UNPRICED FIRM

PROPOSAL

FLARE SYSTEM FOR VME PROCESS

END-USER: HUSKY-CNOOC MADURA LTD

PROJECT: FPU FOR MDA-MBH FIELD

DEVELOPMENT

LOCATION: MADURA STRAIT EAST JAVA,

INDONESIA

John Zink Inq No.:

201505-54041E rev1

Page i
February 7, 2018

VME Technical Services Sdn. Bhd.

B09/01/02/03
Skypark One City
Jalan USJ 25/1
47630 Subang Jaya
Malaysia

Attention: Gugan Mani

Customer Reference: FPU – MDA-MBH Field – Flare Ignition (V-7510)

John Zink Proposal No: FS201505-54041E rev1

Dear Customer:

John Zink Asia Pacific is pleased to provide you with the enclosed Unpriced Technical
Proposal in response to the inquiry for the project reference above.

Please take note we have quoted for variable slot HP tip which is capable to perform smokeless
from low to maximum flow. We have provided the radiation plot for this variable slot tip based on
vertical orientation on vertical stack. If you require for angle tip, this variable slot tip can be
orientated in an angle.

We appreciate your interest in John Zink Hamworthy Combustion and look forward to working
with you. If you require any further information or have any questions, please feel free to contact
us.

Thank you for allowing us this opportunity to be of service.

Sincerely,

Fadelah Ibrahim
Applications Engineer - Flare Systems
Office: + 65 6831 6540
E-mail: Fadelah.ibrahim@johnzink.com
Cc: Vignes.rajagopal@johnzink.com

Page ii
 Contents
Contents .................................................................................................................. iii 
Introduction .............................................................................................................iv 

A  Commercial Section ........................................................................................ 5 

A.1  Priced Scope of Supply ...................................................................................................5 
A.2  Proposed Schedule ..........................................................................................................5 
A.3  Terms and Conditions .....................................................................................................6 
A.4  Commercial Clarifications ..............................................................................................7 

B  Technical Proposal .......................................................................................... 8 

B.1  Scope of Supply ..............................................................................................................8 
B.2  Exceptions, Deviation & Technical Clarifications..........................................................9 
B.3  General Notes ................................................................................................................11 
B.4  Equipment Description..................................................................................................12 
B.5  Process Conditions ........................................................................................................21 
B.6  Sheets & Attachments ...................................................................................................22 
 

Page iii
 Introduction
John Zink Hamworthy Combustion’s emissions-control and clean-air systems perform vital functions in
the world’s most demanding industries—from hydrocarbon and chemical processing, to biofuels,
automobile manufacturing, food processing, pulp and paper, waste management, and many more.
Combining practical problem solving with creative innovation, our people are driven to push the
boundaries of John Zink Hamworthy Combustion’s legacy achievements to develop a clean generation of
products that address the challenges of our clients and an environmentally conscious world.

Headquartered in Tulsa, Oklahoma, John Zink Hamworthy Combustion is home to the best and brightest
process engineers, researchers and scientists from all corners of the globe, and the combustion industry’s
largest research and development test center. Here, we’ve built a unique brain trust of knowledge,
creativity and industrial-scale resources to incubate innovation and propel our industry and mission
forward.

John Zink Hamworthy Combustion upholds the principles of its own Quality Management System, which
fully meets and encompasses ANSI/ISO 9001:2000 requirements. John Zink Hamworthy Combustion is
a part of Koch Industries, a privately held global corporation providing diverse products and solutions for
industries and consumers worldwide.

Page iv
A Commercial Section
A.1 Priced Scope of Supply
Flare System as described in “B1 Scope of Supply”

HP KMI tip with 2 pilots

LP Pipe Flare with 1 pilot

AMFFG Ignition system with SS316 Enclosure

ABS Certification – Design Review & Shop Survey

Fuel Gas Manifold

Junction box for Thermocouple termination

Total Price………………………………………………………..Unpriced

Option:

Thermocouple extension cable……………………………………US$18/m

A.2 Proposed Schedule

Customer Drawings 4 – 6 Weeks After Receipt of PO

Customer Approval 2 Weeks After Receipt of Drawings

Fabrication Time 26 Weeks After Return of Approval Drawings

Note:
1. Fabrication & schedule will be confirmed during firm bid.

5
A.3 Terms and Conditions
Terms and Conditions of Purchase
This bid is based on the John Zink Company Standard Terms and Conditions of Sale
(available on request). John Zink Company is submitting this proposal and price with
the provision that any resulting order shall be based on mutually agreed upon terms
and conditions.

