OPM Book 1 Volume 15 HP and LP Flare System

Note:
This book only contains FSO operational standards

I made this book to help you get references in making operational standards.
Strictly prohibited for sale without the permission of the owner.
if you have questions please contact me at.
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TABLE OF CONTENTS
1.0 PURPOSE...................................................................................................................... 5
2.0 SCOPE........................................................................................................................... 5
3.0 REFERENCES............................................................................................................... 5
3.1 External References...................................................................................................5
3.2 Internal References....................................................................................................5
4.0 DEFINITIONS................................................................................................................. 6
5.0 RESPONSIBILITIES......................................................................................................6
6.0 PROCEDURE................................................................................................................. 6
6.1 Overview..................................................................................................................... 6
7.0 RELATED DOCUMENTS...............................................................................................7
8.0 HEALTH, SAFETY AND ENVIRONMENTAL CONSIDERATIONS................................7
8.1 HEALTH, SAFETY AND ENVIRONMENTAL precautions..........................................7
8.1.1 H2S....................................................................................................................... 7
8.1.2 Detection of H2S by Smell....................................................................................7
8.1.3 Health Effects....................................................................................................... 8
8.1.4 Before Entering Areas with Possible Hydrogen Sulfide.........................................8
9.0 PRE-START CHECKS...................................................................................................8
9.1 Pre-start conditions.....................................................................................................8
9.2 Valve Checklists......................................................................................................... 9
10.0 START-UP PROCEDURE............................................................................................10
10.1 Start-up HP Flare Pilots in Auto Mode with Electric Ignition System.........................10
10.2 Start-up HP Flare Pilots in Manual Mode with Electric Ignition System.....................11
10.3 Start-up HP Flare Pilots Using Flame Front Generator ignition system.....................13
10.4 Start-up LP Flare Pilots in Auto Mode with Electric Ignition System..........................14
10.5 Start-up LP Flare Pilots in Manual Mode with Electric Ignition System.....................15
10.6 Start-up LP Flare Pilots Using Flame Front Generator ignition system.....................17
11.0 NORMAL OPERATION, MONITOR AND WATCHKEEPING CHECKS.......................18
12.0 SHUTDOWN PROCEDURE.........................................................................................19
12.1 Emergency Shutdown...............................................................................................19
13.0 COLD FLARING.......................................................................................................... 19
13.1 Potential Flame out Case 1.......................................................................................19
13.2 Potential Flame out Case 2.......................................................................................19
Abbreviations
ACWL Aviation Control Warning Light

CRO Control Room Operator
DCS Distributed Control System
ESD Emergency Shutdown
F&G Fire and Gas
FI Flow Indicator
FPSO Floating Production Storage Offloading
HP High Pressure
HSE Health, Safety, Environment
ICSS Integrated Control Safety System
KOD Knock Out Drum
LIC Level Indicating Controller
LP Low Pressure
OIM Offshore Installation Manager
OPM Operation Procedure Manual
P&ID Piping and Instrumentation Diagram
PCV Pressure Control Valve
PG Pressure Gauge
PPE Personal Protective Equipment
PTW Permit to Work
TIC Temperature Indicating Controller
1.0 PURPOSE
This Operation Procedure Manual (OPM) provides detailed guidance on the safe and efficient
operation of the Flare System (HP/ LP) at the Company concerned.
2.0 SCOPE
This OPM procedure addresses start-up, operation and shutdown of the system, and includes
procedures on the supplementary operating tasks, which are the responsibility of the Shift
Operator.
All Operating personnel must be fully familiar with the content of this OPM prior to
commencing operation of the System.
This OPM does not supersede, nor does it relieve responsibility for compliance with any other
procedure(s) that may be relevant to the procedure. It should be used in conjunction with the
latest P&IDs, which are referenced as appropriate.
3.0 REFERENCES
3.1 EXTERNAL REFERENCES
Offshore Standard DNV-OS-E201 Oil and Gas Processing Systems
Note: Always refer to the most recent edition of the reference works listed above.
3.2 INTERNAL REFERENCES
Process Description
Process Control Narrative
Process Design Basis
Cause & Effect Matrix
P&ID – HP Flare Distribution
P&ID – HP Flare KOD and Pumps
P&ID – LP/ Acid Flare Distribution
P&ID – LP/ Acid Flare KOD and Pumps
P&ID – Flare Ignition System
General Arrangement HP & LP/ Acid Flare Tip
P&ID Flare Ignition System

