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DOCUMENT TITLE:

FLARE & BLOWDOWN REPORT

THIS IS A TYPICAL PROJECT

EXAMPLE AND MUST BE
THOROUGHLY REVIEWED AND
UPDATED FOR SPECIFIC
PROJECT USE.
REF: “1-20-1-REP-002 “

This document is issued pursuant to an Agreement between Petrofac and CLIENT which agreement sets forth the entire rights,
obligations and liabilities of those parties with respect to the content and use of the report. Reliance by any other party on the
contents of the report shall be at its own risk. Petrofac makes no warranty or representation, expressed or implied, to any other
party with respect to the accuracy, completeness or usefulness of the information contained in this report and assumes no liabilities
with respect to any other party’s use of or damages resulting from such use of any information, conclusions or recommendations
disclosed in this document.

REV. DESCRIPTION OF REVISIONS PREP’D CHK’D APPRV’D COMPANY DATE

APPROVED

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SHEETS INDEX AND REVISIONS

Rev. Section Revision Description

Note: Revision Table to be used on Post-AFD Issues

HOLDS

Hold
Section Description
No.
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ABBREVIATIONS

Abbreviation Description

API American Petroleum Institute

BDV Blowdown Valve
BOPD Barrels of oil per day
BWPD Barrels of water per day
FO Orifice Plate
HIPPS High Integrity Pressure Protection System
HP High Pressure
LAHH Level Trip
LP Low Pressure
MLW Mean Low Water
MMscfd Million standard cubic feet per day
NPS Nominal Pipe Size
PAHH Pressure Trip
PCV Pressure Control Valve
PSV Pressure Relief Valve
TMMP Tanker Mooring and Manifold Platform
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CONTENTS

SHEETS INDEX AND REVISIONS ....................................................................... 2

HOLDS .................................................................................................... 2

ABBREVIATIONS ......................................................................................... 3

1.0 INTRODUCTION ................................................................................. 6

2.0 PROCESS DESCRIPTION ........................................................................ 8

2.1 Description of Process ........................................................................ 8

2.2 Basis of Design ................................................................................. 8

3.0 FLARE AND RELIEF LOAD PHILOSOPHY .................................................... 9

3.1 Relief, Blowdown and Flare Events ........................................................ 9

3.2 External Fire ................................................................................... 9

3.3 Blocked Outlet ............................................................................... 10

3.4 Gas Blowby .................................................................................... 10

3.5 Control Valve Failure ....................................................................... 11

3.6 Utility Failure ................................................................................ 11

4.0 FLARE AND RELIEF SCENARIOS ............................................................ 12

4.1 Application of High Integrity Pressure Protection Systems .......................... 12

4.2 Relief Scenarios .............................................................................. 12

4.3 Flare Scenarios............................................................................... 13

5.0 FLARE NETWORK DESCRIPTION ........................................................... 17

5.1 Design Philosophy ........................................................................... 17

5.2 Facility Layout ............................................................................... 18

5.3 Hydraulics Design Criteria ................................................................. 19

5.4 Flare Scrubber Sizing Basis ................................................................ 19

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5.5 Flare Tip Selection .......................................................................... 19

6.0 FLARE HYDRAULIC STUDY .................................................................. 21

6.1 Pipe Flare ..................................................................................... 21

6.2 Sonic / Coanda Type Flare Tip ............................................................ 21

7.0 FLARE RADIATION ANALYSIS ............................................................... 28

7.1 Flare Radiation Simulation................................................................. 28

7.2 Metocean Data ............................................................................... 28

7.3 Flare Rates and Compositions ............................................................. 28

7.4 Radiation Data and Limit Criteria ........................................................ 29

7.5 Flare Stack Height Determination ........................................................ 30

7.6 Sterile Zone Radius and Flare Location ................................................. 30

8.0 DISPERSION ANALYSIS ....................................................................... 32

8.1 Introduction .................................................................................. 32

8.2 Normal Flare Rate – Gas Dispersion Results ............................................ 33

8.3 Maximum Flare Rate – Gas Dispersion Results ......................................... 33

9.0 CONCLUSIONS ................................................................................ 34

10.0 REFERENCES .................................................................................. 36

11.0 SENSITIVITY OF STERILE RADIUS TO FLOW RATE AND FLARE TIP .................. 37
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1.0 INTRODUCTION
A study was conducted into the flare system for Stage 2 requirements of the
PROJECT development. The purpose of the study was to:
1. Identify all potential contributors (new or existing) to the PROJECT flare
system.
2. Calculate relieving rates for all contributing sources.
3. Identify sources that may occur coincidentally.
4. Determine the largest (sizing) case for above and size the tailpipes and
header for the flare piping.
5. Generate radiation profiles for flaring cases and determine sterile radius.
6. Generate gas dispersion profiles for unignited release cases from the flare
stack.
As a result the following major conclusions were established:
1. The continuous flare rate is 50 to 80 MMscfd.
2. The maximum emergency flare rate is 178 MMscfd. This is based on failure
of the PCV on the LP Production Separator coincidental with normal gas
production from the HP Production Separator.
3. Balanced bellows relief valves are to be used throughout the facility.
4. Existing 4” tailpipe from the PSV on the Gas Lift Separator is to be replaced
with 10” equivalent to accommodate full flow relief of lift gas production of
65 MMscfd.
5. Existing 12” flare header and bridge section to be replaced with 20” piping.
6. A low radiation type flare tip shall be used (following vendor confirmation of
performance).
7. The flare stack for a low radiation coanda type flare is 20” and has an
elevation of 15m [HOLD 1] above the top of the bridge structure.
8. Based on the radiation and gas dispersion analysis, the flare stack is to be
relocated so that it is at least 105 m [HOLD 1] from the platforms. The flare
will be located along the line of the existing flare bridge from ADPP.
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Pipe Flare Tip Coanda Flare Tip

