Saes F 007

Engineering Standard
SAES-F-007 9 January 2018

System Design Criteria of Flares
Document Responsibility: Flare Systems Design Standards Committee
Contents
1 Scope ..................................................................... 2
2 Conflicts and Deviations ......................................... 2
3 References ............................................................. 2
4 Definitions .............................................................. 5
5 Responsibilities ...................................................... 8
6 System Design ....................................................... 8
7 Mechanical and Structural Design ........................ 31
8 Flare and Relief System Design Development ..... 33
9 Maintenance and Repairs .................................... 38
Revision Summary ...................................................... 38
Previous Issue: 1 January 2018 Next Planned Update: 9 January 2021

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Contact: Khaldi, Muhammad M. (khalmm0q) on phone +966-13-8808084
©Saudi Aramco 2018. All rights reserved.

Document Responsibility: Flare Systems Design Standards Committee SAES-F-007
Issue Date: 9 January 2018
Next Planned Update: 9 January 2021 System Design Criteria of Flares
1 Scope
1.1 This standard covers the minimum mandatory requirements for the system
design and installation of flares used to burn combustible gaseous and liquid
discharges in onshore and offshore installations and encompasses equipment and
devices downstream of outlets of relief/depressurizing valves up to and
including flare tips.
1.2 This standard also includes the system design of equipment used to separate
liquid from discharges, where applicable.
1.3 This standard does not include design requirements for temporary flares (such as
well flares) as well as incinerators, thermal oxidizers, and hydrocarbon vent
stacks or equipment used for the burning of combustibles on ships.
1.4 This entire standard may be attached to and made a part of purchase orders.
1.5 This standard covers the design requirements of new flares and the repair of
existing flares.
2 Conflicts and Deviations
2.1 Any conflict between this document and other Applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed in writing to
the EK&RD Coordinator.
2.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302, waiver of a Mandatory Saudi Aramco Engineering
Requirements.
3 References
The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement
SAEP-354 High Integrity Protective Systems Design
Requirements
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SAEP-360 Project Planning Guidelines

SAEP-400 Guidelines for Facility Flaring Minimization Plan
SAEP-405 Flare System Purge Gas Optimization
Saudi Aramco Engineering Standards

SAES-A-102 Ambient Air Quality and Source Emissions Standards
SAES-A-105 Noise Control
SAES-A-112 Meteorological and Seismic Design Data
SAES-A-400 Industrial Drainage Systems
SAES-A-401 Closed Drain Systems (CDS)
SAES-B-006 Fireproofing for Plants
SAES-B-055 Plant Layout
SAES-B-058 Emergency Shutdown, Isolation and Depressuring
SAES-B-063 Aviation Obstruction Marking and Lighting
SAES-D-001 Design Criteria of Pressure Vessels
SAES-H-001 Coating Selection & Application Requirements for
Industrial Plants & Equipment
SAES-H-101V Approved Saudi Aramco Data Sheets - Paints and
Coatings
SAES-L-350 Construction of Plant Piping
SAES-N-001 Basic Criteria, Industrial Insulation
SAES-N-100 Refractory Systems
SAES-N-110 Installation Requirements - Castable Refractories
SAES-T-555 Video Surveillance Systems
Saudi Aramco Materials System Specifications

32-SAMSS-004 Manufacture of Pressure Vessels
32-SAMSS-022 Manufacture of Components for Flare Systems
Saudi Aramco Standard Drawings

AE-036549 Minimum Instrumentations for Separator Vessels
AE-036550 Branch Connections to Flare Headers
Saudi Aramco: Company General Use

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Saudi Aramco Best Practices

SABP-Z-069 Design Guidelines for Flare Gas Recovery Systems
SABP-Z-079 Equipment Overpressure Scenario Identification
Saudi Aramco Engineering Report

SAER-5317 Relief System Evaluation
Saudi Aramco Forms and Data Sheets

SA-7305 Equipment Noise Data Sheet
SA-9543 Data Sheet - Pressure Relief Device-Process
Selection Basis for Flare Systems
SA-9544 Flare Loading Summary
SA-9547 Flare System, Flare Tip Data Sheet
SA-9548 Specification Sheet - Flares
SA-9549 Flare System, Flare Knockout/Seal Drum Data
Sheet
SA-9561 Flare System-Process Data Sheet
SA-9562 Flare System-Utility Data Sheet
3.2 Industry Codes and Standards
American Petroleum Institute

ANSI/API STD 521 Pressure-Relieving and Depressuring Systems,
Sixth Edition, 2014
API STD 526 Flanged Steel Safety-Relief Valves,
Seventh Edition, September 2017
ANSI/API STD 537 Flare Details for General Refinery and
Petrochemical Service,
Third Edition, March 2017
International Society for Measurement and Control