Note: Always refer to the most recent edition of the reference works listed above.
4.0 DEFINITIONS
Asset Management & Operations
Designated Operating Company Contractually & legally responsible for Facility operations
and/ or maintenance.
5.0 RESPONSIBILITIES
Position/ Role/ Competency Profile Responsibility
 Ensures all personnel operate in the facility in

Offshore Installation Manager (OIM)
compliance with this procedure.
Supervisor  Ensure that the permit holder and work party
understand the requirement and safety control
measures of the issued work permits.
 Ensure that all requirements set forth in this
standard and procedure regarding to the
compliance of personnel transfer has been fulfilled.
Operator  At all times all appropriate Personnel Protective
Equipment (PPE) shall be worn and all tools and
equipment shall be inspected prior to use
6.0 PROCEDURE
6.1 OVERVIEW
Flare system on topsides is designed to collect, contain and safely dispose of fluids from the
process facilities during depressurization, emergency relief or minor release from blanket or
purge gas. Two (2) relief header systems are provided on the FPSO, i.e., the HP Flare
Header and the LP/ Acid Gas Flare Header.
The HP Flare Header is routed hydrocarbon relieved to the HP Flare KO Drum , to separates
any condensed liquids from gas prior to combustion at the Flare Tip. Then the collected liquid
from thanked is pumped by 2 x 100% HP Flare KOD Pumps to LP Separator or Slop oil
Tanks.
The LP/ Acid Flare Header is routed hydrocarbon relieved to the LP Flare KOD (xxxx), to
separates any condensed liquids from gas prior to combustion at the Flare Tip. Then the
collected liquid from the KOD is pumped by 2 x 100% LP Flare KOD Pumps (A/ B) to LP
Separator (xxxx) or Slop oil Tanks.
The Flare system package (xxxx) consists of HP Flare Tip and LP/ Acid Gas Flare Tip and a
common HP/ LP/ Acid Gas Flare Ignition package. HP & LP/ Acid Gas Flare tips are located
on the same Flare Stack with the flare tip capable of withstanding an internal deflagration.
The HP Flare Tip is a sonic tip in order to decrease heat radiation and LP Flare Tip is an open
pipe tip. Flare ignition system will be dual ignition system i.e. Flame Front Generator and
Electronic Spark ignition system. The ignition system is of high reliability and does not rely on
the use electric cables on the flare tower to ignite flare gases. The Flare ignition system has
Propane backup system for ignition system in case of fuel gas failure.
Assist gas (fuel gas) is used to increase the calorific value for complete burning when high
H2S gas is released from the process system. Flare headers will be purged with fuel gas, with
nitrogen as back-up in case of loss of fuel gas.
7.0 Related Documents
Note: xxxx-xxx denotes the Origin & Logic Code where the document is site-specific.
8.0 HEALTH, SAFETY AND ENVIRONMENTAL CONSIDERATIONS

In the execution of the subsequent procedures all permit to work, PPE and isolation
procedures required shall be followed.
If any doubt exists as to the correctness of valve positions or sequence of operations then
they should be discussed with the supervisor and approval sought from the Production
Superintendent to change the procedure. These changes shall then be captured on a
permanent basis by submitting them through the required document control procedures.
Specific requirements for HSE are given in each section of the procedures.
8.1 HEALTH, SAFETY AND ENVIRONMENTAL PRECAUTIONS