Flare Header and 20 20”

Bridge Line Size
VTA if 24” required

Sterile Zone Radius 156 105

Stack Height 30 15

Turnup VTA VTA

Turndown VTA VTA

The increase in maximum flare rate from the 80 MMscfd identified in FEED to 178
MMscfd is the result of coincidental flare loads, which were not considered at
FEED. FEED considered only the normal flaring rate which can be up to a
maximum of 80MMscfd. Failure of the pressure control on the LP Production
separator coincident with normal production from the HP Production Separator
can lead to a maximum instantaneous rate to the flare of 178 MMscd.
It should be noted that calculations will require updating when piping isometrics
become available.
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2.0 PROCESS DESCRIPTION

2.1 Description of Process

The Adanga production facilities are to be upgraded to increase its capacity and
to extend its life. A second production platform, ADPP2, is to be added and
bridge linked to the existing ADPP.
The new process configuration includes 2 production separators, one operating at
high pressure (HP) and the other at low pressure (LP). All liquids are transported
from the platform to the nearby TMMP facility via export pumps and a 12” export
line.
The facility will be increased in capacity to 80 MMscfd of gas, 40,000 bopd and
40,000 bwpd. In addition, the lift gas requirement for the facility is also
increased. To cope with the increase in capacity, a larger flare system than is
currently available is required for the Adanga facility.
2.2 Basis of Design

Key design bases are as follows [1]:

Maximum Gas Production 80 MMscfd
Maximum Lift Gas Production 65 MMscfd
Maximum Oil Production 40,000 bopd
Maximum Water Production 40,000 bwpd

LP Production Separator
Pressure min op / max op / design 100 / 170 / 363 psig
Temperature 25 °C

HP Production Separator
Pressure min op / max op / design 150 / 320 / 363 psig
Temperature 25°C

Lift Gas Separator

Pressure operating / design 1200 / 1349 psig
Temperature 25°C
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3.0 FLARE AND RELIEF LOAD PHILOSOPHY

3.1 Relief, Blowdown and Flare Events

The following events may result in relief loads on the flare network on ADPP:

• External Fire

• Blocked Gas Outlet

• Blocked Liquid Outlet

• Gas Blowby

• Control Valve Failure

• Utility failure
Automated blowdown of the HP and LP Production Separators and the Gas Lift
Separator occurs on confirmed detection of fire and gas. Manual blowdown of
these and other vessels is not considered as part of this study.
Continuous flaring of associated gas at 80 MMscfd is part of the normal process
route until completion of Stage 3 of the Adanga Development.
Each event type is considered in more detail in the following paragraphs.
3.2 External Fire

In the event of external fire, the vessels within the affected fire zone will be
subject to heat ingress and possible overpressure.
The increase in pressure is the result of liquid vaporisation or fluid expansion.
None of the vessels in the Adanga development are insulated.
The relieving conditions are identified in Table 3.1. The temperature associated
with the fire case relief is determined as the bubble point temperature at the
relief pressure. In the cases identified the liquid hydrocarbon is supercritical and
liquid thermal expansion relief rates apply. The composition of the gas
discharging through the PSV is that which is in equilibrium with the liquid under
relieving conditions.
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Table 3.1: FLUID CONDITIONS FOR FIRE RELIEF

Component Location / Description Relief Set Relief Comments
Tag Pressure Temperature
barg (psig) °C
MBD-181 LP Production Separator 24.4 (361) 189
MBD-182 HP Production 24.4 (361) 43
Separator
MBD-170 Gas Lift Separator 91.2 (1322) 58
MBD-183 Test Separator 24.4 (361) 166
MBF-180 Fuel Gas Separator 17.3 (250) - Gas Only
MAF-191/192 Fuel Gas Filters 17.3 (250) - Gas Only
KAQ-950 ADS Pig Receiver 96.6 (1400) - Supercritical
KAQ-960 ADS Test Line Pig 96.6 (1400) - Supercritical
Receiver
KAH-930 Export Pipeline Pig 49.7 (720) - Supercritical
Launcher

3.3 Blocked Outlet

The cases considered here include the accidental blockage of either gas or liquid
outlets from a vessel.
In the case of a blocked gas outlet, the relief rate is considered to be the gas
inlet rate into the system at relieving conditions.
If the liquid outlet is blocked, there is no relief case to consider. However, the
normal operating mode for the Adanga platform in Stage 2 of the Adanga
Redevelopment is to route gas to flare. As a result, there is potential for the
liquid to back-up and carry-over into the flare system. The flare system is
designed to cope with such a scenario.
3.4 Gas Blowby

Gas blowby from streams feeding a given vessel is applicable where the design
pressure of upstream equipment exceeds that of the downstream equipment.
The blowby rate through a control valve of given Cv is determined assuming the
upstream source is at normal operating pressure while the downstream
equipment is at the relief set pressure. If the valve Cv used in the blowby rate
definition is an estimation, verification of the rate must be performed upon final
equipment selection.
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3.5 Control Valve Failure

The pressure control valves on the two production separators are specified as fail
locked (fail in position).
However, API RP 521 stipulates that no reduction in relief capacity should be
considered when using fail locked or fail closed control valves. Therefore,
capacity must be available in the flare network to relieve the gas flow associated
with a fully open control valve.
Failure of liquid level control valves is covered by blocked liquid outlet scenarios
for failure to the fully closed position and gas blowby scenarios for failure to the
fully open position.
3.6 Utility Failure

Electricity generation and instrument air are provided on the ADPP facility.
Failure of electricity generation will result in loss of instrument air pressure. In
the event of loss of instrument air, control valves, shutdown valves and
blowdown valves return to their specified failure positions.
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4.0 FLARE AND RELIEF SCENARIOS