ISA-84.00.01-2004 Functional Safety: Safety Instrumented Systems
for the Process Industry Sector (2004)
- Parts 1, 2, & 3
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4 Definitions
Acid Gas: A gas containing H2S and/or CO2, with a lower heating value of
18,600 kJ/scm (500 BTU/scf) or less.
AIV: Acoustically Induced Vibration
Burn Pit: A pit where the flared fluids enter through a horizontal tip. The fluids are
flared as they enter the pit. Usually, a burn pit is used to flare a stream containing
liquids.
CFMS: Corporate Flare Monitoring System
Design Engineer: The Engineering Company responsible for specifying on the data
sheets the process and mechanical design requirements for flare systems.
Dry Gas Seal: A device used to reduce the amount of purge gas required to maintain a
safe level of oxygen upstream of the seal.
Elevated Flare: Refer to SAES-B-055 Section S-2.
Enclosed Ground Flare: An enclosed ground flare's burners are inside a shell that is
internally insulated. This shell reduces noise, luminosity, heat radiation and provides
wind protection. A high pressure drop nozzle is usually adequate to provide the mixing
necessary for smokeless operation. However, multi-jet, multi-tip, and multi-stage are
utilized for these flares.
Flare Gas Recovery System (FGRS): A system to recover the daily normal
continuous flare gas, and direct it back to the processing facility using a compressor.
Flare Manufacturer: The company responsible for the manufacture of complete flare
systems, or components of flare systems, in accordance with 32-SAMSS-022.
Flaring Minimization Plan (FMP): A comprehensive Site Specific Flaring

Minimization Plan (FMP) includes a consistent and focused approach to monitor,
classify, report and control flaring in the facility by implementation of identified flare
mitigation measures.
Real-Time Flaring Monitoring System (FMS): Real-Time Flaring Monitoring

System (FMS) will allow a Saudi Aramco facility the ability to monitor the source wise
flaring losses on a periodic and real time basis. The system leverages existing
automation technologies (DCS & PI) and available real-time measurements of control
valves (PCV) openings to quantify the flared quantities in terms of standard cubic feet.
FFG: Flame Front Generator

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Flare System: Includes all piping, valves, pressure vessels and devices downstream of
relief/depressuring outlet block valves, to and including flare tip(s).
Flash Back Protection System: A system to prevent a flame front from traveling back
to the upstream piping and equipment. Normally, flash back is caused when air
(oxygen) inadvertently introduced into the flare system.
Front End Loading (FEL): Front End Loading (FEL) is a ‘Stage and Gate’ process to
facilitate project planning definition and decision-making that defines the activities to
be performed during each Stage / Phase and the decisions to be made at each Gate.
Refer to SAEP-360 for more information.
High Integrity Protective System (HIPS): High Integrity Protective System is an

instrumented shut down system that meets the minimum requirement of an
ISA S84.00.01, SIL-3 system.
High Pressure Air Assist System (HPAAS): High Pressure Air Assist System for
smoke suppression of flares. A system to achieve smokeless flare operation utilizing
compressed air.
Incinerator: A furnace in which a combustible material is burned and in which the

residence time and burning zone temperature are controlled.
Liquid Blowdown Drum: A vessel which retains liquid from a liquid closed drain
and/or from safety relief valves in liquid service and discharges evolved vapor to the
relief system.
Liquid Seal Drum: A horizontal or vertical vessel in which a liquid (usually water)
level is used to maintain a positive pressure in the relief system upstream of the seal
drum, under conditions of no flow. Also, used for staging between flares or a flare gas
recovery system and a flare.
Mach Number: It is defined as the ratio of a fluid’s velocity, measured relative to

some obstacle or geometric figure, divided by the speed of sound (sonic velocity)
through the fluid. It can also be defined as actual fluid velocity divided by velocity at
which sound waves propagate through the fluid at associated temperature.
Main Flare Header: A main line (normally off-plot) which receives vapor or gas
discharge from the unit headers or unit knockout drums and terminates at a flare or the
base of the flare stack. The main flare knockout drum and/or liquid seal drum is in the
main flare header unless they are located at the base of the flare stack.
Main Flare Knockout Drum: A vessel, located in either a main flare header or at the
base of a flare stack, which removes liquids that condense in or are carried over into the
flare system.
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Maximum Continuous Flow: A flow which may be continuous for periods from a few
minutes to days or weeks. An example is flaring associated gas. (The maximum
continuous flow in a unit relief header, in a multi-unit plant, may not be the flow that
contributes to the maximum continuous flow in the main flare header).
Maximum Instantaneous Flow: This flow is due to depressurization and/or an

emergency relief. It is the maximum sum of the loads resulting from any single
contingency considered for emergency relief and/or emergency shutdown requiring
depressurization, and the plant(s) or unit(s) feed gas flow associated with that relief or
shutdown situation.
Multi-tip Multistage Flare: A flare made up of a number of stages, where each stage
usually has more than one tip. The tips are of proprietary designs and are designed to
burn smokeless and with low radiation due to the high velocity flow from each tip.
It is usually staged by means of control valves and rupture devices (as a safety backup
to each control valve). It may be elevated or low level.
Multi Point (Multi Tip) Ground Flares (MGF): Non-elevated” flare system that
mainly include multi-tip flare systems adopting multi flare tip nozzles, staging of flared
gas based on pressure and provided with a radiation shield if required. The multi-point
or sometimes called multi-tip flares have their burning points deigned to ensure efficient
and 100% smoke free operation at various design capacities.”
Normal Continuous Flow: The flow due to combustible purge gas and other small
continuous sources and normal venting.
Commentary Note:
The value of normal continuous flow shall also include the leakage rate during normal
plant operation, and be estimated based on the rate after five or ten years of operation.
Rates are typically between 0.05 and 0.5% of the maximum instantaneous flow which
must be quantified based on historical data of similar plant.
P&ID: Piping and Instrument Diagram
PFD: Process Flow Diagram
Pipe Type Flare Tip: A flare tip which is constructed from a pipe or thin-walled
hollow cylinder (sometimes called a barrel), with addition of pilots and flame retention
devices for flame stability. The flare gas passes through the barrel.
Relief System: A system of valves and piping used during an emergency to rapidly
reduce pressure in process equipment.
Saudi Aramco Engineer: The Chairman of Flare Systems Design Standards Committee.