It is important that all personnel involved in the operation of this system, should be aware of
H2S.
WARNING! :
PERSONNEL SHOULD UNDER NO CIRCUMSTANCES CROSS THE FENCE LINE AND
ENTER THE STERILE AREA WHEN THE FLARES ARE LIT.
8.1.1 H2S
Hydrogen sulphide (H2S) is a colorless, flammable, extremely hazardous gas with a “rotten
egg” smell. It occurs naturally in crude petroleum and natural gas, and can be produced by
the breakdown of organic matter and human/ animal wastes (e.g., sewage). It is heavier than
air and can collect in low-lying and enclosed, poorly ventilated areas such as basements,
manholes, sewer lines and underground telephone/ electrical vaults.
8.1.2 Detection of H2S by Smell

 Can be smelled at low levels, but with continuous low level exposure or at higher
concentrations you lose your ability to smell the gas even though it is still present.
 At high concentrations – your ability to smell the gas can be lost instantly.
 DO NOT depend on your sense of smell for indicating the continuing presence of
this gas or for warning of hazardous concentrations.
8.1.3 Health Effects

Health effects vary with how long, and at what level, you are exposed. Asthmatics may be at
greater risk.
 Low concentrations – irritation of eyes, nose, throat, or respiratory system; effects can
be delayed.
 Moderate concentrations – more severe eye and respiratory effects, headache,
dizziness, nausea, coughing, vomiting and difficulty breathing.
 High concentrations – shock, convulsions, unable to breathe, coma, death; effects can
be extremely rapid (within a few breaths).
8.1.4 Before Entering Areas with Possible Hydrogen Sulfide

 The air needs to be tested for the presence and concentration of hydrogen sulfide by a
qualified person using test equipment. This individual also determines if fire/ explosion
precautions are necessary.
 If gas is present, the space should be ventilated.
 If the gas cannot be removed, use appropriate respiratory protection and any other
necessary personal protective equipment (PPE), rescue and communication equipment.
Atmospheres containing high concentrations (greater than 100 ppm) are considered
immediately dangerous to life and health (IDLH) and a self-contained breathing apparatus
(SCBA) is required.
 Do not drain any hydrocarbon liquids to the decks. If no drain is available, collect liquid
into an approved container, using appropriate grounding systems, PPE and dispose of it
properly.
9.0 PRE-START CHECKS

The following steps describe the pre-start checks prior to commencement start-up of flare
system.
9.1 PRE-START CONDITIONS
No. Action Authority Checks√
Ensure all outstanding permits on the fuel gas system have

1.
been closed out and returned to the Control Room
2. All drains, vents, purge and sample points are closed.
3. All instrument and level bridle drain valves are closed

All instrument isolation valves are open and all instrumentations
4.
are online.
Ensure all pipe work is complete and all plugs/ caps/ blanks etc.
5.
are fitted
All spades and spectacle blinds are in the correct position as
6.
per the Flare System P&IDs
Ensure that the F&G, ICSS and Safety Shutdown System are
7.
operational.
Ensure fuel gas is available from the gas processing facility for
8.
start-up of the flare system and dependent utilities
No. Action Authority Checks√
Confirm that the following Systems are in operation:

 Power Generation and Distribution System
 Instrument and Utility Air
9.
 Closed Drains
 Fuel gas system
 Nitrogen system
10. Aviation control warning light (ACWL) is blinking continuously.
11. All temporary defeats have been cleared.

Establish communication between all personnel involved in this
12.
procedure
9.2 VALVE CHECKLISTS
Valve Tag No. Valve Description Position
Refer to P&ID No. xxxxxx – P&ID HP Flare Distribution
Ball valve on inlet of purge fuel gas meter FI-6104 CLOSED

Ball valve on outlet of xxxx OPEN
NORMALLY
Bypass ball valve of xxxx
CLOSED
NORMALLY
Bypass globe valve of xxxx
CLOSED
Ball valve at downstream of nitrogen control valve xxxx CLOSED
Ball valve at upstream of xxxx OPEN
Ball valve at downstream of xxx OPEN
Ball valve on inlet of HP Flare Header CLOSED
Refer to P&ID No. xxxxx – P&ID LP/ Acid Flare KOD and Pumps
HP Flare KO Drum xxx inlet valves LOCKED OPEN

