Flare System
In Oil & Gas
Function of Flares
• The primary function, as defined by API 521, is to
convert flammable, toxic, or corrosive vapors into
less objectionable compounds.
• Flares are primarily used for burning off flammable
gas released by pressure relief valves during any
over-pressure scenario of plant process
unit/equipment, due to process upset or during
startups & shutdowns, and for the planned
combustion of gases over relatively short periods.
Reasons of Flaring
1. During well production testing after drilling is
completed
2. For safety and during emergencies and
maintenance
3. For managing gas during compression and
processing
4. Flaring at well sites to recover oil
Types of Flare
1. Elevated Flare
2. Ground Flare
1. Enclosed Flare
2. Open Flare
Typical Flare System with Elevated
Flare
Segregation of Flares
1. Service
1. Acid gas flare
2. Cold dry flare
3. Warm wet flare
2. Pressure
1. Atmospheric
2. Low pressure
3. High pressure
Flare Knock-Out Drum
1. Objective
1. Separate bulk liquid from gas
2. Limit liquid droplet size entrained with gas to the flare
3. Provide adequate residence time for liquid
2. Sizing basis
1. Based on API 521
2. Separation of liquid droplet size of 300-600 microns considering the design
case for the flare
3. 20-30 minutes of liquid hold-up time based on a relief case that results in
maximum liquid
4. No internals to facilitate separation
5. Many orientations / options possible, horizontal KODs most preferred
Flare Knock-Out Drum Elevation
• KO drum elevation determined by pump NPSH requirement
• To reduce pipe rack elevation options are
• Reduce KOD elevation (option 1)
• Use vertical can pump
• Locate pump within pit
• Locate KO drum within pit
• Use intermediate KO drums (option 2)
Flare KOD Liquid Removal
• Remove liquid from flare KOD after relief to avoid overfill during future relief event
Options
1. Draining to evaporation pond or closed drain drums
2. Liquid removal by flare KOD pumps
3. Heater to be installed in KOD where freezing, pour point issues exist
4. Rate of liquid removal to consider frequency and amount of liquid release
5. High level in flare KOD to be considered for plant shutdown
Sizing of Flare KOD
• LLLL shall be sufficiently high to avoid any sludge deposition impacting LT nozzle
(150 mm in above figure not correct, consider 300 mm minimum for services
which are not clean).
• LLLL shall be minimum 700-300 in case flare drum electrical heaters need to be
installed.
• LLLL Level at which pump trips.
• LLL Level at which both pumps stops
• HLL Level at which first pump starts
• HHLL Level at which second pump starts
• HHHLL Level at which entire plant goes into pressurized trip.
Flare KOD sizing depends on two
aspects
• Liquid Hold up requirement during a major liquid or two phase release.
• Sufficient distance shall be available between inlet device bottom and HHHLL.
It is possible to have manually initiated depressurization even after HHHLLL.
Any possible liquid shall be accommodated above HHHLL.
• Distance between HLL and HHHLL shall be designed to
accommodate maximum liquid release scenario.
Some standards this distance is between HHLL and HHHLL.
• Liquid particles separate When the residence time of the vapor or gas is equal to or greater then the
time required to travel the available vertical height at the dropout velocity of the liquid particles and
• When the gas velocity is sufficiently low to permit the liquid dropout to fall. This vertical height is
usually taken as the distance from the maximum liquid level.
Liquid Seal Drum
1. Objective
1. Prevent flashback from flare tip back to flare headers
2. Avoid air ingress into flare system during sudden temperature
changes
leading to condensation and maintain positive system pressure
2. Use
1. Used in flare gas recovery systems
2. Staged flaring between enclosed flare and full size emergency
flare
3. Design specifications
1. Water as liquid sealing fluid not recommended for extremely
cold releases; water-glycol mixtures of sufficient
concentration used instead