Payment Terms
Our proposed payment terms shall be as follows upon 30 days receipt of original
invoice:-

10% - Upon order placement

25% - Upon 1st issue interface documents (GA, P&ID, Production schedule)
35% - Upon order of major materials (TBC during KOM)
20% - Upon start of Fabrication
10% - Upon Submission of Final Documentation

Taxes & Duties: Prices do not include applicable taxes and/or export duties.

Delivery: Delivery terms will be FCA Manufacturing Facility

Warranty: According to John Zink Company Standard Terms and Conditions of Sale.
12 months upon date of commissioning or 18 months upon date of delivery,
whichever comes earlier.

Validity: This Commercial and Technical Proposal is valid for sixty (60) days from
date of issuance.

Cancellation Schedule :- 0 – 2 weeks ARO 0% of PO Price

2 – 10 weeks ARO 10% of PO Price
10 – 14 weeks ARO 25% of PO Price
14 – 20 weeks ARO 50% of PO Price
20 – 24 weeks ARO 75 % of PO Price
Above 24 weeks, 100% of PO Price

6
A.4 Commercial Clarifications

1 John Zink Asia Pacific is submitting this price and technical proposal only with
the understanding and condition that any resulting order shall be based upon
mutually agreed upon terms and conditions negotiated in good faith before the
order is issued.

2 John Zink Asia Pacific will not be liable for any lost profits, special, indirect,
incidental or consequential damages whether arising under warranty, contract,
negligence, strict liability, indemnification, or any other cause or combination of
causes whatsoever. This limitation shall apply notwithstanding any failure of
essential purpose of any limited remedy. Zink's liability is limited to the price
allocable to the equipment determined defective, and in no event will Zink's
cumulative liability be in excess of the total contract price, whether arising under
warranty, contract, negligence, strict liability, indemnification, or any other cause
or combination of causes whatsoever. Buyer's remedies are specifically limited to
the repair or replacement of the equipment and are exclusive of all other remedies.
Should these remedies be found inadequate or to have failed of their essential
purpose for any reason whatsoever, Buyer agrees that return of the full sales order
price to it by Zink shall prevent the remedies from failing of their essential
purpose and shall be considered by Buyer as a fair and adequate remedy.

7
B Technical Proposal
B.1 Scope of Supply

 One (1) KMI-12-6-VS Pressure Assist KMI Multipoint Coanda Flare Tip with pilots.

 One (1) Lot pilot gas manifold in SS316.

 One (1) John Zink model EEF-U-4 Utility Flare Tip with pilot.

 One (1) AR-4 Airrestor Purge Reduction Device come with LP flare.

 Three (3) WindPROOFTM Pilots with Thermocouple. Thermocouple will be used for
pilot flame detection.

 One (1) Junction Box will be provided for Thermocouple termination.

 One (1) Lot ABS design review and shop survey. Shop survey will be for three visits
– Flare tip final dimensional check, FAT of ignition system & Panel final dimensional
check.

Common Ignition:
 One (1) lot Auto/Manual Flame Front Generator for three pilots. Ignition Panel
Enclosure SS316, ExD for Zone 2, IIA, T3. Skid will include ignition module, valves
and piping. Valves and piping will be carbon steel and socket weld as per John Zink
Standard design. Painting will be as per project Spec.

Skid frame will be Carbon Steel construction and painted to marine coat system

8
B.2 Exceptions, Deviation & Technical Clarifications

1. John Zink has proposed separate HP and LP arrangement. This arrangement is to

prevent LP flame from impinging on HP tip during purge or low flow operation. We
proposed 2 pilots for HP and 1 pilot for LP. We will provide reducer to meet
customer’s tie-in point for HP & LP tip.

2. The LP flare must be downwind of the HP flare based on the predominant wind
direction to prevent decreased life of the HP flare. We have proposed for now vertical
arrangement for HP and if need to be installed included, KMI is able to be in this
orientation too.

3. Control Panel Enclosure is EExd SS 316 suitable for ZONE 2 GROUP IIA/B T3.
Junction box for thermocouple extension will be provided in SS316 material without
certification.

4. No vessel motion will be included in our base of scope.

5. No protective coating & painting shall be applied on Stainless material. Stainless Steel
surface shall be natural finish. Stainless steel is not blasted, pickled, or coated.