CAR SEAL
HP Flare KOD Pump xxx / B suction valves
OPEN
CAR SEAL
HP Flare KOD Pump xxxx A/ B discharge valves
OPEN
Refer to P&ID No. xxxxx – P&ID LP/ Acid Flare Distribution
Ball valve on inlet of purge fuel gas meter xxx CLOSED

Ball valve on outlet of xxxx OPEN
NORMALLY
Bypass ball valve of xxx
CLOSED
NORMALLY
Bypass globe valve of xxxx
CLOSED
Ball valve at downstream of nitrogen control valve xxxx OPEN
Ball valve at upstream of xxx OPEN
Ball valve at downstream of xxx OPEN
Ball valve on inlet of LP/ Acid Flare Header CLOSED
Refer to P&ID No. xxxxxx – P&ID LP/ Acid Flare KOD and Pumps
Valve Tag No. Valve Description Position
LP/ Acid Gas Flare KO Drum xxx inlet valves LOCKED OPEN
CAR SEAL
LP/ Acid Gas Flare KOD Pump xx A/ B suction valves
OPEN
CAR SEAL
LP/ Acid Gas Flare KOD Pump xx A/ B discharge valves
OPEN
Refer to P&ID No. xxxx – P&ID Flare Ignition System
Isolation valves of Fuel Gas control valve xxx CLOSED

NORMALLY
Bypass valves of Fuel Gas control valve xxx
CLOSED
Assist fuel gas valve to LP Flare Tip OPEN
Isolation valves of Fuel Gas meter xxx OPEN
NORMALLY
Bypass valves of Fuel Gas meter xxx
CLOSED
Propane Cylinder xx supply valves CLOSED
Valve on downstream of Propane control valve xxx CLOSED
Instrument air supply valve OPEN
10.0 START-UP PROCEDURE

The following procedure describes the start-up of the HP/ LP Acid Flare System after a plant
shut down for maintenance.
10.1 START-UP HP FLARE PILOTS IN AUTO MODE WITH ELECTRIC IGNITION SYSTEM
The following task describes the start-up of HP Flare Pilots using electric spark ignition
system as Primary Ignition System. If the AUTO MODE operation of HP Flare Electric Ignition
System is Malfunction or Failure, the control system will attempt to re-ignite the pilots. And if
re-ignition is Unsuccessful, Perform steps refer to Section 10.2 Start-up HP Flare Pilots in
MANUAL MODE with Electrical Ignition System or 10.3 Start-up HP Flare Pilots using Flame
Front Generator Ignition System.
No. Action/ Remarks Authority Checks√
Confirm the manual valves on flare system are aligned as per