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Shock Chilling Effect: The temperature of a fluid causing shock chilling.

Shock chilling is defined as the rapid decrease in temperature of a component caused by
a sudden flow of fluid colder than -20°C (-4°F) and at a temperature lower than the
initial temperature of the component by 40°C (72°F) regardless of pressure.
SIL-3: Safety Integrity Level 3 (SIL-3) refers to the ISA S84.00.01 definition of the
probability of failure on demand for a Level 3 safety system. The probability of failure
on demand for a Level 3 system is specified as 10-³ to 10-4.
Temporary Flares: Flare systems used on temporary basis such as well flares,
construction flares or non-permanent flares for pipelines depressuring.
Unit Knockout Drum: A vessel, located in a unit or close to the boundaries of a unit
which retains liquid carryover and/or condensate discharged from a unit relief header
and discharges the vapor to a main flare header.
Unit Relief Header: A pressure relief line associated with a particular unit.
Unit headers collect the vapors/liquids from the various safety relief and depressuring
valve discharge lines for discharge to a unit knockout drum or to a main flare header.
5 Responsibilities
5.1 The Design Engineer is responsible for specifying the process and mechanical
design requirements and completing the data sheets in accordance with this
standard.
5.2 The Flare Manufacturer is responsible for the manufacture of flare system
components, which includes the complete sizing, mechanical design, code and
structural calculations, supply of all materials, fabrication, non-destructive
examination, inspection, testing, surface preparation, and preparation for
shipment, in accordance with the completed data sheets and 32-SAMSS-022.
6 System Design
6.1 Design Considerations
6.1.1 General
In order to ensure plant safety, flare systems shall be continuously

available and capable of its intended performance through all operating-
plant emergency conditions including a site-wide general power failure.
Flare system and flare-tip type selection shall be based on an overall

technical, environmental and economic evaluation. The Saudi Aramco
Engineer together with the proponent and Facilities Planning Department
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shall be involved in the initial scope development, determination of

smokeless capacity and selection of a flare system. The flare system
shall be supplied from an approved Saudi Aramco flare manufacturer.
6.1.2 Reliability
The flare and related mechanical components shall be designed to

operate and properly perform for the specified service conditions for a
minimum of 5 years without the need for an outage of the operating
facility unless otherwise specified by the user. Flare availability and
reliability are strongly dependent, however, on the design of the related
mechanical equipment and on its installation, commissioning,
maintenance, and operation.
To enhance the reliability of the larger diameter flare tips greater than
48 inches, a staged flare system is required. The staging concept might
be also economically attractive in terms of life cycle cost considering
utility use such as purge gas and assist steam/air as applicable in addition
to prolonging tip life. In a staged flare combination, a flare gas recovery
system (FGRS) shall constitute the first stage. The FGRS system shall
not be used as the 1st stage for 2nd stage flare tips larger than 48” and a
small duty flare shall be used in this case. Use of duty flares can be
exempted by Saudi Aramco Engineer in case the 2nd stage flare utilize a
smokeless or semi-smokeless tip design.
Commentary Note:
It has been experienced in Saudi Aramco facilities that the large single
flare tips experience frequent damage due to flame impingement at the
daily normal continuous flaring rates. Staged flaring is expected to
considerably reduce the flare tip damage and hence enhances
operations reliability and reduces maintenance cost.
6.1.3 Smokeless Design for New Plants
For facilities with normal continuous flaring rates less than 1 MMSCFD,
a smokeless flare tip design shall be used if an FGRS is not installed.
The smokeless technology selection shall be used based on economics
and available utilities. The in-house High Pressure Air Assist System
(HPAAS) shall be preferentially utilized to achieve smokeless flaring for
Gas-Oil Separation Plants (GOSPS) and similar facilities with normal
continuous flaring rates less than 1 MMSCFD unless other options are
more economically viable.
For emergency or non-routine flaring purposes, full or partial smokeless

capacity can be used based on user requirements or site specific

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environmental regulations. HP flares in offshore production platforms or

at onshore gas handling and NGL facilities shall incorporate 100%
smokeless technology over the full range of capacity whenever
technically feasible. In some cases, smokeless flares might be also used
to minimize radiation exposure for plot space limited locations.
For locations where heavy hydrocarbons might be expected to be flared
like refineries for example, at least 10% smokeless capacity of the
maximum emergency load shall be incorporated. Selection and design of
smokeless technologies for all types of flares shall be approved by Saudi
Aramco Engineer.
6.1.4 Flare Gas Recovery Systems
6.1.4.1 For new facilities with normal continuous flaring rates equal or
greater than 1 MMSCFD, a Flare Gas Recovery system
(FGRS) shall be installed.
Commentary Note:
The need to install an FGRS for facilities with normal