6. ABS Certification will be for design review and shop survey for final inspection.
Customer will do the certification with ABS. John Zink will support in providing any
documents /drawings for certification. Client will provide contact person from ABS
for our communication.

7. Vendor Data supplied will be JZ standard documents. John Zink shall submit the
Drawings / Documents for approval through e-mail in PDF format only. We will
submit General Arrangement drawings for customer approval.

8. Interconnecting Pilot and Ignition Piping are not in our scope.

9. Customer specification/Approved Vendor list does not apply to JZ proprietary

equipment flare tip, pilots and ignition system.

10. Flare Tip & Pilots shall not be designed or fabricated as a pressure vessel / pressure
retaining part / piping codes. Flare Tip and Pilots are considered as proprietary items
which design and built to John Zink standard.

11. All raw materials, plate, flanges, gaskets, fittings, structural steel, piping material,
consumable, fasteners etc. shall be purchased from trader / supplier from open market.

12. Utility consumption is considered as approximate & preliminary and to be confirmed

during detail engineering.

9
13. HP Flare tip proposed can handle 700 to 1000-micron liquid droplet size.

14. Ignition system proposed is Auto/Manual system and pilot detection is by

Thermocouple. Thermocouple extension cable will need to run on conduit and
conduit will be by others. We have not include thermocouple extension cable in our
scope but we have provided the unit price.
15. All bought-out items such as Electricals, Valves and Instrumentation are provided as
per manufacturer standard including vendor standard documentation, fabrication,
testing, painting etc. No MTRs and Country of origin requirement shall be provided
for such bought-out items.

16. No special tools are required. Flare tips & Ignition skid will come with lifting lugs.

17. Any rule, regulation, or standard issued by states and governments applicable to your
flare system design and emissions, if submitted to John Zink Company will be
evaluated.

18. Proposed equipment design and scope of supply comply with only those specific client
specifications provided with the requisition. Nested or referenced specifications that
were not provided by purchaser with the requisition are specifically excluded from
this proposal.

19. If client specification call for submittal or calculations for review, John Zink Company
does not agree to submit such calculations unless specifically agreed to elsewhere in
this proposal.

20. FAT is only applicable for the panel testing.

21. Our LP tip will come with built in velocity seal. HP will not have any seal. With
Variable slot tip, the opening is almost close during low flow. KMI will be smokeless
from purge to maximum flow.

10
B.3 General Notes

1. John Zink Company reserves the right to fabricate all or parts of this system at one or
more facilities in our international subcontract fabrication facilities as required
providing any advantage in executing any contract resulting from this proposal.

2. All dimensions, design, material thickness, etc. in this proposal are preliminary and
subject to modification, in compliance with specifications, after final engineering.

3. The flare tips are designed to John Zink standards. The proposal is based on existing
weld procedures and qualifications. No additional procedures or testing have been
included. This proposal is based on the use of manual and automated welding
processes, including SAW, for the stainless-steel flare tip(s) and piping components.

4. The Delivery Schedule is based upon drawing approval by the customer as a hold
point therefore, any delay in approving and returning these drawings by the customer
will subsequently extend the contractual delivery date John Zink shall furnish
drawings to customer only and shall address only customer’s comments not to various
authorities.

5. Changes required by the Buyer or its agents after the initial drawing review my result
in delays and additional engineering or drafting costs. Such costs, together with
increases in fabrication costs that will result from these changes, will be presented to
the client and must be approved before work commences.

6. Documentation as per John Zink standard, no requirement on material sourcing and

drawing approval within one week.

7. If client specifications call for submittal of calculations for review, John Zink
Company does not agree to submit such calculations unless specifically agreed to
elsewhere in this proposal.

8. Vendor Data supplied will be John Zink standard documents. JZ shall submit the
Drawings / Documents for approval through e-mail in PDF format. We will submit
General Arrangement drawings for customer approval.

11
B.4 Equipment Description

JOHN ZINK HIGH PRESSURE KMI-MULTIPOINT INDAIR COANDA SMOKELESS

FLARE

Our recommended design for this application is the use of a high pressure KMI flare tip for the
HP flare. The HP flare will provide 100% smokeless, low radiation flaring without the need for
an air blower or other assist medium.

The Indair flare utilized in the KMI flare tip has been used for over 30 years in hundreds of
applications requiring a low radiation, smokeless, high pressure flare design. In recent years
the use of multiple Indair flares operated in parallel has been used very successfully in a wide
range of applications and configurations.