4.1 Application of High Integrity Pressure Protection Systems

The application of a HIPPS has been assessed in terms of the potential for
reducing the maximum flare load. A HIPPS will serve to reduce the load only for
a relief case due to PAHH failure. However, it can be seen from Table A1 in
Appendix 1 that the maximum flare rates are independent of the overpressure
protection scenarios, and will not be reduced by the application of a HIPPS.
4.2 Relief Scenarios

The sizing cases and flow rates for pressure relief valves (new and existing) are
listed in Table 4.1. Note that for some systems the relief sizing case is less than
the maximum flaring case, which is presented in Table 4.2. A more detailed
description of each of the flaring / relieving scenarios considered in this analysis
is provided in Appendix A.
The pressure pilots on the wellheads are not considered to be guaranteed
protection devices for the separators, despite being linked by locked open
pathways. The setpoints for these pilots may be higher than the design pressure
of the production vessels, and therefore would provide no additional
overpressure protection.
Table 4.1: Relief rates for PSv Sizing
Relief Equipment Equipment Sizing Sizing Discharge
Valve Protected Title Case Relief Rate Route
(kg/hr)

PSV-181E MBD-181 & LP Production Blocked 77,033 ADPP Flare

LP Manifolds Separator Gas

Outlet

PSV-182E MBD-182 & HP Production Blocked 18,771 ADPP Flare

HP Manifolds Separator Gas

Outlet

PSV-170A MBD-170 Gas Lift Blocked 61,600 ADPP Flare

Separator Gas
Outlet

PSV-170B Piping Fuel Gas Failed 27,000 ADPP Flare

Header PCV

PSV-183E MBD-183 & Test Test Blocked 7,200 ADPP Flare

Manifold Separator Gas
Outlet
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Relief Equipment Equipment Sizing Sizing Discharge

Valve Protected Title Case Relief Rate Route
(kg/hr)

PSV-180 MBF-180 Fuel Gas Failed 16,300 ADPP Flare

Scrubber PCV

PSV-191 MAF-191 Fuel gas Filter External 350 ADPP Flare

Fire

PSV-192 MAF-192 Fuel gas Filter External 350 ADPP Flare

Fire

PSV-930 KAH-930 Export External 480 ADPP Flare

Pipeline Pig Fire
Launcher

PSV-940 KAQ-940 Ukpam Pig External 360 Local drain on

Receiver Fire ADPP

PSV-955 KAQ-950 ADS Pig External 360 ADPP Flare

Receiver Fire

PSV-965 KAQ-960 ADS Test Line External 290 ADPP Flare

Pig Receiver Fire

PSV-986 KAQ-980 EBE Pig External 290 Local vent on

Receiver Fire ADRP1

PSV-986 KAQ-990 EBNE Pig External 290 Local vent on

Receiver Fire ADRP1

PSV-9XX KAH-9XX Future Export External 290 Local vent on

Line Pig Fire ADRP1
Launcher

4.3 Flare Scenarios

The sizing flow rate and case for each system in the Adanga facility (existing and
new) are presented below. It should be noted that in some systems there are
flare sizing cases that are not caused by PSV relief. This is due to the need for
continuous flaring in Stage 2 of the Adanga Redevelopment. The rates presented
are the sizing cases for the tailpipes that transport fluids from each system to the
flare header.
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API RP 521 [4] stipulates that consideration shall be given for the flare loads
resulting from a valve in its fail open position, regardless of specified failure
position. This is due to the potential for instrument system failure or
misoperation.
Some of the flaring cases identified above can occur simultaneously and so the
coincidental flaring cases given in Table 4.3 are considered. These represent
sizing flow rates for the flare header and the flare bridge piping.
Table 4.2: Sizing Flare Rate Per System
Case System Sizing Case Consequence Sizing Flare Rate Comments
No.
1 MBD-181 Blocked Full 59,146 kg/hr gas
LP Production Liquid Outlet Production
181,434 kg/hr HC
Separator Flow through liquids
PCV-181B.
213,720 kg/hr water

2 Failure of Increased Gas 171,354 kg/hr gas 158 MMscfd

PCV Flow
0 kg/hr HC
liquids
246 kg/hr water

3 MBD-182 Blocked Full MBD-182 17,421 kg/hr gas

HP Production Liquid Outlet Flow through
57,013 kg/hr HC
Separator PCV-182B liquids
66,566 kg/hr water

4 Failure of Increased Gas 53,614 kg/hr gas 60 MMscfd

PCV Flow
0 kg/hr HC
liquids
85 kg/hr water

5 MBD-170 Blocked Gas Full Gas Flow 61,600 Relief case

Gas Lift Separator Outlet controlling
6 MBD-183 Blocked Full Test 7,200
Test Separator Liquid Outlet Separator
Production
through
PCV-726.
7 MBF-180 Failed PCV Gas from HP 16,300 Failed PCV
Fuel Gas Scrubber on inlet Separator case
routes to flare controlling
via Fuel gas
Scrubber
8 MAF-191 /192 External 700 Relief case
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Case System Sizing Case Consequence Sizing Flare Rate Comments

No.
Fuel Gas Filters Fire Relief controlling

9 KAH-930 External 480 Relief case

Export Pig Launcher Fire Relief controlling

10 KAQ-950 External 360 Relief case

ADS Pig Receiver Fire Relief controlling

11 KAQ-960 External 290 Relief case

ADS Test Line Pig Fire Relief controlling
Receiver
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Table 4.3: Flare Header Sizing, Co-Incidental Cases

