing)

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - IV

P&ID’s

 Refer attached P&ID: PMB001-0021.

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - V

Previous Inspection Reports

 Refer attached previous inspection reports:

1. ISG-REG-10-ANOM-007
2. ISG-REG-10-ANOM-008
3. ISG-REG-10-ANOM-009
4. ISG-REG-10-GEN-002
5. ISG-REG-11-GEN-002
6. ISG-REG-12-GEN-009
7. ISG-REG-14-GEN-004
8. ISG-REG-15-GEN-007

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - VI

Workscope Modifications Sheet

Sl. No. WORKSCOPE MODIFICATION DATE REQUESTED BY

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - VII
Time Logging Sheet

Operator : In Salah Gas

Field : REG
Equipment : HP Flare Stack (K-FX-043001)
DATE

MAN HOURS
OVERTIME
DOWN TIME
COMMENTS:

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - VIII

New / Amended Drawings

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014

 APPENDIX - IX

Completed Inspection / Anomaly Reports

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FORM NO. AIE-F-PRJ-033 REV. 01 / ISSUE JANUARY 2014