1.
Valve Checklists.
Ensure that Level Indicating Controller xxx and Temperature
2. Indicating Controller xxxx HP Flare KO Drum xxxx are set in
AUTO MODE and correct set point.
Ensure HP Flare KOD Pumps xxx A/ B is set in AUTO MODE
and HP Flare KOD Pump A as LEAD Pump and KOD B as LAG
pump.
Note:
3. The LEAD Pump starts automatically when HP KOD high level
set point reaches at 450 mm, while a LAG Pump starts
automatically when high high level set point reaches at 550 mm
and Both Pumps stops on reaching low low level at 300 mm
simultaneously.
4. Purges the HP flare headers with required rate and adjust flow
accordingly by opening appropriate purge valve supply as
follows:
 If fuel gas purges selected open fuel gas purge valve
xxxx.
 If nitrogen supply purges select open nitrogen supply
valve xxxx.
Confirm fuel gas supply is available and fuel gas supply
pressure is within normal operating range.
Note:
5.
If fuel gas supply is not available, ensure there are sufficient
propane cylinders xxxx and obtain supervisor approval to
switch fuel gas supply with Propane.
Turn the HP Flare PILOT IGNITION MANUAL/ OFF/ ON switch
6.
to the ON position at Local Control Panel.
Open the valves controlling the pilot gas supply for all pilots and
allow sufficient time for the pilot gas to reach the pilot heads
(approx. 1 minute for every hundred linear feet of pipe distance
from valve train to pilot head).
7. Note:
The pilot gas valve train consists of a Fuel Gas valve train and
Propane valve train. Open only the appropriate valve train and
always keep the unused one closed. Open valve right before
getting ready to light pilots to avoid unnecessary fuel waste.
Turn the HP Flare POWER OFF/ ON switch to the ON position.
8. The POWER ON indicator will illuminate indicating the system
has been energized.
Within several minutes, confirm HP Flare PILOTS ON lamps on
local control panel are lit to ensure the pilot has been ignited.
Note:
9.
If the pilot lamps are not lit and a pilot failure alarm and Reset
the failed pilot’s controls by turning the MAN/ OFF/ ON selector
switch to OFF and then back ON to restart ignition.
10. Confirm visually that the HP pilots are lit.
Once the pilots have been ignited, the system is ready to
11.
accept waste gas flow.
10.2 START-UP HP FLARE PILOTS IN MANUAL MODE WITH ELECTRIC IGNITION SYSTEM
The following task describes the start-up of HP Flare Pilots using electric spark ignition
system in MANUAL MODE due to AUTO MODE operation of HP Flare Electric Ignition
System is Malfunction or Failure. And if MANUALMODE ignition is Unsuccessful, Perform
steps refer to Section 10.3 Start-up HP Flare Pilots using Flame Front Generator Ignition
System.

1.
Valve Checklists.
Ensure that Level Indicating Controller xxxx and Temperature
2. Indicating Controller TIC-1702 of HP Flare KO Drum xxxx are
set in AUTO MODE and correct set point.
3. Ensure HP Flare KOD Pumps xxx / B is set in AUTO MODE
pump.
Note:
The LEAD Pump starts automatically when HP KOD high level

simultaneously.
Purges the HP flare headers with required rate and adjust flow
follows:
4.  If fuel gas purges selected open fuel gas purge valve
xxx .
valve xxxx .
Note:
5.
6.
to the MANUAL position at Local Control Panel.
7. Note:
has been energized.
Press and hold the HP Flare PILOT #1 MANUAL SPARK
pushbutton. After 30seconds or verified pilot ignition, release
the pushbutton.
Note:
9.
This creates a spark by the pilot burner element installed on the
flare tip. And If the pilot does not ignite on the first attempt, wait
for one minute and repeat step above until the pilot is
successfully ignited.
Within several minutes, confirm HP Flare PILOT #1 ON lamp at
Note:
10.
The time delay is a result of the time required for the pilot
thermocouple to reach the minimum temperature set point.
Keep in mind that the time delay may vary.
After the pilot has been ignited, switch HPPILOT #1 MANUAL/
11. OFF/ ON selector switch to MANUAL position at local control
panel.
12. Repeat steps 8 through 11 to ignite PILOTS #2 and # 3.
14.
10.3 START-UP HP FLARE PILOTS USING FLAME FRONT GENERATOR IGNITION SYSTEM
The following task describes the start-up of HP Flare Pilots using Flame Front Generator
Ignition System due to AUTO MODE and MANUAL operation of HP Flare Electric Ignition
System is Malfunction or Failure.

1.
Valve Checklists.
2. Indicating Controller xxxx of HP Flare KO Drum xxxx are set in
Ensure HP Flare KOD Pumps xxxx / B is set in AUTO MODE
pump.
Note:
3. The LEAD Pump starts automatically when HP KOD high level
simultaneously.
Purges the HP flare headers with required rate and adjust flow
follows:
xxxx .
valve xxxx.
pressure on xxxx is within normal operating range.
Note:
5.
Ensure instrument air supply is available to combustion
6. chamber and air supply pressure on xxxx is within normal
operating range.
7.
has been energized.
9. Verify that the pilot fuel gas supply valves are open.
Align air and gas to FFG lines by opening valves on the ignition
gas valve train and valve on pilot gas line.
Note:
10. The pilot gas valve train consists of a Fuel Gas valve train and
Allow sufficient time for the air gas mixture to completely fill the
ignition line from the valve train to the Pilot head (approximately
11.
1 minute for every hundred linear feet of pipe distance from
valve train to pilot head).
Quickly press then release the FFG MANUAL SPARK