Case Description Equipment Coincident Sources Individual Flare Comments
No. Rates (kg/hr)
12 -Failed Open PCV on LP Production Separator MBD-181 - Blocked Liquid 147080 Max gas case for flare-
MBD-181 HP Production Separator MBD-182 Outlet 18771 178 MMscfd.
-Normal MBD-182 - Normal Production
Production
13 -Blocked Liquid LP Production Separator MBD-181 - Blocked Liquid 454300 – see 454300 kg/hr made up of
Outlet MBD-181 HP Production Separator Outlet comments 59,146 kg/hr gas,
-Normal MBD-182 MBD-182 181,434 kg/hr HC liquids
Production - Normal Prod’n 18771 and 213,720 kg/hr water
14 -Normal MBD-181 / LP Production Separator MBD-181 - Normal Prod’n 58177
182 Production HP Production Separator MBD-182 - Normal Prod’n 18771
-Blocked Gas Outlet Gas Lift Separator MBD-170 - Blocked Gas Outlet 61558
MBD-170
15 -Normal MBD-181 LP Production Separator MBD-181 -Normal Prod’n 58177 141000 kg/hr made up of
Production HP Production Separator MBD-182 -Blocked Liquid Outlet 141000 – see 17,421 kg/hr gas
-Blocked Liquid comments 57,013 kg/hr HC liquids
Outlet MBD-182 and 66,566 kg/hr water
16 -Normal MBD-181 / LP Production Separator MBD-181 -Normal Prod’n Total flow is 77033 The sum of these flows
182 Production HP Production Separator MBD-182 -Normal Prod’n cannot exceed full
-Blocked Gas Outlet Test Separator MBD-183 -Blocked Gas Outlet production of 80MMscfd
MBD-183
17 Platform LP Production Separator MBD-181 -Blowdown 1528 Vessel blowdown rates
Depressurisation HP Production Separator MBD-182 -Blowdown 2615 only, does not result in a
Test Separator MBD-183 -Blowdown 233 sizing case.
Gas Lift Separator MBD-170 -Blowdown 4365
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5.0 FLARE NETWORK DESCRIPTION

5.1 Design Philosophy

The requirements of the flare system design are specified to ensure that the
performance of the individual components of the system is not limited by the system
itself. The flare header and tailpipes should be sized so that the backpressure at a
balanced bellows type PSV does not exceed 50% of the set-pressure of that PSV at
the discharge rate associated with 10% overpressure. These values are provided in
Table 5.1.
Further consideration is given to ensuring safe fluid velocities in the pipelines to
avoid sonic velocities, in line with the recommendations given in API RP 521 [4], and
excessive vibration in the piping network.
Table 5.1 presents the set pressures for all relief valves in the flare network, and
also the normal upstream pressures for blowdown valves. In certain cases, the
maximum allowable backpressure is limited by the design pressure of the flare
network piping, which is rated at ANSI 150# throughout and has a design pressure of
18 bara.
Table 5.1 : Maximum Allowable backpressures
Component Location / Description Relief Set Blowdown Maximum
Tag Pressure Upstream Allowable
Pressure Backpressure
bara bara bara
Pressure Relief Valves
PSV-181E LP Production Separator 25.4 - 12.7
PSV-182E HP Production Separator 25.4 - 12.7
PSV-170 A/B Gas Lift Separator 91.2 - 18 (1)
PSV-183E Test Separator 25.4 - 12.7
PSV-180 Fuel Gas Scrubber 19 - 8.5
PSV-191/192 Fuel Gas Filters 19 - 8.5
Blowdown Valves and Flow Orifices
FO-XXX LP Production Separator - 7.9 – 12.7 3.5
FO-XXX HP Production Separator - 11.4 – 23.1 3.5
FO-XXX Test Separator - 8.9 - 13.7 3.5
FO-XXX Gas Lift Separator - 83.8 18 (1)
Pressure Control Valves
PCV-181 LP Production Separator - - 3
PCV-182 HP Production Separator - - 3
PCV-130A Gas Lift Separator - - 18 (1)
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Note 1. Maximum allowable operating pressure for 150# piping.

5.2 Facility Layout
The arrangement and associated length of piping comprising the flare network has
been estimated from the relative locations of equipment on the Adanga facility, as
defined by the plot plans [Ref. 2 & 3]. The tailpipe lengths are subject to a 50%
increase to account for fittings and any subsequent changes to the equipment
layout, and are presented in Table 5.2. These are to be verified against piping
isometrics as they become available.
For hydraulic simulations it is assumed that the flare bridge length is 175m and the
flare is 25m in height.
The actual length and height are determined as part of the flare radiation
assessment, and is dependent on the type of flare tip. This is discussed in greater
detail in Section 7.0.
The bridge between ADPP2 and ADPP is approximately 50m in length.
The line sizes for piping associated with normal flaring has already been performed.
The pipe sizes are also presented in Table 5.2.
Table 5.2: Flare Network piping summary
Equipment Item Equipment Type of Flow NPS for Total Piping
Description Normal Length (m)
Flaring
MAF-191/192 Fuel Gas Filters Fire case relief - 7
- Future Relief / Blowdown - -
Compression
MBF-180 Fuel Gas Scrubber Relief - 7
MBD-182 Relief Relief - 3m to tie-in
HP Production
with 14” line
Separator
MBD-182 Assoc Gas Normal Flow / Relief 14” 14
MBD-181 Relief Relief - 3m to tie-in
LP Production
with 20” line
Separator
MBD-181 Assoc Gas Normal Flow / Relief 20” 27
MBD-170 Gas Lift Separator Relief - 37
MBD-183 Test Separator Normal Flow / Relief 6” 50
KAQ-950 ADS Pig Receiver Fire case relief - 43
KAQ-960 ADS Test Line Pig Fire case relief - 47
Receiver
KAH-930 Export Pig Fire case relief - 25
Launcher
Flare Header Normal Flow / Relief 20” 12
Header to Scrubber Normal Flow / Relief 20” 9
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ADPP2 to ADPP Bridge link Normal Flow / Relief - 75

Flare Bridge Normal Flow / Relief 20” 175

Flare Stack Normal Flow / Relief 20” 25

5.3 Hydraulics Design Criteria

New flare headers and tailpipes were sized to ensure that the criteria for both the
emergency flaring case and the normal flaring case are met. Any existing piping was
also checked to ensure compatibility with Stage 2 demands.
Under Emergency Flaring conditions:
1) The gas velocity does not exceed 0.5 Mach in the main header and 0.7 Mach in
the tailpipes.
2) Back-pressures (at flare sources) are maintained below those figures tabulated
in Table 5.1.
Under Normal Flaring (continuous flaring) conditions:
1) The gas velocity does not exceed 0.2 Mach.
2) Erosional velocity limitations are observed.
3) Back-pressures (at flare sources) are maintained below those figures tabulated
in Table 5.1.
5.4 Flare Scrubber Sizing Basis

The flare scrubber is designed to remove liquid droplets above 300 µm from the
vapour stream during normal flare operation. Under emergency flaring conditions,
this specification is relaxed to 600 µm.

