MEP-R-ES-007-Flare Stack, Flare Tip and Flame Front Generator

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

3

2

CODES AND STANDARDS

3

2.1 2.2

3 4

3

Applicable Codes and Standards Applicable COMPANY Specifications

DESIGN

4

3.1 3.2

4 5

Process Design Vertical Flare Stack

4

INSPECTION AND TESTING

8

5

DOCUMENTATION

8

6

PREPARATION FOR SHIPMENT

9

7

GUARANTEE

9

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

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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

2

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

3

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

Rev 0

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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.

5

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

Rev 0

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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.

7

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