pushbutton to produce a spark in the ignition chamber.
Note:
12.
This will ignite the gas in the ignition chamber. The fireball
produced will be pushed down the ignition line by the still
flowing air/ gas mixture.
Within several minutes, confirm HP Flare PILOT ON lamps at
Note:
13.
After the pilots has been ignited, close valves gas supply and
15.
utility air supply to FFG igniter lines.
16.
10.4 START-UP LP FLARE PILOTS IN AUTO MODE WITH ELECTRIC IGNITION SYSTEM
The following task describes the start-up of LP Flare Pilots using electric spark ignition system
as Primary Ignition System. If the AUTO MODE operation of LP Flare Electric Ignition System
is Malfunction or Failure, the control system will attempt to re-ignite the pilots. And if re-
ignition is Unsuccessful, Perform steps refer to Section 10.5 Start-up LP Flare Pilots in
MANUAL MODE with Electrical Ignition System or 10.6 Start-up LP Flare Pilots using Flame
Front Generator Ignition System.

1.
Valve Checklists.
2. Indicating Controller xxxx of LP Flare KO Drum xxxx are set in
Ensure LP Flare KOD Pumps xxxx / B is set in AUTO MODE
and LP Flare KOD Pump A as LEAD Pump and KOD B as LAG
pump.
Note:
3. The LEAD Pump starts automatically when LP KOD high level
simultaneously.
Purges the LP flare headers with required rate and adjust flow
follows:
xxxx
valve xxxx
5. Confirm fuel gas supply is available and fuel gas supply
Note:

Turn the LP Flare PILOT IGNITION MANUAL/ OFF/ ON switch
6.
to the ON position at Local Control Panel.
7. Note:
Turn the LP Flare POWER OFF/ ON switch to the ON position.
has been energized.
Within several minutes, confirm LP Flare PILOTS ON lamps on
Note:
9.
If the pilot lamps are not lit and a pilot failure alarm and Reset
the failed pilot’s controls by turning the MAN/ OFF/ ON selector
switch to OFF and then back ON to restart ignition.
10. Confirm visually that the LP pilots are lit.
11.
10.5 START-UP LP FLARE PILOTS IN MANUAL MODE WITH ELECTRIC IGNITION SYSTEM
The following task describes the start-up of LP Flare Pilots using electric spark ignition system
in MANUAL MODE due to AUTO MODE operation of LP Flare Electric Ignition System is
Malfunction or Failure. And if MANUAL MODE ignition is Unsuccessful, Perform steps refer to
Section 9.3 Start-up LP Flare Pilots using Flame Front Generator Ignition System.

1.
Valve Checklists.
2. Indicating Controller xxxx of HP Flare KO Drum 20-VN-1710
are set in AUTO MODE and correct set point.
Ensure LP Flare KOD Pumps xxxx A/ B is set in AUTO MODE
pump.
Note:
simultaneously.
4. Purges the LP flare headers with required rate and adjust flow
follows:
 If fuel gas purges selected open fuel gas purge valve
XXX

valve xxxx
Note:
5.
6.
7. Note:
has been energized.
Press and hold help Flare PILOT #1 MANUAL SPARK
pushbutton. After 30seconds or verified pilot ignition, release
the pushbutton.
Note:
9.
This creates a spark by the pilot burner element installed on the
flare tip. And If the pilot does not ignite on the first attempt, wait
for one minute and repeat step above until the pilot is
successfully ignited.
Within several minutes, confirm LP Flare PILOT #1 ON lamp at
Note:
10.
After the pilot has been ignited, switch LP PILOT #1 MANUAL/
11. OFF/ ON selector switch to MANUAL position at local control
panel.
12. Repeat steps 8 through 11 to ignite LP PILOTS #2 and # 3.
14.
10.6 START-UP LP FLARE PILOTS USING FLAME FRONT GENERATOR IGNITION SYSTEM
The following task describes the start-up of LP Flare Pilots using Flame Front Generator
Ignition System due to AUTO MODE and MANUAL operation of LP Flare Electric Ignition
System is Malfunction or Failure.