In order to take advantage of the many operating benefits of the multiple Indair flare design,
John Zink has developed a range of designs that provides a cost effective, low maintenance
solution to a wide range of flare applications.

KMI Multipoint INDAIR Flare The KMI Multi-Point INDAIR flare tip design utilizes
multiple small diameter Indair flare tips mounted on a
common flare body. At the heart of the KMI Multi-Point
INDAIR flare tip is the cast Indair flare tip. John Zink has
developed a range of small Indair flare tips (4” to 12” tulip
diameter) that fabricated as solid castings. The entire tulip
assembly is a thick, solid stainless steel casting. This is in
contrast to the large Indair tulip assembly that requires
welding of a rolled plate tulip cone to the forged tulip bowl
assembly. The use of multiple small diameter cast tulip
assemblies provides many benefits including eliminating
weld seams in the high heat area and allowing for very
exacting fabrication tolerances.

The design of the KMI Multi-Point Indair flares uses an

array of small cast Indair flare tips arranged in a pattern to assure adequate aeration of each
individual Indair flare tip, while also ensuring cross-lighting between the individual tips.

The layout of the KMI Multi-Point Indair flare tip is very similar to that used by most
conventional multi-point sonic flare tips. The main body of the flare tip has multiple small
diameter arms that “Tee” off the main body in a symmetrical pattern. The major advantage
with the KMI Multi-Point INDAIR flare tips is the use of unique Coanda Principle of the
Indair flares. These Indair multi-point “nozzles” are much more efficient at entraining and
pre-mixing air into the flame than a conventional sonic flare tip nozzle.

12
The INDAIR flare was developed to provide a safe and
How the COANDA
reliable high efficiency flare tip to produce smokeless,
low radiation flare design without the need for outside Effect works
assist media such as forced air or steam. The Indair flare
is a pressure-assisted flare design which utilizes the
internal energy within high-pressure gas streams to
produce a highly aerated, turbulent flame.

The Indair flare utilizes the “Coanda Effect” to entrain

and mix air into the hydrocarbon gas stream. High-
pressure gas is ejected radially from the annular slot at
the base of the Indair tulip. Instead of continuing
horizontally, the gas adheres to the Coanda profile and is
diverted through 90 degrees, entraining up to 20 times
its own volume of air in the process.

The pre-mix air/gas mixture creates very efficient, 100%

smokeless combustion of the flare gases. The flame produced by this efficient pre-mixed
combustion is a very low radiation, low luminance flame. The flame length is less than half of
that produced by a conventional flare tip. The flame is also a thin, stiff, pencil shape that is
not easily distorted by crosswinds.

In contrast to the wind sensitive flame produced by a conventional flare, the Indair flare
produces a flame with a high directional stability which is not easily distorted by cross-winds.
The flame is extremely stable; in fact, Indair flares have been operating successfully in the
North Sea in wind speeds in excess of 100 mph.

Even with the best run production/separation installations, liquid carry-over to the flare line
can take place, particularly under emergency relief conditions. With conventional pipeflares
or multi-point sonic flare tips this can be a serious potential hazard giving rise to 'flaming rain'
falling and pollution affecting a wide area.

The intense shear in the Indair slot region ensures efficient atomization of liquids, aiding
vaporization and combustion. The Indair flare is capable of burning 25% by weight of liquid
carry-over without any fall-out or smoke production whatsoever. The Indair flare tip can
effectively atomize liquid particles with size in excess of 1000 microns. This feature means
that, in many cases, the flare may be operated without a liquid knockout drum in the HP flare
line.

The Indair design that is recommended for applications requiring high turndown is a “variable
slot” design. The slot width (which determines the tip outlet area) remains at a small size
during low gas flow rates and increases proportional with increase in gas flow. This design
provides near infinite smokeless turndown design while maintaining high maximum flow
capacities. This variable slot Indair design, therefore, produces 100% smokeless flaring from
minimum (purge) to maximum design flow rates.

13
 Variable Slot INDAIR Flare Tip Variable Slot INDAIR Flare Tip
Minimum Slot Width Maximum Slot Width

Tulip Cone
Tulip Cone

Coanda
Coanda
Profile
Profile

Tulip Bowl
Tulip Bowl
Annular Slot
Annular Slot
(maximum width)
(minimum width)

The high tolerance fabrication of the cast KMI Multi-Point INDAIR flare tips allows very
small minimum slots, thereby providing infinite turndown. The flames produced by each of
the individual, multipoint Indair flare tips remain thin and stiff under all flow conditions. This
prevents any possibility of “flame lick” between the multi-point nozzles that causes severe
damage to conventional multi-point sonic flares.