continuous flaring rates equal or more than 1 MMSCFD can be
exempted based on practicality or technical limitations as
approved by Saudi Aramco Engineer. Examples include very
dirty or low value gasses where the recovered gas has no
practical use. This exemption does not include treatment of
recovered sour gas if needed.
6.1.4.2 For existing facilities, the requirements to install an FGRS will

based on the Flare Minimization Plan (FMP) recommendations
for each facility along with SAES-A-102 requirements.
6.1.4.3 For facilities with normal continuous flaring rates less than 1
MMSCFD, a flare gas recovery system (FGRS) can be
installed based on economics and site specific environmental
regulations.
6.1.4.4 For guidance on selection, design and application of FGRS

systems, refer to SABP-Z-069.
6.1.5 Flare Minimization for Existing Facilities
For all existing facilities, the proponent shall complete a site specific
Flare Minimization Plan (FMP) as stipulated in SAEP-400 and
Appendix I of SAES-A-102. The proponent shall implement all the
technically and operationally feasible mitigation measures identified by
the site specific FMP to reduce the normal continuous flaring rates to
less than 1 MMSCFD. A Flare Gas Recovery System (FGRS) could be
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considered only after the implementation of all the relevant site specific
FMP mitigation measures.
6.1.6 Flare Minimization for New Facilities
For all new facilities, global design and operational best practices as
applicable for the project for flare minimization shall be incorporated.
The facilities shall also incorporate a real time Corporate Flare/Burn Pit
Monitoring System (CFMS) during the design phase.
6.2 Flare System Components
6.2.1 A flare system shall consist of (but is not restricted to) the following
basic components:
1) Safety relief and/or depressuring valve discharge piping
2) Main and unit relief headers
3) Main flare knockout drum(s) and pump out facilities (except for
burn pits)
4) Flare stack(s) for elevated flare(s)].
5) Burn pit suitably lined with refractory, surrounded by a protective
dike (for burn pits)
6) Flare tip(s)
7) Pilots
8) Ignition system
9) Purge Gas Connections
10) Flashback protection system
11) Monitoring panel
12) Flare gas flowmeters for low and high flaring ranges, and purge gas
flow meter(s)
6.2.2 The need for the following components in a flare system shall be
evaluated based on individual system requirements:
1) Seal (liquid or dry)
2) Isolation valves (in the relief piping)
3) Unit knockout Drum(s) and pump-out facilities
4) Liquid seal drum(s)
5) Unit isolation valves and spectacle blinds and purge connections.
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6) Access platform for maintenance and operations.

7) Other Auxiliary Components as stipulated in the purchase order or
specified by the vendor, refer to API STD 537 Section 4.11 for
examples of these components
6.3 Flare Gas Loads
6.3.1 A flare system shall be designed to handle normal continuous flows,

maximum continuous flows, and maximum instantaneous flows.
The base case for flare design is the conventional system, and shall not
take into account instrumented safety shutdown systems.
6.3.2 For HIPS applications, refer to SAEP-354.
6.3.3 Potential tip damage due to operation at normal continuous flows shall
be considered in evaluating the different flare systems and flare tips.
6.4 Design Temperature
6.4.1 The operating temperature shall be the temperature of gas/liquid being

handled, taking into account the temperature change across valves.
6.4.2 A minimum margin of 30°C (54°F) shall be added to the maximum

operating temperature to determine the design temperature.
6.4.3 The design temperature of piping, vessels, and attachments required for
flare systems shall include consideration for shock chilling effects.
Consider the gas expansion and/or liquid vaporization for light
hydrocarbon or other materials which may lead to lower temperature
conditions in a flare system, requiring a choice of material other than that
which would be selected on the basis of maximum flare design
temperature.
6.4.4 In all cases the materials of construction shall be suitable for the full
range of design metal temperatures.
6.5 Design Pressure
6.5.1 The design pressure of a flare system shall be based on the maximum
back pressure developed during flaring.
6.5.2 Under no circumstance shall the design pressure be less than 50 psig
(345 kPag).
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6.5.3 The Saudi Aramco Engineer shall specify:

1) The limiting process design pressure at the inlet of process unit
knockout drums for special high pressure flare systems.
2) Any exceptions for low pressure systems.
6.6 Horizontal Spacing and Height
6.6.1 The spacing of flares from other equipment and facilities shall meet the
minimum requirements to satisfy the following constraints:
1) Basic spacing
2) Thermal radiation
3) Air quality
4) Noise
6.6.2 Optimum Flare Location
6.6.2.1 For optimum location of new flares, normal wind direction

must be considered. Flares shall be located in the prevailing
crosswind direction of the facilities in order to prevent the flare
from igniting any gases released from the plant. See Figure 1
for clarification.
6.6.2.2 For existing flares evaluation or expansion of existing flares

falling in the downwind direction, a risk assessment study
evaluating the ignition potential and flammability analysis for
gasses released from the process and ignited by the flare should
be conducted in line with SAES-B-055 spacing requirements or
if deemed necessary by LPD. Such a study should be approved
by LPD.