1.
Valve Checklists.
2. Indicating Controller xxxx of LP Flare KO Drum xxxx are set in
Ensure HP Flare KOD Pumps xxx / B is set in AUTO MODE
pump.
Note:
simultaneously.
Purges the LP flare headers with required rate and adjust flow
follows:
xxx.
valve xxxx.
pressure on xxxx is within normal operating range.
Note:
5.
propane cylinders xxx and obtain supervisor approval to switch
fuel gas supply with Propane.
Ensure instrument air supply is available to combustion
6. chamber and air supply pressure on xxx is within normal
operating range.
7.
has been energized.
9. Verify that the pilot fuel gas supply valves are open.
Align air and gas to FFG lines by opening valves on the ignition
gas valve train and valve on pilot gas line.
Note:
10. The pilot gas valve train consists of a Fuel Gas valve train and
Allow sufficient time for the air gas mixture to completely fill the
ignition line from the valve train to the Pilot head (approximately
11.
1 minute for every hundred linear feet of pipe distance from
valve train to pilot head).
Quickly press then release the FFG MANUAL SPARK

pushbutton to produce a spark in the ignition chamber.
Note:
12.
This will ignite the gas in the ignition chamber. The fireball
produced will be pushed down the ignition line by the still
flowing air/ gas mixture.
Within several minutes, confirm LP Flare PILOT ON lamps at
Note:
13.
After the pilots has been ignited, close valves gas supply and
15.
utility air supply to FFG igniter lines.
16.
11.0 NORMAL OPERATION, MONITOR AND WATCHKEEPING CHECKS

Normal operation of this system consists primarily of monitoring the process conditions and
operation of the various control loops, visual inspection of piping and equipment should be
conducted as part of normal Operator rounds.
Operator observations are important for early detection of potential problems to limit the
negative impact of process upsets, equipment malfunctions, and shutdowns.
MONITOR the overall operation ensuring that levels, pressures,

flow, temperatures, and other variables are within their normal
1.
operating parameters. Ensure that the minimum and maximum
design limits are not exceeded
Regularly walk the system to visually inspect for leaks, damage,
and any system abnormality. REPORT any leaks, malfunctions
2.
or irregular operating occurrences to the Team Leader as soon
as possible
Regularly liaise with the Control Room Operator to crosscheck
the accuracy of the instrumentation, i.e. the comparison
3.
between the local instrument and the transmitted value in the
DCS
Visually inspect the condition of the system equipment and pipe
4. work for corrosion/ deterioration including the security of pipe
hangers/ fittings
12.0 SHUTDOWN PROCEDURE
This procedure provides a safe and efficient means of shutting down the HP and LP/ Acid
Flare System when the system has been running normally and is need to be shut down as
part of a planned, total shutdown of the process facilities.
Action/ Remarks Authority Checks√
1. Cross-refer to OPM Book 1 Volume 10 Fuel Gas Treatment.

Before the process is shutdown, ensure that the liquid levels in the HP
2. and LP Flare KO drums are lowered as low as possible to the
Separator or Slop Tank.
When fuel gas is no longer required Shutdown fuel gas supply refer to
3.
OPM Book 1 Volume 10 Fuel Gas Treatment.
4. Close fuel gas valves supply to HP and LP Flare System
5. Confirm that Flare System planned shutdown is now complete.
12.1 EMERGENCY SHUTDOWN

The shutdown of the HP and LP/ Acid Flare System can be initiated automatically by the
shutdown system or manually by the operation of an ESD pushbutton in the process area or
control room, which are clearly identified.
The cause and effect logic attached to each specific trip is illustrated in detail in the Cause
and Effect Matrix.
13.0 COLD FLARING