The vessel is also sized to safely process liquids associated with the maximum liquids
relief case. (blocked liquid outlet on LP Production Separator MBD-181).
The sizing flow rates are normal gas flow of 80 MMscfd, maximum gas of 178 MMscfd
and maximum liquids of 454,300 kg/hr.
5.5 Flare Tip Selection

The flare analysis is performed using a pipe flare tip as the base case. A pipe flare
tip pressure drop of 0.5 bar has been assumed and the flare system should be
reanalysed upon receipt of vendor information.
The recommended maximum velocity for a pipe flare tip is 0.5 mach, and the stack
and flare tip should be sized accordingly.
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The use of an engineered flare tip, such as a sonic or coanda type, can reduce
radiation but results in an increased back pressure in the header. Typically,
advanced flare tips will require a 1 bar dP. Under continuous flaring conditions in
Stage 2 of the Adanga Redevelopment, the use of a sonic flare tip may be possible.
However, in Stage 3 there is no continuous flaring and the operation of an
engineered flare tip must be verified by the tip vendor.
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6.0 FLARE HYDRAULIC STUDY

The hydraulics of the flare network have been evaluated in HYSYS. The model
comprises each tailpipe and the flare header and bridged connections as described
in Table 5.2.
The normal continuous flare rate is 50 to 80 MMscfd. The maximum instantaneous
flare rate is 178 MMscfd. This is the result of failure open of PCV-181B on the LP
Production Separator co-incidental with normal gas production from the HP
Separator.
6.1 Pipe Flare
For a pipe flare, the maximum expected pressure drop across the tip is 0.5 bar.
Tables 6.1 and 6.3 present the expected backpressure at the relief valves and at the
flare scrubber, and the velocities and Mach numbers resulting in the piping during
flare events.
The hydraulic analysis showed that the existing 12” flare header is too small for
Stage 2 requirements and so this line should be replaced by a new 20” header. The
maximum observed Mach number in the flare stack of 0.54 may be considered by
vendors (HOLD 1), and consequently vendor confirmation of the acceptability of the
flare stack size is required. In the event that this is unacceptable, the bridge
section and flare tip should be 24”.
The tailpipe from the Gas Lift Separator MBD-170 is an existing line of 4” NPS. This
is undersized for the increased relief loading, and it is recommended that this line is
replaced with a 10” equivalent.
6.2 Sonic / Coanda Type Flare Tip

For an engineered flare tip, the maximum expected tip pressure drop across the tip
is 1.0 bar. The subsequent increase in backpressure means that the Mach number
remains below 0.4 for a 20” flare stack.
The increase in backpressure resulting from the engineered flare tip does not impact
on the operation of balanced bellows type relief valves.
The fire case for each vessel is considered to occur simultaneously. The sizes of the
tailpipes have been verified.
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Table 6.1 : PIpe Flare System BACKPressures and Velocities for Single Source Cases
Event Source Rate Total Gas Tailpipe Tailpipe Mach No in Back-pressure P at Flare Velocity in Mach No
to Flare NPS Velocity Tailpipe at Source Scrubber Flare Bridge At Tip
kg/hr MMscfd inches m/s - bara bara m/s -
Normal Flare MBD-181 77033 80 20” 76 0.19 2.02 1.94 100 0.255

Blocked Liquid Outlet on MBD-181 454,300 67 20” 58 0.13 2.46 1.83 80 0.215
MBD-181 multiphase
Fail Open of PCV-181B MBD-181 147300 158 20” 100 0.250 2.94 2.74 166 0.48
with 95% maximum stop
Full Flow Relief from MBD- MDB-170 61600 65 10” 217 0.59 5.4 1.8 73 0.20
170
Failed PCV-180AorB Fuel Gas 16300 17 6” 197 0.5 1.7 1.54 22 0.06
Table 6.2 : SONIC / COANDA Flare System BACKPressures and Velocities for Single Source Cases
Event Source Rate Total Gas Tailpipe Tailpipe Mach No in Back-pressure at P at Velocity in Flare Mac
to Flare NPS Velocity Tailpipe Source Flare Bridge h
Scrub No
ber At
Tip
kg/hr MMscfd inches m/s - bara bara m/s -
Normal Flare MBD-181 77033 80 20” 63 0.16 2.4 2.35 74 0.1
9
Blocked Liquid Outlet on MBD-181 454,300 67 20” 49 0.12 2.8 2.26 62 0.1
MBD-181 multiphase 6
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Fail Open of PCV-181B MBD-181 147300 158 20” 91 0.23 3.2 3.0 132 0.3
with 95% maximum stop 6
Full Flow Relief from MBD- MDB-170 61600 65 10” 175 0.45 5.55 2.2 56 0.1
170 4
Failed PCV-180AorB Fuel Gas 16300 17 6” 147 0.37 2.16 2.04 17 0.0
4
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Table 6.3 : PIPE FLARE SYSTEM BACKPRESSURES AND VELOCITIES FOR CO-INCIDENTAL CASES
Coincident Rate Total Gas Tailpipe Tailpipe Mach No Back-pressure P at Flare Velocity in Mach No
Sources (kg/hr) to Flare NPS Velocity in Tailpipe at Source Scrubber Flare Bridge on Bridge
kg/hr MMscfd inches m/s - bara bara m/s -
Normal Flare MBD-181 58262 80 20” 57 0.14 2.01 1.94 98 0.256
MBD-182 18771 12” 68 0.17 2.02
Blocked Liquid Outlet on MBD-181 454300 87 20” 51 0.12 2.67 2.0 103 0.28
MBD-181 + Normal Flare MBD-182 18771 12” 55 0.14 2.44
Rate from MBD-182
Blocked Liquid Outlet on MBD-181 58262 84 20” 53 0.13 2.16 2.0 100 0.264
MBD-182 + Normal Flare MBD-182 141000 12” 71 0.18 2.95
Rate from MBD-181

