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Updated
Standard Operation Manual For
Mubarraz Flare System
Feb. 2013
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GAS FLARING:
1- Excess gas / tank vent gas and acid gas can be flared through two flare stacks, high
pressure and low pressure in case of s/d or equipments maintenance.

2- The gas from settling tanks, pump run tanks vent in normal case goes to the tank vent gas
blower and acid gas from Amine units goes to C-200. But in case if gas blower or C-200
S/D or maintenance the gas goes to flare.

3- Both the high pressure and low pressure flares are equipped with a pilot flare, which has a
constant supply of sweet gas from the amine unit.
HIGH PRESSURE FLARE:
1- Excess gas from V-509 / V-790 / V-795 and pressure safety valves goes to the high
pressure flare.

2- Acid gas from Amine units in normal case goes to C-200 , but in case if C-200 S/D or
under maintenance , gas goes to flare.

3- The liquid that is released or entrained in the gas is knocked out in the high pressure flare
K.O. Drum (V-1220). The flare drum is provided with an overflow line to a concrete pool to
avoid any liquids going to the flare. This overflow line is equipped with a siphon breaker
which prevents the vessel from completely emptying out. There should always be a liquid
level in the k.o.drum to avoid gas escaping through the liquid overflow line to the concrete
pool.

4- A k.o drum pump, P-220, pumps out liquid from the k.o. drum to the degassing boot inlet.
The pump runs automatically, being activated by level switch, LSHL-1220 and LSLL-1220
(High and Low Levels). The k.o drum is provided with high and low liquid level alarm

5- The gas from the k.o drum goes to the flare stack through a water seal drum.
LOW PRESSURE FLARE:
1- The gas from the settling tanks, pump run tanks vents , goes to the Tank vent gas blower, but
in case if gas blower S/D or under maintenance, gas goes to flare. Any liquids that are
released or entrained in the gas are knocked out in the low pressure flare k.o drum, V-1210.

2- The k.o. drum is provided with overflow line to a concrete pool to avoid any liquid going to the
flare stack. This overflow line is equipped with a siphon breaker which prevents the vessel
from completely emptying out.

3- There should always be a liquid level in the k.o. drum to avoid gas escaping through the
overflow line to the concrete pool.

4- The k.o. drum has a pump, P-210, which pumps out liquid, and returns it to the degassing
boot inlet. The pump runs automatically, and is activated by level switches, LSH / LSL-1210
(High and Low levels). K.o. drum also has high and low liquid level alarms, LAH / LAL - 1210.

5- The gas from the K.O. drum goes to the flare stack through a water seal drum.
* PILOT IGNITER:
A flare pilot igniter is used to ignite the two flare pilots during start-up. Fuel gas and air are
supplied separately to the flame front generator, through flow and pressure regulators. They
are mixed together, and a spark introduced in a combustion chamber. This spark travels to
the pilot tip, where ignition takes place.
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GAS SYSTEM AND FLARE
* The gas is separated from the oil at different stages of the process. The gas that is
separated in the degassing boots and strippers, goes to the gas recovery compressor, then
to the amine unit, for sweetening. The separated gas is called sour gas, and contains acid
gases(hydrogen sulphide and carbon dioxide). These gases are removed in the amine unit.

* The sweet gas that is produced in the amine unit, is used as fuel gas for the heaters,
strippers, reboilers, flare pilots and incinerator, also as supply gas for the gas turbine
generators (G.T.G.). Excess gas from V-509 / 790 / 795 and from pressure safety valves
(PSVs) goes to the high pressure flare line. Gas from the settling tanks, pump run tanks goes
to tank vent gas blower and acid gas from the amine units goes to C-200. but in case if gas
blower or C-200 S/D or maintenance the gas goes to flare. Any liquids that are released or
entrained in the gas, are knocked out in the high and low pressure flare K.O. drums, and
pumped back to the degassing boot. The gas then goes to the flare stacks.

* Gas that is separated from the liquids in the oil separator D-103, goes to the fuel gas K.O.
drums V-125/135, and is used as fuel gas for the heaters H-120/130.

* The gas flow from West Mubarraz goes to the fuel gas slug catcher V-602, then to the fuel
gas interstage scrubber V-795 and before going to compressors K-101 it goes to the gas
holder, then to the fuel gas drain separator V-1050, for use as supply gas for the G.T.G.

* Any liquids from V-795, D-103 and V-1160 are returned to the oil inlet line to degassing
boot. There is also a return line to the oil strippers.

* A flare pilot igniter is used to ignite the pilot flame. Sweet gas and air are supplied
separately to the flame front generator, mixed together, and a spark introduced in a
combustion chamber. This spark travels to the pilot tip, where ignition takes place.

* Should the ignition system fail, then a 'Vary' pistol will be used.
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GAS BALANCE

GAS PRODUCTION:
* The oil which comes from the wells is accompanied with gas.

* This gas is separated from the oil at different stages in the process (inlet separators,
degassing boots and settling tanks.)

* The components of the gas depend upon the gas/oil separating conditions, and is called
sour gas.
GAS PROCESSING:
* The produced sour gas contains acid gases (hydrogen sulphide H 2S and carbon dioxide
CO2) and is treated in the amine unit for removal of these gases.
GAS CONSUMPTION:
* The sweet gas which is produced in the amine unit is used as fuel gas for the oil heaters, oil
strippers, reboilers, flare pilots and incinerator.
* Heaters, H-120/130 Approx. 300 ~ 350 MSCFD
-

* Reboilers, H-640/780 Approx. 80 MSCFD

-

* Reboiler, H-3640 Approx. 260 MSCFD

-

* Strippers Approx. 1000 MSCFD

-

* The separated gas from the degassing boots and strippers goes to the fuel gas inlet
scrubber V790, into the gas recovery compressor, then to the process gas scrubber
V- 1160 and onto the amine units for sweetening.
GAS COMPOSITION:
The composition of the gas is dependent on the gas / liquid separating conditions, of
temperature and pressure.
- Constant temperature + high pressure = light gas
- Constant temperature + low pressure = heavy gas

Average gas composition of :-

Inlet Separator Degassing Boot
Name Symbol Vol % Vol %
1- Methane CH4 38.5 8.60
2- Ethane C2H6 21.7 19.3
3- Propane C3H8 18.3 32.3
4- Iso-Butane C4H10 3.10 7.50
5- Normal-Butane C4H10 6.00 16.0
6- Iso-Pentane C5H12 1.50 4.50
7- Normal Pentane C5H12 1.60 4.70
8- Hydrogen Sulphide H2S 3.00 3.90
9- Carbon Dioxide CO2 6.10 3.10
10- Nitrogen N2 0.20 0.10
11- Molecular Weight - 32.04 44.39
12- Specific Gravity - 1.11 1.54
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CHECK POINTS DURING OPERATION :

1- Liquid level in - High Pressure Flare K.O. Drum 50%

K.O. Drums of gauge glass.
- Low Pressure Flare K.O. Drum 30%
of gauge glass.

2- - Seal drums
Drain Condensate
- Pilot Flare Gas Line

3- Check Pump
- Normally in "Auto" position.
Switch Modes

4- Check high level

- Fill float chamber with water
alarm

5- Check the pump - Pressure

manually for a - Mechanical Seal
few seconds. - Abnormal sounds

6- Check concrete
- For traces of oil
water pool

7- Check pilot igniter.