Conventional sonic flare tips have a fixed outlet area design. The smokeless turndown for
these types of designs is roughly proportional to the maximum flow design operating pressure
versus the pressure at which sonic velocity occurs.

Sonic pressure for most hydrocarbon gas streams will occur at about 10-12 psig back
pressure. Therefore the smokeless turndown for conventional fixed outlet area flare tips is:

Turndown < Max. Operating Pressure

Sonic Pressure

For instance, if the maximum design pressure for a conventional sonic flare tip is 50 psig, the
turndown would be less than 5:1. This would mean that at flow rates from 0-20% of
maximum the flare could produce smoke. For most flare systems this 0-20% range is the
typical normal operation. A conventional sonic flare tip would therefore smoke during most
normal operations.

The only solution for providing reasonable smokeless turndown with a convention sonic flare
tip is to provide an elaborate multi-flare tip design with many flare stages separated by control
valves. This type of design is therefore very expensive to install and maintain.

14
The unique variable slot Indair flare tip provides infinite smokeless turndown without the
need for these elaborate staged multi-flare designs. A single Indair flare tip provides 100%
smokeless flaring and high flaring capacity with a very low radiation flame. The spring-
loaded mechanism is extremely reliable, with a design similar to that used in safety relief
valves.

The variable slot has been installed in over 500 installations worldwide for over 30 years.
With smokeless flaring being a more important design feature in recent years the variable slot
Indair has become the choice of most major oil and gas producers.

15
EEF-U, Energy Efficient Utility Flare Tip

The John Zink Energy Efficient Utility Flare Tip is a cost-effective alternative that serves the
three primary functions of a flare tip:

 Maintains Stability
 Minimizes Burn-back
 Reduces Flame Pull-down.

Design Basis:
flame retention
The most common type of flare is the “pipe” flare. A pipe flare segments
consists of a flanged piece of pipe, with an ignition source at the
pilot
exit. Although these flares are very common, they are not
adequate flaring devices. Frequently these types of flares are windshield
prone to have flame lift-off, where the flame becomes unstable at
high flow rates. Flame lift-off can result in the flame being
extinguished, and having unburned gases released into the
atmosphere. In addition, pipe flares typically have a short service
life. The tip is not protected from flame burning the outside or
inside of the tip, and the tip life is reduced. John Zink’s Utility
flare is designed to be cost effective and simple, as is the pipe
flare, but also enable stable burning and extended flare tip life.
waste gas

ring of fire
Stability:
Typical pipe flares exhibit incomplete ignition, and in cases of high
exit velocity, may go out due to limited flame stability. To eliminate
air
this problem, John Zink provides a flame retention tip that creates a
waste
low-pressure zone at the tip’s exit orifice. This low-pressure zone
gas insures both complete ignition of the waste gases and flame stability
at high exit velocities.
flam e
retention tips

16
Flame pull-down:
As wind blows across a flare tip, a low-pressure zone is created on the
downwind side of the flare. This low-pressure zone pulls the flame
flare tip
downward, causing the gases to impinge and burn on the shell. A
wind
windshield protects the flare tip by eliminating the low-pressure zone direction

and preventing flame impingement directly on the tip shell in windy

conditions. This added protection results in longer flare tip life. John
Zink flare tips greater than 8 inches are equipped with a stainless-steel waste
gas

windshield that surrounds the upper section of the burner.

low pressure

Internal Burning:
One of the most prominent mechanisms responsible for the
failure of a flare tip is internal burning. A flare tip will typically wind
direction
experience internal burning if it operates at a low waste gas exit
velocity in windy conditions. Under these operating conditions,
the wind will create an internal recirculation pattern near the tip air / fuel

outlet creating internal burning. Larger diameter flare tips are mixture

more likely to experience internal burning inside the flare tip

shell. Burn-back can greatly reduce tip life by deforming the waste
structure and embrittling the tip material. As a result, John Zink gas

lines the upper section of the larger utility flare tips with
refractory (see data sheet). This refractory type and thickness has
proven successful in severe thermal shock applications, and significantly increased the tip life
of large tips.