Cold Flaring is not envisaged on board due to the high toxicity and flammability of the gas
condensate. There are however, two scenarios for a potential Cold Flaring (Flame Out)
situation.
13.1 POTENTIAL FLAME OUT CASE 1

The first scenario assumes that there is not enough gas being purged from the process due to very
low flow production rates. In this case, operators would have to increase the purge gas to
flare by reducing sales gas and thus increasing the back-pressure on vessels such as the HP
Separator and TEG Contactor etc. This would cause more gas through the PCV’s to the flare
header enabling re-ignition of the flare. We do not envisage this scenario ever happening, as
if the production from the WHP was to decrease, sales gas would be reduced automatically.
13.2 POTENTIAL FLAME OUT CASE 2

The second scenario would be caused by production from WHP shut down and then restart in
particularly high wind conditions whereby insufficient gas may be available to give a steady-
state flame at the flare tip. In this scenario, high winds could potentially extinguish the flare.
The flare would then have to be maintained via the export gas buy back valve, by which we
would open the valve to allow export gas back onto the FPSO to maintain fuel gas pressure.

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OPM Book 1 Volume 15 HP and LP Flare System

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Note:

This book only contains FSO operational standards

ACWL Aviation Control Warning Light

3.1 EXTERNAL REFERENCES

Offshore Standard DNV-OS-E201 Oil and Gas Processing Systems

3.2 INTERNAL REFERENCES

Process Control Narrative

Process Design Basis

Cause & Effect Matrix

P&ID – HP Flare Distribution

P&ID – HP Flare KOD and Pumps

P&ID – LP/ Acid Flare Distribution

P&ID – LP/ Acid Flare KOD and Pumps

P&ID – Flare Ignition System

General Arrangement HP & LP/ Acid Flare Tip

P&ID Flare Ignition System

Position/ Role/ Competency Profile Responsibility

 Ensures all personnel operate in the facility in

8.0 HEALTH, SAFETY AND ENVIRONMENTAL CONSIDERATIONS

8.1 HEALTH, SAFETY AND ENVIRONMENTAL PRECAUTIONS

8.1.2 Detection of H2S by Smell

8.1.3 Health Effects

8.1.4 Before Entering Areas with Possible Hydrogen Sulfide

9.0 PRE-START CHECKS

9.1 PRE-START CONDITIONS

No. Action Authority Checks√

Ensure all outstanding permits on the fuel gas system have

3. All instrument and level bridle drain valves are closed

Confirm that the following Systems are in operation:

11. All temporary defeats have been cleared.

9.2 VALVE CHECKLISTS

Valve Tag No. Valve Description Position

Refer to P&ID No. xxxxxx – P&ID HP Flare Distribution

Ball valve on inlet of purge fuel gas meter FI-6104 CLOSED

HP Flare KO Drum xxx inlet valves LOCKED OPEN

Refer to P&ID No. xxxxx – P&ID LP/ Acid Flare Distribution

Ball valve on inlet of purge fuel gas meter xxx CLOSED

Refer to P&ID No. xxxx – P&ID Flare Ignition System

Isolation valves of Fuel Gas control valve xxx CLOSED

10.0 START-UP PROCEDURE

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

automatically when high high level set point reaches at 550 mm

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

Quickly press then release the FFG MANUAL SPARK

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

propane cylinders xxxx and obtain supervisor approval to

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

 If nitrogen supply purges select open nitrogen supply

No. Action/ Remarks Authority Checks√

Confirm the manual valves on flare system are aligned as per

Quickly press then release the FFG MANUAL SPARK

11.0 NORMAL OPERATION, MONITOR AND WATCHKEEPING CHECKS

No. Action/ Remarks Authority Checks√

MONITOR the overall operation ensuring that levels, pressures,

Action/ Remarks Authority Checks√

1. Cross-refer to OPM Book 1 Volume 10 Fuel Gas Treatment.

5. Confirm that Flare System planned shutdown is now complete.