Engineering standard

Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy Sep, 2011 Revision A

Engineering Standard Flare Tip and Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements

Original draft issue

Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

Page 1 of 8

Sep, 2011

Table of Contents

Table of Contents.2 List of Tables3 1.0 2.0 3.0 4.0 5.0 Introduction & Scope4 Purpose..5 Acronyms..6 Reference Standards.7 General Engineering Notes8

Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

1.0 Introduction and Scope

The intent of this Specification is to outline the minimum technical and quality requirements for Design, Manufacture, Inspection and Testing of Flare Tip & Flare Ignition Package, selected and procured for McDermott projects. To ensure that the Engineering and Quality requirements are clear and consistent across all projects, irrespective of the End User, this Specification must be considered by all Project Teams in addition to Client specific requirements, specifications, and instructions.

2.0 Purpose
The purpose of this Engineering Standard is to supplement the requirements of a particular Project to enhance and clarify specific aspects of Design, Manufacture and Inspection & Testing for Flare Tip and Flare Ignition Package. The requirements laid down in this Engineering Standard must be read in conjunction with Project Specifications, Datasheets, and International Standards. The same shall not to be interpreted as limiting whereby Vendor is relieved of their responsibilities. Mechanical guarantee for the performance of the Flare Tip & Flare Ignition Package are in the Vendors scope. Provision for all the materials to meet the specified performance requirements are deemed as part of Vendors scope of supply. Any deviations to the Project specifications, Datasheets, International standards, and this Engineering Standard shall be clearly highlighted in deviation list.

3.0 Acronyms

Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

4.0 Reference Standards

The latest edition of the referenced industry codes and standards that are in effect of the issue date of the purchaser order (including applicable addenda) shall apply, unless otherwise specified.

SPECIFICATION API STD 537 API STD 521 (ISO23251) ASME B31.3 ASME B16.5 BS2742 EEMUA 140 ASME Sec V ASME IX ASME B16.5 AWS D1.1/D1.1M BS EN288 NFPA 58 NFPA 68 ISA/ANSI MC96.1

TITLE Flare Details for General Refinery and Petrochemical Service Pressure Relieving and Depressuring Systems Process Piping Pipe Flanges and Flanged Fittings Notes on the use of the Ringlemann and miniature smoke charts Noise Procedure Specification Non Destructive Testing Welding and Brazing Qualification Steel Pipe Flanges and Flanged Fittings Structural Welding Code Steel Specification and approval of welding procedures for metallic materials Standard for the storage and handling of liquefied petroleum gases Guide for Venting Deflagration Temperature Measurement Thermocouples

Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

5.0 GENERAL ENGINEERING NOTES

5.1 All the bought out items shall be from the Company approved vendors. 5.2 The requirements laid down in this requisition are the minimum and the same shall not be interpreted as limiting whereby vendor is relieved of their responsibilities. Complete performance and mechanical guarantee of the Flare Tip and Flare Ignition package are in Vendors scope. Provision of all the materials to meet the specified performance requirements are deemed as part of Vendors scope of supply. 5.3 All equipment shall be designed to achieve a design life of 25 years. It is recognized that the design life will not apply to items subjected to general wear and tear (e.g. bearings, seal faces, liners, gaskets, wear rings and bushings). These will be inspected / replaceable as part of plants maintenance plan. 5.4 The Flare Tip and Flare Ignition Panel shall be designed for various load cases like in-situ, transportation, wind and earthquake. The design calculations shall be submitted for Purchasers review and approval accordingly. 5.5 The Flare Tip and Flare Ignition Panel shall be suitable to install and operate in offshore saline marine environment. 5.6 Vendor shall confirm the suitability of the material of construction o flare tip with respect to operating and design conditions, heat and corrosion resistance. 5.7 Vendor shall guarantee the flare tip smoke production shall meet the requirements as defined in Clients specification or data sheet. 5.8 Vendor shall design the Flare Tip and Flare Ignition Package in such a manner that all the items shall be easy accessible for operation and maintenance. 5.9 Vendor shall furnish minimum venting rate to sustain flame (turn down ratio of flare tip) with flare gas composition specified on the data sheet. 5.10 Vendor shall specify purge gas requirement for offered flare tip. 5.11 Unless specified otherwise, the limits for the radiation due to flaring operating at all levels of the platform shall be in accordance with API STD 521. 5.12 If specified, the heat shield shall be designed and supplied to avoid expose to flare radiations. 5.13 Unless specified otherwise, the noise level due to flaring operating shall be limited to 85 dB (A) on the platform while flaring with peak flow rate.
Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