Performance Prediction:
The dramatic increase in environmental awareness, throughout the world, has made it
extremely important to accurately predict flare performance. This is why, in 1996, we set out
to improve our flare prediction techniques. After conducting an extensive series of flare tests
in our research and development center, we have now developed mathematical models, in the
form of computer programs, which consider all of the important flame characteristics:

Flame Momentum Flame Buoyancy Steam Momentum

Steam Jet Efficiency Gas Characteristics Smoking impact on radiation

Considering all characteristics of a flame ensures that we provide our clients with the best
prediction available.

A detailed description of the flare is included on an attached data sheet.

17
John Zink WindPROOF High Performance Pilot

The John Zink WindPROOF Pilot is the best that pilot technology has to offer, with a
combination of fuel efficiency and stability in adverse weather conditions. The WindPROOF
Pilot stands up to the most severe winds and rain with the long-lasting performance of our other
pilot models.

Figure 1: WindPROOF Pilot During Operation

Stable in winds up to a velocity of 160 mph in all positions around the flare tip, the WindPROOF
Pilot consist of a tip and tip windshield, ignition and fuel piping, a mixer and strainer assembly,
and a mixer windshield. The WindPROOF is stable in the worst conditions while consuming as
little as 45 SCFH of fuel gas. Also included are one integral thermowells for thermocouple pilot
detection. The WindPROOF can burn a wide variety of fuels without adjustment.

WindPROOF was designed and tested at the only pilot test facility of its kind in the world. At
John Zink’s International Research and Development Center, we use full scale testing to push our
flare products to extraordinary limits. Det Norske Veritas (DNV), the world’s most widely
respected product verification and Certification Company, witnessed John Zink Company’s test
of the WindPROOF pilot and verified that the WindPROOF remained lit under test conditions
that exceeded 160 mph winds and 30 inches of rainfall per hour.

18
EEF-AR, Airrestor Purge Reduction Device

The John Zink Airrestor is a velocity dependent device functioning on the premise that
atmospheric air enters the flare system by traveling along the inner wall of the flare tip. The
Airrestor is a cone shaped obstruction located inside the tip which first, prevents the air from
traveling further down the inner wall, and second, redirects the air upward toward the center
of the tip. Then, the reduction in flow area increases and focuses the purge gas flow at the
center of the tip forcing any atmospheric air out of the tip.

John Zink Company recognizes the increasing operating cost of purge gas. To demonstrate
the effectiveness of purge reduction devices in reducing purge gas requirements and in
preventing oxygen from entering the flare system, John Zink built three identical, full-size
flare stacks. One is equipped with a Molecular Seal, one with an Airrestor, and one is without
any purge reduction device. The stacks were tested over an eight month period and the
oxygen content 20 feet below the flare tip was measured.

(1)
Type Purge Gas Velocity, fps Oxygen, %
Molecular Seal 0.01 0.0
Airrestor 0.04 6-8
Plain Stack 0.35 6-8
(1)
20 ft below flare tip

As shown by the above test data, the Airrestor significantly reduces the purge gas velocity.
With the Airrestor, a purge gas velocity of 0.04 fps is required to insure an acceptable oxygen
level under all adverse weather conditions. However, without the Airrestor, a minimum
purge velocity of 0.2 - 0.5 fps is required. If an oxygen free environment or protection from a
potential loss of purge gas is necessary, a Molecular Seal is recommended.

A detailed description of the Airrestor is included on the attached data sheet.

19
AUTO FFG, Automatic Flame Front Generator Ign. Sys.

The John Zink Automatic Flame Front Generator (FFG) ignition system provides reliable
pilot ignition, supported by over 40 years of experience. The FFG combines ignition fuel and
compressed air at a mixing tee with the ignition gas mixture flowing through an ignition line
to the pilot tip. After filling the ignition line with the air-fuel mixture, an electrical spark is
initiated at the mixing tee. After ignition, a point source of flame travels through the ignition
line and ignites the pilot gas at the pilot tip. Each pilot is ignited in sequence. The figure
below depicts a typical three pilot automatic ignition system control panel.

After performing tests with simulated pipelines and examining existing systems, John Zink
has determined that the FFG ignition system can be located in excess of 1,000 feet from the
pilot. This placement variability offers operational flexibility and increased safety.

Each pilot is equipped with a thermocouple which monitors the pilot flame. In addition, the
FFG panel includes a local alarm light and personnel signal contacts for remote alarm
systems. The automatic relight feature provides constant flame monitoring via a type K, 310
stainless steel sheathed thermocouple. Unmanned and immediate initiation of the ignition
sequence is made in the unlikely event pilot flame is lost. Pressure regulators are provided for
both gas and air to maintain gas-air ratios for proper ignition, and solenoid valves allow
automatic reignition of the pilot. Manual ignition of each pilot is possible, if necessary.