Fail Open of PCV-181B MBD-181 147300 178 20” 92 0.23 3.2 3.0 182 0.54
(with 95% Max Stop) + MBD-182 12” 43 0.10 3.15
18771
Normal Flare Rate from
MBD-182
Fail Open of PCV-182B + MBD-181 58262 121 20” 47 0.12 2.4 2.3 135 0.37
Normal Flare Rate from MBD-182 52150 12” 159 0.39 2.6
MBD-181
Blocked Gas Outlet on MBD-181 77033 145 20” 55 0.14 2.73 2.60 154 0.44
MBD-170+ Normal Flare MBD-170 61558 10” 147 0.37 5.68
Rate from MBD-181
Blocked Gas Outlet on MBD-181 57954 80 20” 68 0.17 2.04 1.93 95 0.25
MBD-183+ Normal Flare MBD-183 43000 6” 56 0.14 2.02
Rate from MBD-181
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Platform Depressurisation MBD-181 1528 9.1 20” 2 0.005 1.53 1.53 11 0.03
MBD-182 2615 12” 12 0.03 1.53
MBD-183 233 6” 2.9 0.007 1.53
MBD-170 4365 10” 19 0.05 1.57

Table 6.4 : SONIC / COANDA FLARE SYSTEM BACKPRESSURES AND VELOCITIES FOR CO-INCIDENTAL CASES
Coincident Rate Total Gas Tailpipe Tailpipe Mach No Back-pressure P at Flare Velocity in Mach No
Sources (kg/hr) to Flare NPS Velocity in Tailpipe at Source Scrubber Flare Bridge on Bridge
kg/hr MMscfd inches m/s - bara bara m/s -
Normal Flare MBD-181 58262 80 20” 48 0.12 2.41 2.35 74 0.19
MBD-182 18771 12” 56 0.14 2.42
Blocked Liquid Outlet on MBD-181 454300 87 20” 58 0.15 2.62 2.52 91 0.24
MBD-181 + Normal Flare MBD-182 18771 12” 52 0.13 2.60
Rate from MBD-182
Blocked Liquid Outlet on MBD-181 58262 84 20” 45 0.11 2.5 2.4 77 0.2
MBD-182 + Normal Flare MBD-182 141000 12” 83 0.20 3.2
Rate from MBD-181

Fail Open of PCV-181B MBD-181 147300 178 20” 84 0.2 3.5 3.3 146 0.41
(with 95% Max Stop) + MBD-182 12” 40 0.1 3.4
18771
Normal Flare Rate from
MBD-182
Fail Open of PCV-182B + MBD-181 58300 120 20” 41 0.1 2.9 2.7 105 0.28
Normal Flare Rate from MBD-182 12” 139 0.34 2.8
53700
MBD-181
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Blocked Gas Outlet on MBD-181 77033 145 20” 50 0.13 3.0 2.9 120 0.33
MBD-170+ Normal Flare MBD-170 61558 10” 129 0.33 5.9
Rate from MBD-181
Blocked Liq Outlet on MBD-181 70000 80 20” 54 0.15 2.4 2.3 74 0.19
MBD-183+ Normal Flare MBD-183 43000 6” 47 0.14 2.4
Rate from MBD-181
Platform Depressurisation MBD-181 1528 9.1 20” 1.5 0.004 2.03 2.02 8.5 0.02
MBD-182 2615 12” 9.2 0.023 2.03
MBD-183 233 6” 2.2 0.005 2.03
MBD-170 4365 10” 14 0.03 2.06

Table 6.5 : FIRE RELIEF CASES – COINCIDENTAL FLOW, SONIC TIP

Vessel Tag Rate Total Gas Tailpipe Tailpipe Mach No Back-pressure
to Flare NPS Velocity in Tailpipe at Source
kg/hr MMscfd inches m/s - bara
LP Separator MBD-181 475 3.1 14 / 20 9 <0.05 2.1
HP Separator MBD-182 2517 2.7 8 / 12 14 <0.05 2.1
Test Separator MBD-183 1333 1.0 6 12.7 <0.05 2.1
Gas Lift Separator MBD-170 1446 1.5 10 4.6 <0.05 2.1
Fuel Gas Scrubber MBF-180 350 0.37 3 12.4 <0.05 2.1
Fuel Gas Filters MAF-191/192 700 0.74 2 56 0.14 2.1
Export Pig KAH-930 480 0.33 1 160 0.4 4.6
Launcher
ADS Pig Receiver KAQ-950 360 0.1 2 3 <0.05 2.1
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ADS Test Line Pig KAQ-960 290 0.1 2 4 <0.05 2.1

Receiver
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7.0 FLARE RADIATION ANALYSIS