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Notes:
1. Consider the wind rose data from EPD to select the appropriate flare location.
2. Proposals for 45° upwind flare locations from plants require LPD/P&CSD approval.
These proposals will be considered only in limited cases where cross wind locations are not
available and when supported with wind rose data analysis and quantitative risk assessment
studies.
Figure 1 – Clarification of Acceptable Flare Locations for Onshore Facilities
6.6.3 The thermal radiation, gas dispersion, air pollution and noise constraints
shall be met by a combination of horizontal spacing and height.
6.6.4 The minimum horizontal spacing requirements for flares shall be in

accordance with SAES-B-055.
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6.7 Radiation
6.7.1 The location of flare systems shall include the effects of flare heat
radiation on personnel. The maximum onshore permissible flare
radiation levels for personnel exposure shall be as given in Table 1.
6.7.2 For offshore facilities, radiation shields are used more often than onshore
due to the space constraints unique to offshore which also provide more
means for escape. The maximum radiation limits for personnel shall be
as follows (excluding solar radiation):
1) For maximum instantaneous flaring, 2,000 BTU/hr-ft² (6.3 KW/m²)
2) For maximum continuous flaring, 1,000 BTU/hr-ft² (3.2 KW/m²)
3) In a position where continuous manning may be required
1,000 BTU/hr-ft² (3.2 kW/m²)
Table 1 - Maximum Onshore Flare Radiation Intensities

for Personnel Exposure, Excluding Solar Radiation
Flare Radiation Conditions
kW/m² BTU/hr-ft² (Refer to Notes 1, 2, and 3)
Areas where personnel can be continuously
1.6 500
exposed.
Areas where personnel access shall be restricted
3.2 1,000
(for onshore facilities).
Areas where exposures up to several minutes may
4.7 1,500
be required, with appropriate clothing.
Areas where exposures of up to 30 seconds may be
6.3 2,000
required, with appropriate clothing.
Areas where personnel have access, e.g., at grade
9.4 3,000 below the flare, or on a service platform on a nearby
tower. Exposure must be limited to a few seconds.
Notes:
1) Personnel can be continuously exposed in an area in which the total radiation when
flaring would be 500 BTU/hr-ft² (1.6 kW/m²) from the flare, plus solar radiation.
2) On vessels, towers or other elevated structures where rapid escape is not possible,
ladders must be provided on the side away from the flare, so that structures may
provide some shielding when the flare radiation intensity is greater than
2,000 BTU/hr-ft² (6.3 kW/m²).
3) Facilities adjacent to flares shall be evaluated for the acceptable radiation exposure.
6.7.3 The maximum radiation intensity, excluding solar radiation, for

equipment/structures shall be 3,500 BTU/hr-ft² (11.0 kW/m²), except for
flare headers for which 5,000 BTU/hr-ft² (15.7 kW/m²) is acceptable.
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6.7.4 Lower radiation limits may be required for equipment/structures

sensitive to high temperatures.
6.7.5 For radiation calculations, a wind speed of 22 mph (32 ft/s) shall be
used. When considering temperature sensitive equipment/structures a
range of wind speeds must be used to estimate the maximum
temperature.
6.7.6 The preferred method of radiation calculation for pipe type flares is in
accordance with Brzustowski and Sommer's method as outlined in
Annex C of API STD 521. Other methods specified in API STD 521
may be used especially for burn pits and flame length calculations
based on the conditions laid out in API STD 521. The Flare
Manufacturer shall determine and guarantee the radiation levels for all
flares to meet Saudi Aramco Requirements. The fraction of heat
radiated “F factor” shall be determined based on the flare gas
composition. In all cases the value of fraction of energy radiated shall
not be less than 0.15.
6.7.7 For the maintenance of a flare tip while other flares are operating,
locate flare stacks such that the radiation at flare tip maintenance
platforms from any adjacent flares will not exceed 1,000 BTU/hr-ft²
(3.2 kW/m²) for maximum continuous flaring and 1,500 BTU/hr-ft²
(4.7 kW/m²) for maximum instantaneous flaring, excluding solar
radiation. For multiple demountable derrick flare stacks sharing the
same derrick, radiation limits for adjacent flares may not be applicable.
However, radiation shields to enable maintenance for demountable
derrick flares should be provided.
6.7.8 When more than one elevated flare and/or ground flare are located in a
common flare area, the maximum permissible radiation levels specified
above are applicable to combined radiation from all flare systems in
the area. However, if standby flares are provided, only one of two
mutually replaceable units shall be taken into account for
determination of the combined radiation levels.
6.7.9 The sizing and location of flares in a common flare area shall ensure
the possibility of maintenance of standby units when other units are
operating. The radiation level at a maintenance point shall not exceed
1,500 BTU/hr-ft² (4.7 kW/m²).
6.7.10 For burn pit flares, the last 100 m (328 ft) of flare headers and auxiliary
piping shall be buried underground or protected by radiation shields.
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6.7.11 For burn pit flares, ignition panels should be protected with a radiation
shield.
6.8 Air Quality
Ambient air quality constraints, as specified in SAES-A-102, shall apply, during

flaring, to the air dispersion of pollutants and the resulting ambient air quality
levels outside of the recognized or official boundary of the facility.
6.9 Noise Level
Allowable noise levels shall be determined by the Design Engineer in

accordance with SAES-A-105. Allowable noise levels shall be specified on
Saudi Aramco Form SA-7305.
6.10 Smokeless Flaring for Reduced Visible Emissions
6.10.1 Flares shall be designed with a smokeless capability sufficient to meet

the opacity constraints of SAES-A-102.
6.10.2 Smokeless design shall be in accordance to paragraph 6.1.3 of this