A detailed description of the ignition system is included in the attached data sheet.

20
B.5 Process Conditions

Utility Requirements:
 Pilot Gas: 50 SCFH of N.G. at 10 psig per pilot

 Ignition Control Panel Power: 230 Volt, 50 Hz, 1 phase for each Control Panel

 Purge Gas: HP – 240 SCFH & LP – 13 SCFH with Arrestor

Note: Purge gas can be any gas that will not go to dew point in ambient conditions and
does not contain oxygen.

PROCESS DATA – DESIGN CASE

Flare Type HP LP
Design Flowrate (MMSCFD) 175 2
Gas Composition (Mole%) As per Doc Num.: Process Data
Sheet for Flare Tip Package

Molecular Weight 16.65 16.43

Temperature (°C) 34 34

FLARE TIP DATA

Flare Type HP LP
Flare Tip Model KMI-12-6 U-4
Flare Tip Diameter (inch) 18 4
Flare Tip Length (feet) 10 10
Pressure Drop Required (psig) 36 0.03

21
B.6 Sheets & Attachments

AUTOMATIC FLAME FRONT GENERATOR

FOR 3 PILOTS
DESIGN INFORMATION
IGNITION METHOD FLAME FRONT GENERATOR (FFG)
MONITORING METHOD THERMOCOUPLE
ENCLOSURE EEXD CAST ALUMINUM SUITABLE FOR ZONE 2, GROUP IIA, T3
MANUFACTURING SPECIFICATIONS
WELDING WQS AND WPR PER ASME SECTION IX
PAINT SPECIFICATION SP-1 HANDCLEAN SURFACE PREPARATION
EPOXY PRIMER, ENAMEL FINISH COAT
CONNECTION INFORMATION
DESCRIPTION SIZE QUANTITY TYPE
INCOMING POWER SUPPLY ¾” 1 NPTF
IGNITION GAS INLET ½” 1 NPTF
IGNITION AIR INLET ¾” 1 NPTF
FFG IGNITION LINE 1” 3 NPTF
THERMOCOUPLE 1” 1 NFPT
REMOTE ALARM CONTACT ¾” 1 NPTF
WEIGHTS AND DIMENSIONS
WEIGHT 925 # HEIGHT 72”
LENGTH 66” DEPTH 19”
UTILITY CONSUMPTION
TYPE DESCRIPTION
NATURAL GAS 150 SCFH, 15.0 PSIG
AIR 1,500 SCFH, 15.0 PSIG
ELECTRICITY 3 A (230 V, SINGLE PHASE, 50 HZ)

22
 EEF-U-4
UTILITY FLARE TIP

MANUFACTURING SPECIFICATIONS
WELDING WPS AND PQR PER ASME SECTION IX
PAINT CARBON STEEL: SSPC-SP6 SURFACE PREPARATION
2 COATS HIGH TEMP. ALUMINUM, 1-2 MILS DFT
STAINLESS STEEL: NONE REQUIRED

NOZZLE INFORMATION
DESCRIPTION SIZE QUANTITY TYPE
WASTE GAS INLET 4” 1 ANSI 150 LB RFWN FLANGE
PILOT GAS INLET 3/4” 1 PLAIN
IGNITION LINE INLET 1” 1 PLAIN

CONSTRUCTION MATERIAL
SECTION MATERIAL
LOWER RISER 310 SS
UPPER RISER 310 SS
RETENTION RING 310SS
INLET FLANGE 316 SS

DESIGN INFORMATION
OVERALL LENGTH 10’-1”
WEIGHT 175 LB
PILOT QUANTITY 1

UTILITY CONSUMPTION
PURGE RATE(a) 130 SCFH
13 SCFH WITH AR-4

(a)
ANY GAS (AMBIENT STATE) THAT DOES NOT REACH
DEW POINT, SELF-IGNITE, OR CONTAIN OXYGEN
NOTE: (1) SCHEMATIC MAY NOT DEPICT ACTUAL DESIGN.
(2) WILL PROVIDE REDUCER TO MATCH CUSTOMER’S
TIE-IN POINT.