7.1 Flare Radiation Simulation
Radiation analysis was conducted using the BP software Cirrus Version 7.0. This
is used to determine isopleths, which represent points of constant radiation level
relative to the flare location.
Cirrus includes functionality to determine radiation from pipe flares as well as
proprietary coanda type flares. Indair and Mairair types can be modelled. The
Indair tip is a low radiation tip and is used throughout this study.
The flare header and stack diameter is 20”, which is based on the backpressure
requirements for a pipe flare. In Cirrus, the Indair tip performance is insensitive
to this diameter and the same value is used when assessing a sonic flare.
The purpose of this exercise was to determine the minimum separation required
between the flare stack and the Adanga production and riser platforms, in order
to ensure that radiation generated by the flare does not exceed the
recommended limits given in Section 7.4.
7.2 Metocean Data
Wind direction is predominantly from the south or south west and has a
velocity of no greater than 7 m/s. However, squalls can occur throughout the
year. These coincide with high velocity winds from an easterly direction with
gusts up to 30 m/s [5].
DNV offshore structural design codes recommend that flare born radiation be
determined at a 1 hour mean wind velocity with a return period of one year [7].
Maximum wind speed for prevailing winds 7 m/s
1 hour mean wind velocity (1 year return period) 16 m/s
1 minute mean wind velocity 20 m/s
Ambient Air Temperature 25°C
Maximum Relative Humidity 70%
7.3 Flare Rates and Compositions
The maximum continuous flare rate is 80 MMscfd whereas the maximum
emergency flare rate is 178 MMscfd.
A simplified composition has been adopted for the flare simulations, and is
presented in Table 7.2. A simplified composition has been adopted to minimise
convergence failure within the Cirrus software.
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Table 7.1: SIMPLIFIED COMPOSITION USED FOR FLARE RADIATION ANALYSIS

Component Gas to Flare (mol
%)

Methane 91

Ethane 5.2

Propane 3.8

7.4 Radiation Data and Limit Criteria

Solar radiation level is 0.631 kW/m² [1].
The radiation limits recommended by API RP 521 [4] are provided in Table 7.1.
These values are total radiation levels and are therefore inclusive of solar
radiation. The maximum radiation level allowable from the flare is the total
radiation less the solar radiation component.
The flare shall be located such that operators (provided with suitable clothing)
on ADPP, ADPP2 and ADRP1 can be exposed to continuous flare radiation not
exceeding 1.58 kW/m². Excluding the background solar radiation, the maximum
allowable radiation from the flare itself is 0.95 kW/m². Activities on the flare
bridge during operational flaring will not be allowed, and this restriction should
be included as part of operating procedures for the facilities.
Under emergency releases, the allowable radiation limit is 4.7 kW/m². Under
such conditions, emergency activities lasting several minutes can be carried out
by personnel without shielding but with appropriate clothing.
The height of the flare stack shall be determined such that the base of the flare
and the bridge shall not be subject to radiation in excess of 15.77 kW/m² for the
design flare rate.
Table 7.2 : Recommended Design Total Radiation levels

Case Total Radiation Allowable Flare

Level Radiation
(kW/m²) (kW/m²)

Continuous exposure with appropriate clothing 1.58 0.95

Emergency Actions lasting several minutes, no 4.73 4.10

shielding but appropriate clothing
Emergency Action lasting 1 minute, no shielding but 6.31 5.68
appropriate clothing
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Design flare release, exposure limited to a few 9.46 8.83

seconds only for escape
Allowable level for structures, where operators are 15.77 15.14
not present and where shelter is available.

7.5 Flare Stack Height Determination

The flare height has been determined for both pipe flare and Indair coanda type
tips. The flow rate for stack height determination is the maximum emergency
flare rate for the facility of 178 MMscfd. The radiation limit is that allowable for
structures without the presence of personnel, which Table 7.2 shows to be
15.77 kW/m2.
The sensitivity of the stack height to wind speed is examined up to 16 m/s, which
is the 1 hour mean wind velocity with a return period of one year as
recommended for use with this scenario by DNV [7].
For a pipe flare, the minimum required height is 30m. For an Indair coanda type
tip the stack should be a minimum of 15m in height. These values are based on
simulation data and require vendor confirmation. Figure 7.3 shows that further
increases in stack height correspond to less than equivalent reductions in sterile
zone radius, and are therefore of limited value.
7.6 Sterile Zone Radius and Flare Location
The location of the flare is defined by the allowable radiation exposure on the
platforms under a normal flaring case. A sterile zone is established around the
flare such that radiation does not exceed safe limits.
The field layout and available bridge connections mean that the flare bridge is
longer than the sterile radius defined by the radiation study. The flare extends
from ADPP but the ADPP2 platform is located closer to the flare. As the
schematic in Figure 7.4 shows, the relative location of ADPP2 to ADPP means that
a bridge section of approximately 40m beyond the sterile radius is required to
ensure ADPP2 is safe from excessive flare radiation.
The distances presented in Tables 7.3 and 7.4 are the minimum distance between
the flare and any of the platforms upon which personnel may be present. The
bridge length from ADPP to the flare is required to be longer due to the relative
arrangement of ADPP, ADPP2 and ADRP1.
As a result, a pipe flare would require a 156m sterile zone and a coanda flare
would require a 105m sterile zone.
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Table 7.3: Maximum SAFE Distances – PIPE Flare

Flare Height = 30m above bridge

Radiation Normal Normal Flare Failure of Failure of

level Flaring + Gas Lift PCV-181B PCV-181B with
Separator with 95% 95% Stop +
Relief maximum Normal
stop MBD-182 Flow

Rate (MMscfd) 78 145 158 178

Rate (kg/s) 20.4 37.3 41.2 46.4

Condition Normal Emergency Emergency Emergency

Allowable K 1.58 4.63 4.63 4.63

(kW/m²)

Safe Distance 156 109 112 115

(m)

Note: data generated in Cirrus and requires vendor confirmation.