standard.
6.10.3 Flares which are installed with one or more air blowers shall be
capable of burning flare gas without blowers in operation. The use of
two speed motors shall be considered. The tripping of blowers shall
not cause flame out.
6.10.4 If a steam-assisted flare is selected, the Design Engineer shall

determine the steam requirements for the flare, and consider these in
the overall plant steam requirements.
6.11 Acid Gas Flaring
6.11.1 For pipe-type flare tips 36 inch (914 mm) and smaller, the minimum
acceptable lower heating value shall be 500 BTU/scf (18,600 kJ/scm).
If the heating value of the gas is below this value, additional combustible
gas shall be added so that the overall heating value meets the minimum
required above. Assist combustible gas shall be added into the acid gas
flare header far enough upstream to ensure good mixing.
6.11.2 For pipe-type flare tips 914 mm (36 in) and smaller, the tip exit
velocity (for acid gas plus assist combustible gas) shall be limited to a
maximum of 145 ft/s (45 m/s).

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6.11.3 For pipe-type flare tips larger than 914 mm (36 in) that do not use
assist fluid for smokeless operation, lower heating values or higher
velocities may be used if desired for economic reasons, with the
recognition that there is not the same assurance of stable burning as for
the conditions in 6.11.1 and 6.11.2. The flare tip manufacturer's
recommended (based on assisted gas and acid gas compositions)
minimum heat content versus maximum tip velocity relationship
should be used to determine the limiting values. In all cases the lower
limit of minimum heat content used for design shall be a lower heating
value of 350 BTU/scf (13,000 kJ/scm). All flares in this category shall
be reviewed by the proponent and the Saudi Aramco Engineer.
6.11.4 The use of proprietary flare tips that are especially designed for
burning low heat content gases shall be reviewed with the Saudi
Aramco Engineer.
6.11.5 The designer shall consider the possibility of solids deposition in an

acid gas flare system, and design the system to handle such solids as
may form.
6.12 Offshore Flaring
6.12.1 Manned platform complexes shall be provided with a flare that is

located on a separate structure remote from other platforms and joined
to other platforms by a bridge mounted relief header with a personnel
access way.
6.12.2 Preference shall be given in offshore un-manned platforms to boom

type mounted flares on the same structure or using an extension bridge.
The decision for using boom flares will be based on radiation and
dispersion analysis as well as flare capacity. Maximum flare capacity
for boom flares will be based on manufacturer input, flare system
constructability, and maintainability.
6.12.2 The flare tip direction or the firing angle in boom flares shall be to the
vertical direction.
6.12.3 For design of offshore flares, refer to API STD 537 Annex-D unless
otherwise specified in this standard.
6.13 Burn Pit Flares
6.13.1 Refer to SAES-A-102 on the usage and installation of burn pits.
Page 18 of 38
Exception:
Except for remote areas or exclusively industrial locations, where there

are essentially no spacing limitations, avoid burn pit flares.
Additionally, for some applications or semi-remote areas like flaring of
on-shore gas wells or pipelines, a horizontal flare or burn pit may be
required to handle liquid slugs without the need to install a KO Drum in
such remote areas. Provide burn pit flares when specifically requested
by the Saudi Aramco Engineer, and approved by the Saudi Aramco
Environmental Protection Department Manager.
6.13.2 If a burn pit is initially allowed based on exceptions provided above,

the final decision for installing and locating the burn pit will based on
radiation analysis, dispersion analysis and ignition potential for
process units releases as specified in paragraph 6.6.2.2 above and as
applicable. If a burn pit cannot be installed or location is not
acceptable for safety or environmental reasons; then, an elevated flare
shall be installed.
6.13.3 Where burn pits are allowed as per SAES-A-102, a liquid recovery
system shall be considered where feasible before sending the liquids
to the flare.
6.13.4 Multipoint Ground Flares
6.13.4.1 Saudi Aramco Engineer approval is required for use of

Multipoint Ground Flares or Enclosed Ground Flares.
6.13.4.2 Multipoint Ground Flares (MGF) tips are not classified as

short flares. MGF is considered as special type of flare
specifically designed using pressure staging principle and
providing highly efficient smokeless burning of flared gas
in addition to the radiation shielding provided.
Multi-burner flares are capable of smokeless combustion
at high flow rates with lower radiation levels which can in
some cases reduce plot space required for the flare
system. Refer to API STD 521 Section 5.7.4.1 and
API STD 537 Section A.1.5.3 for design of MGFs.
6.13.4.3 There are some considerations that need to be taken into

account when using MGFs during design and selection
over other types of flares. In addition to high cost,
dispersion analysis results of the flared streams especially
during flame-out condition affecting safety, health, or
environmental aspects should be considered for decision
making for selecting MGFs. Moreover, igniting potential