5.14 The flare tip shall be designed such that change out shall be a remote case. If change out scenario arrives, it shall be designed such that change out can be carried out safely with minimum requirement of manpower and equipment. Vendor shall provide a procedure for handling of flare tip and shall supply any special tools required in this regard. 5.15 Vendor shall carry out positive material identification for stainless steel and nickel alloy materials. 5.16 Vendor shall recommend flare tip elevation and orientation with respect to boom/platform to reduce radiation, dispersion and noise levels on to the platform. 5.17 Vendor shall furnish the thrust loads on flare header or flare pipe while flare peak design flow rate. 5.18 In general, all piping, instrumentation & cabling from the flare ignition panel to the flare tip shall be in vendor scope of supply, unless otherwise specified. 5.19 For signal & power transmission between flare ignition panel/ LCP and flare tip, all thermocouple compensating cables and ignition cables shall be supplied by vendor as free issue. All intermediate junction boxes shall also be free-issued by vendor for installation on flare boom and deck. Quantities shall be as specified in the project. 5.20 The control and safeguarding systems must be designed with a high level of remote diagnostics capability, with local and remote control functionalities. 5.21 All junction boxes, terminal boxes and control panels shall be provided with bottom side cable entries. No top entries are acceptable. (will be included in common E & I spec) 5.22 The cable glands shall be suitable for hazardous area classification and the material of construction of cable glands shall be nickel coated brass. (will be included in common E & I spec) 5.23 A minimum of 25% of spare terminals and 25% spare entries shall be provided in on Flare Ignition panel and terminal boxes. (will be included in common E & I spec) 5.24 Thermocouple cable and Ignition Cable shall be suitable to withstand temperature due to flare radiation. 5.25 All the field instruments, thermocouple cables, ignition cables, conduits, fittings and junction boxes shall be suitable for continuous operation without any degradation for the maximum temperature radiation expected from the flare. Vendor shall select location and material for the above items taking into consideration the maximum temperature radiation calculated by vendor. 5.26 Vendor shall also select robust thermocouples that will be suitable for the maximum temperature expected during full flare condition and shall work without any degradation under normal flaring conditions. 5.27 In case of duplex thermocouples, at least one thermocouple of each duplex pair for every pilot shall be wired up to the local control panel.
Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

5.28 All transmitters installed inside the flare ignition panel shall be SIL 2 certified. 5.29 If specified that pilot gas is clean fuel (i.e. Propane), then the propane cylinder skid/rack/quad shall be designed for suitable offshore lifts in accordance with BS EN12079. 5.30 If Flare Ignition system is specified as Pellet Ignition System, then vendor shall advise the bending radius for pellet guide pipe. 5.31 If Pellet Ignition System is specified, Vendor shall provide the flow rate and pressure of motive gas (air or nitrogen) to launch the pellet. 5.32 All electrical and instrument components including cable trays and conduits shall be earthed. The parallel earthing shall be employed. Series looping of equipment earthing is not permitted. (will be included in common E & I spec) 5.33 Approved welding procedure specifications, PQRs, NDT and Inspection Procedures, lists of approved welders and their copies of certifications shall be submitted for review and approval. 5.34 Vendor shall carry out 100% radiography on all Flare Tip weld joints. 5.35 The mechanical handling aid for provided to handle the components or items weighing more than 25kg. 5.36 Vendor shall provide reliability and availability figures for all equipments. Which shall include Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR). 5.37 The Flare Tip and Flare Ignition Package shall be preserved and packed such that it should be suitable for 6-8 months storage after shipment before any preventive maintenance done. 5.38 Vendor shall supply one set of installation and Pre-commissioning spares for Flare Tip and Flare Ignition Panel. 5.39 If specified, Vendor shall supply one set of Commissioning and Start-up spares for each Flare Tip and flare Ignition Panel. 5.40 Vendor shall supply one set special tools and tackles required for operation and maintenance of Flare Tip and Flare Ignition Package. 5.41 Vendor shall furnish the list of recommended 2 year spare parts list. 5.42 Non conformities (if any) shall be managed by issue an NCR. Vendor shall submit resolution to an NCR to PURCHASER within 7 days from the date of issue. 5.43 Vendor shall provide a list of sub-vendor for purchasers review. If vendor proposes alternative sub-vendor(s) for to those listed on the project approved vendor list, then the sub-vendor(s) shall be qualified in accordance with project procedures and the same will be subject to approval of PURCHASER and END USER. 5.44 Vendor shall submit 'Supplier Document Register List (SDRL)' considering the various requirements of the Purchase Order. It shall list out all the documents (upto & including final documentation) to be provided by the Vendor as part of
Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011

the order. During the review of this, the Purchaser will assign 'Company document number' for each document/drawing. This will be in addition to the document/drawing number assigned by Vendor. In all the correspondences, Vendor shall quote Company document number only. 5.45 Following documents/drawings are critical and Vendor needs to submit on priority. GA Drawings PID's Data sheets Cable block diagrams Wiring drawings Control system functional description Weight and COG Information Inspection and Test Plan Quality Control Plan WPS/PQRs 5.46 Vendor shall provide a full Certification manual on completion of the works. The content of which shall be submitted and agreed as part of the SDRL 5.47 Vendor shall submit all the documents except drawings with a standard project vendor data cover sheet. Prepared & Review signatures by Vendor are mandatory on the cover sheet. 5.48 Should a conflict exist between documents, it shall be responsibility of the vendor to call attention to the discrepancy and request a written ruling or interpretation from the purchaser. Failure to do so shall not result in additional cost to MDR for correction of discrepancies during fabrication. 5.49 All labels, tags, name plates for instrument, panel, equipment and sub-equipment nameplates shall be made of 316 stainless steel as a minimum.

Engineering Specification Flare Tip & Flare Ignition Package Design, Manufacture, Inspection and Testing Requirements
Bhaskar Reddy

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Sep, 2011