Table 7.4: MAXIMUM SAFE DISTANCES – INDAIR COANDA FLARE TIP

Flare Height = 15m above bridge

Radiation Normal Normal Flare + Failure of Failure of

level Flaring Gas Lift PCV-181B PCV-181B with
Separator with 95% 95% Stop +
Relief maximum Normal
stop MBD-182 Flow

Rate (MMscfd) 78 145 158 178

Rate (kg/s) 20.4 37.3 41.2 46.4

Condition Normal Emergency Emergency Emergency

Allowable K 1.58 4.63 4.63 4.63

(kW/m²)

Safe Distance 105 69 72 76

(m)

Note: data generated in Cirrus and requires vendor confirmation.

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8.0 DISPERSION ANALYSIS

8.1 Introduction
Shell FRED software version 4.0.0.0 is also used to perform dispersion
calculations. The same input data for the flare arrangement as provided in
Section 7.0 for radiation analysis is used for dispersion modelling. It should be
noted that the dispersion analysis has been performed with a wind speed of 20
m/s as this is the upper limit of the capability of FRED. The values are checked
against Cirrus output for identical input conditions.
Table 8.1 gives the upper and lower flammability levels generated in FRED for
the simplified gas composition.
Table 8.1: Flammability Limits for Flare gas

Vol/Vol%

Lower Flammable Limit (%) 4.6

Upper Flammable Limit (%) 14.5

The results are summarised in Table 8.2. They indicate that the natural
dispersion of the gas is sufficient to take any gas cloud outside of the
flammability envelope in approximately 18 m. The concentration is reduced to
50% of LFL by 38 m, which is well beyond the location of the platforms. This
distance is also significantly less than the radiation safe distance, and is
therefore not the sizing distance for the flare bridge.
Table 8.2: Calculated Distance Required for Dispersion
Normal Flaring Maximum Flare Rate

Rate (MMscfd) 78 78 178

Rate (kg/s) 20.4 20.4 46.4

Wind Velocity (m/s) 7 20 20

Values Determined by FRED

Distance to Upper Flammable Limit (m) 3.2 3.7 3.4

Distance to Lower Flammable Limit (m) 13.9 17.5 15.3

Distance to 50% of Lower Flammable Limit (m) 31.6 35 37

Values Determined by Cirrus

Distance to Upper Flammable Limit (m) 2.9 3.4 3.0

Distance to Lower Flammable Limit (m) 11 15.2 11.3

Distance to 50% of Lower Flammable Limit (m) 27 38 30

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8.2 Normal Flare Rate – Gas Dispersion Results

8.3 Maximum Flare Rate – Gas Dispersion Results

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9.0 CONCLUSIONS
A study was conducted into the flare system for Stage 2 requirements of the
Adanga development. The purpose of the study was to:

• Identify all potential contributors (new or existing) to the ADPP flare system.

• Calculate relieving rates for all contributing sources.

• Identify sources that may occur coincidentally.

• Determine the largest (sizing) case for above and size the tailpipes and
header for the flare piping.

• Generate radiation profiles for flaring cases and determine sterile radius.

• Generate gas dispersion profiles for unignited release cases from the flare
stack.
As a result the following major conclusions were established:

• The maximum continuous flare rate is 50 to 80 MMscfd.

• The maximum emergency flare rate is 178 MMscfd. This is based on failure of
the PCV on the LP Production Separator coincidental with normal gas
production from the HP Production Separator.

• Balanced bellows relief valves are to be used throughout the facility.

• Existing 4” tailpipe from the PSV on the Gas Lift Separator is to be replaced
with 10” equivalent to accommodate full flow relief of lift gas production of
65 MMscfd.

• Existing 12” flare header and bridge section to be replaced with 20” piping.

• A low radiation type flare tip shall be used (following vendor confirmation of
performance).

• The flare stack for a low radiation coanda type flare is 20” and has an
elevation of 15m [HOLD 1] above the top of the bridge structure.

• Based on the radiation and gas dispersion analysis, the flare stack is to be
relocated so that it is at least 105 m [HOLD 1] from the platforms. The flare
will be located along the line of the existing flare bridge from ADPP.
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Pipe Flare Tip Coanda Flare Tip

Flare Header and 20 20”

Bridge Line Size
VTA if 24” required

Sterile Zone Radius 156 105

Stack Height 30 15

Turnup VTA VTA

Turndown VTA VTA

The increase in maximum flare rate from the 80 MMscfd identified in FEED to
178 MMscfd is the result of coincidental flare loads, which were not considered at
FEED. FEED considered only the normal flaring rate which can be up to a
maximum of 80MMscfd. Failure of the pressure control on the LP Production
separator coincident with normal production from the HP Production Separator
can lead to a maximum instantaneous rate to the flare of 178 MMscd.
It should be noted that calculations will require updating when piping isometrics
become available.
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10.0 REFERENCES
API Recommended Practice 521
Metocean Data Report, Calabar Estuary FPSO Antan Terminal, Document No.
L18468/NDE/SLF, 17th June 1998.
GPSA Engineering Databook, 11th Edition.
DNV –OS-C101 Design of Offshore Steel Structures (LRFD Methods).
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11.0 SENSITIVITY OF STERILE RADIUS TO FLOW RATE AND FLARE TIP

A study was undertaken to examine the sensitivity of the sterile zone radius to
the normal flaring rate. In reducing the normal flare rate from 80MMscfd to 50
MMscfd, the sterile radius is reduced by approximately 26m for a pipe flare and
22m for a coanda flare.

If the sterile zone is determined for a normal flare rate of 50MMscfd, then at 80
MMscfd a pipe flare could expose personnel to 650 BTU/hr.ft2, which is sufficient to
reach a pain threshold in approximately 50 seconds. For a coanda flare, this
same case would see personnel exposed to close to 700 BTU/hr.ft2. In both
cases, this is unacceptable for the normal operation of the facility.

Flow Rate, Sterile Radius, m

MMscfd Pipe Flare Indair Coanda
Tip
50 128 83
60 138 91
70 148 98
80 156 105