Page 19 of 38
of process vents or leaks should be also evaluated as per

paragraph 6.6.2.2 above. Another major consideration for
selecting MGF’s is reliability and maintainability as it
would be normally difficult to perform maintenance on a
specific part or stage of the flare inside the radiation
shield while the flare is running. The situation can be
more aggravated for sour and non-clean service when
some sections of the MGF would need to be isolated
during failure resulting in reduced capacity or unit
shutdown. As such, sparing philosophy should be
carefully evaluated if these types of flares are to be used.
Use of MGF is normally more advantageous for clean and
no-sour service.
6.14 Relief System Piping
6.14.1 Relief system piping shall be designed taking into consideration all
factors noted in API STD 521 unless otherwise specified in this
standard.
6.14.2 Header Segregation
6.14.2.1 Disposal system design including relief piping should

assess the requirement to segregate flare headers and
relief streams on the basis of material design, pressure,
temperature, fluid composition/physical properties in
addition to plugging potential when incompatible fluids
are mixed.
6.14.2.2 Cold fluids should be completely segregated from

water-wet fluids to prevent ice/hydrate formation.
Complete segregation of cold reliefs will require a
dedicated cold flare system to be provided in order to
address safe disposal of cold reliefs in terms of ice
formation in flare headers or freezing of knockout drum
or water seal fluids. Saudi Aramco Engineer approval is
required for installation of partially segregated cold
reliefs.
6.14.2 Relief lines shall be sized to ensure that back pressures developed
during flaring do not affect the flowing capacity of safety relief valves,
depressuring valves or pressure control valves that discharge into a
flare system. Consideration must be given to separate high and low
pressure flare systems instead of combined large high and low
pressures in order to minimize header sizes. Saudi Aramco Engineer
Page 20 of 38
approval is required for flare headers and flare tips larger than 48 in
(1219 mm) diameter.
6.14.3 Relief Piping and Tip Velocities
6.14.3.1 For new flare systems, the velocities in the tail pipes shall
not exceed 0.7 Mach. The velocities in the flare headers
and subheaders shall not exceed 0.5 Mach. For standard
new flare tips, the tip exit velocity shall not exceed
0.5 Mach. For high pressure (HP) flare tips that operate
at sonic or subsonic conditions, the tip exit velocity shall
be per Flare Tip Vendor recommendations.
6.14.3.2 The velocities for retrofit/revamp designs of existing

systems, can be allowed to increase slightly from given
thresholds above if certain design parameters are met and
based on consultations with flare vendor. Approval from
Saudi Aramco Engineer is required for deviation from
these targets.
6.14.4 Relief system piping shall be evaluated for acoustically induced

vibration (AIV) as per SAES-L-310 and SAER-5317 as well as
potential vibration from all sources, including dead-leg effects, slug
flows, shock loading and shock waves, wave refraction and rarefaction,
turbulence generated in the flare systems and relief valve “chattering.”
Commentary Note:
SAER-5317 contains empirical formulas resulting from field tests of

acoustic vibrations resulting from pressure drops across control valves.
These formulas may be used as reference for the evaluation of
acoustical vibration due to high sound levels in flare systems.
6.14.5 All piping (including headers between flare knockout drums and flares)
shall be self-draining into unit and/or flare knockout drums.
A minimum slope of ¼-inch in 10 feet (21 millimeters per 10 meters)
is required for all relief and flare piping.
6.14.6 Liquid pockets must be avoided. However, if pockets are unavoidable;

then, the pockets shall be provided with either a drum with automatic
disposal to the main flare line or pump-away capacity. Disposal of the
liquid to a lower elevation sump via liquid disposal control valves (or
liquid seal systems) is an acceptable alternative to pump-out facilities.
The flare header downstream of the sump/drum shall be designed for
slug flow.

Page 21 of 38
6.14.7 Laterals for pressure relief valves, depressuring valves and pressure
control valves shall enter the flare header from above and at an oblique
angle to the header. Reference Standard Drawing AE-036550.
In some cases, for existing systems, where a shutdown is not tolerable
and a 90 degree hot tap is required, detailed stress analysis in addition
to AIV analysis shall be conducted and approved by CSD before
allowing 90 degree connections. In this case, written confirmation
from operating facility organization that a shutdown is not feasible in
addition to Saudi Aramco Engineer approval is required.
6.14.8 Headers shall be at least the same size as the laterals, and preferably
shall be at least one pipe size larger.
6.14.9 If a flare system serves more than one unit, a block valve and spectacle
blind at the unit plot limits are required to allow the unit to be taken out
of service for turnarounds without having to take down all units
connected to the flare system. Provide a 50 mm (2 in) gate valve with
a blind flange for vent connection on the unit side of this isolation
valve for purging the unit flare header prior to the unit startup.
6.14.10 When isolation valves are required in the relief piping, they shall be
provided with locked open or car-sealed open and painted orange.
6.14.11 Header piping must be adequately supported. If liquid can be

introduced at the same time that vapor is flowing into the system, the
potential for slug flow must be considered. If slug flow can occur,
piping bends must be supported for slug flow, or local knock-out
drums shall be added.
6.14.12 Header piping must be designed to allow for thermal growth during
releases. The maximum heat radiation for long flaring durations shall
be used to determine the hot spot temperatures of the exposed parts of
the flare header to be considered for designing the thermal expansion
loops in the flare header at the hot spot places.
If slug flow cannot be eliminated, both the requirement of 6.14.10 and

this paragraph shall be satisfied.
Commentary Note:
Designs that allow for thermal growth often are in conflict with providing
the rigid support required to resist slugs flow.
6.14.13 Block valves used for flare systems shall be installed such that valve
stems are oriented 45° below horizontal and shall not pose an
obstruction to normal personnel access in the walkway.
Page 22 of 38
6.15 Knockout Drums
6.15.1 Knockout drums may be designed to incorporate the function of a

liquid seal drum. However, combination drums, in which the knockout
and seal functions are in the same compartment, shall only be used in
those systems where carryover is not expected because of the process
or because of upstream liquid knockout drums.
6.15.2 A liquid/water seal drum shall be designed to minimize the