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 EEF-AR-4
AIRRESTOR PURGE REDUCTION DEVICE
MANUFACTURING SPECIFICATIONS
WELDING WQS AND WPR PER ASME SECTION IX
PAINT NONE REQUIRED

CONSTRUCTION MATERIAL
SECTION MATERIAL
AIRRESTOR 310 SS

DESIGN INFORMATION
INLET SIZE 4”
WEIGHT 3 LB

UTILITY CONSUMPTION
PURGE RATE(1) 13 SCFH
(1) ANY GAS (AMBIENT STATE) THAT DOES NOT REACH DEW POINT, SELF-IGNITE, OR CONTAIN OXYGEN
NOTE: SCHEMATIC MAY NOT DEPICT ACTUAL DESIGN.

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 JOHN ZINK WINDPROOF FLARE PILOT
MANUFACTURING SPECIFICATIONS
WELDING WPS AND PQR PER ASME SECTION IX
PAINT SPECIFICATION CARBON STEEL: SSPC-SP6 SURFACE PREPARATION
2 COATS HIGH TEMP. ALUMINUM, 1-2 MILS THICK
STAINLESS STEEL: NO COATINGS REQUIRED

NOZZLE INFORMATION
DESCRIPTION SIZE QUANTITY TYPE
PILOT GAS INLET 3/4” 1 PLAIN END
FFG IGNITION LINE 1” 1 PLAIN END
THERMOCOUPLE CONNECTION 3/4” 1 NPTF
MATERIALS OF CONSTRUCTION
PILOT TIP
310 SS
ASSEMBLY
FFG IGNITION LINE 310 SS
FUEL LINE 310 SS
UPPER BRACKET 310 SS
LOWER BRACKET 310 SS
MIXER HF ALLOY
STRAINER CS
DESIGN INFORMATION
HEAT RELEASE 50,000 BTU/HR
OVERALL LENGTH 8’-7”
WEIGHT 75 LB
ORIFICE SIZE #54 MTD
THERMOCOUPLE
K
TYPE
NUMBER OF
1
THERMOCOUPLES
STRAINER MESH 60/100
UTILITY CONSUMPTION PER PILOT
NAT. GAS DESIGN
50 SCFH
FLOW
PROPANE GAS
22 SCFH
DESIGN FLOW
NATURAL GAS
7 TO 20 PSIG (10 PSIG STANDARD)
PRESSURE RANGE
PROPANE
5 TO 15 PSIG (7 PSIG STANDARD)
PRESSURE RANGE
PERFORMANCE
WIND RESISTANCE 160+ MPH
RAIN RESISTANCE 30+” PER HOUR

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 MULTI-POINT INDAIR FLARE DATA SHEET NO:
54041
SPECIFICATIONS: Model KMI-12-6
PROCESS DATA
GAS STREAM HP Max Flow
FLOW MAXIMUM 175 mmscfd
FLOW MINIMUM PURGE
MOLECULAR WEIGHT 16.44 Cast INDAIR
TEMPERATURE 34 deg C I-12-VS Tips
INLET PRESSURE
36 Psig

Pilot
UTILITIES Nozzle
PILOT FUEL GAS 50 SCFH (per pilot)
PURGE GAS 240 SCFH

PILOTS
QUANTITY 2 TYPE WindProof
THERMOCOUPLES 1 TYPE Type K

DIMENSIONS (approx.)
HEIGHT 15' - 0" WIDTH TBA
WEIGHT

MATERIALS Flare
TULIP CASTING CK20 Body
BODY& ARMS SS 310
PILOT SS 310
PILOT NOZZLE SS 310 Pilot Inlet
LIFTING LUGS SS 310
NO. OF NOZZLES 6
SIZE OF NOZZLES WB Inspirator
TYPE OF NOZZLES 1-12 Assembly
PILOT MANIFOLD CS
Ignition Inlet
SURFACE FINISH / PAINT (carbon steel) Main Gas
SANDBLAST SP-6 Inlet
PRIMER CZ-11 2-3 mil
TOP COAT none -

NDE
RADIOGRAPHY 10 % spot radiography
RADIOGRAPHY none

TERMINAL POINTS
GAS INLET 24" Class 150 RFWN CS
PILOT INLET 1" Class 150 RFWN CS
IGNITION INLET 1" Class 150 RFWN CS

REMARKS
Picture is for reference only. Actual flare tip GA will be provided after award.

26
27
 HP Flare Tip
Flow vs Pressure Curve
200.00

180.00

160.00

140.00
Flow MMSCFD

120.00

100.00

80.00

60.00

40.00

20.00

0.00
0 5 10 15 20 25 30 35 40

Pressure psig

MW= 16.44 Temp= 35.0°C

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