accumulation of hydrocarbon liquid.
6.15.3 Knockout drums shall not be designed to incorporate the function of a

liquid blowdown drum for closed drain system. The CDS drum of the
closed drain system in accordance to SAES-A-400 and SAES-A-401
may be used to serve safety relief valves in liquid service provided that
there is no negative impact on the closed drain system or the allowable
back pressures for the relief valves.
6.15.4 The sizing and design of a gravity separation (knockout) drum shall be
based on the method of API STD 521, sections 5.7.9 and 5.9
respectively unless specifically mentioned in this standard.
6.15.5 The maximum design liquid level for horizontal unit knockout drums
and for those horizontal main flare knockout drums not in series with
unit knockout drums shall be 50% of the drum diameter. Main flare
knockout drums in series with unit knockout drums may have design
levels up to 80% of the drum diameter.
6.15.6 Knockout drums shall have sufficient capacity to ensure residence time
in excess of particle drop-out time based on the drop-out velocity
required to remove particles larger than 400 microns.
6.15.7 The hold-up capacity of liquid in knockout drums, due to emergency

releases, shall be sized for a minimum release of 20 minutes duration
with no pump-out. Liquid hold-up is normally defined between High
Liquid Level (HLL) and High High Liquid Level (HHLL).
Consideration shall be made for vapor condensation in flare lines
during cold weather.
6.15.8 Knockout drums shall not include demister pads or other devices prone
to fouling. Vessels of proprietary design that include non-fouling
internals to minimize vessel sizes for liquid separation may be used.
6.15.9 Consider providing each unit knockout drum with an internal liquid seal
if discharging direct to a flare stack without an off-plot knockout drum.

Page 23 of 38
6.15.10 The need for a unit knockout drum and pump-out facilities located
above ground on each process unit, or group of units when two or more
units are grouped together and are to be shutdown together, shall be
evaluated.
6.15.11 Provide a main flare knockout drum (on the common flare line) close
to the flare stack for any of the following cases:
1) Flare line serves more than one operating unit.
2) Distance from process unit to flare stack exceeds 200 m (656 ft).
3) Condensation rate in flare lines is sufficient to make liquid
drainback from stack to on plot knockout drum impractical.
6.15.12 Flare knockout drums and pump-out facilities shall be located above
ground.
6.15.13 Select the location of main flare knockout drums to ensure personnel
working on equipment will not be subjected to a heat intensity
(excluding solar radiation) higher than 1,500 BTU/hr-ft² (4.7 kW/m²)
under design flaring conditions.
6.15.14 The distance from the main flare knockout drum to the base of the flare
shall not exceed 100 m (328 ft). This can be exempted in some cases
for spacing and other requirements provided that the designer will
conduct hydraulic analysis to make sure back pressures and PZV
capacities are acceptable. Additionally, the designer should conduct
condensation calculations to verify if additional liquid KO
Drums/pump-out capacities and heat tracing are required.
6.15.15 Each drum shall be equipped with two automatically operated pumps,
one on primary stand-by, one on secondary stand-by. Disposal of the
liquid to a lower elevation sump via liquid disposal control valves (or
liquid seal systems) is an acceptable alternative.
6.15.16 The minimum required capacity of each pump/line shall be based on

pumping out or draining the total drum contents from the maximum
accumulated liquid level to low liquid level in two hours.
6.15.17 If both pumps are motor driven, each motor shall be supplied from a
separate (physically separated) double-ended (secondary selective)
switchgear lineups and the normal feed for each motor shall be from a
different source of incoming power (i.e., different transmission lines).
Where separate sources of incoming power are not available, one
motor shall be fed from a generator that is either on-line continuously
Page 24 of 38
or capable of being automatically started and put on line within one

minute. A diesel engine to drive the pump is an acceptable alternative
to the generator and electric motor driven pump.
6.15.18 The minimum instrumentation requirements on each drum are local

pressure gauge, level gauge, level switches to start/stop pumps, and
high and low level alarms with remote indications. See Standard
Drawing AE-036549.
6.15.19 The high-high and low-low level alarms should be entirely independent
from the start/stop switches and their vessel connections. There shall
be remote indication of the operating status of each pump. Remote
indications of the high and low level alarms and status of each pump
shall be in a constantly attended location.
6.16 Flare Tips
6.16.1 Flare tips shall maintain a stable flame over the entire operating range
and shall minimize flare tip and auxiliaries damage at low relief rates
or daily continuous flow rates to the flare tip.
6.16.2 The velocity of vapors at the flare tip shall be (both for the maximum
instantaneous and normal continuous flaring) within the bounds that
allow for stable flame performance and proper combustion of the
material being flared.
6.16.3 The effect of normal continuous daily flaring, maximum continuous

flaring, maximum instantaneous flaring and instantaneous flow
changes within these flaring rates, with a sustained wind velocity from
zero to maximum design wind speed shall be included during design
evaluation.
6.16.4 Flare tips shall be designed to minimize flame impingement on the

outside or the inside of the tip and on any part of the support structure
regardless of gas flow rate, wind speed or wind direction.
6.16.5 For maintenance purposes, means shall be provided for access to and
lowering of the flare tip of elevated flares. Access shall also be provided
to the flare tip of ground flares and the manways of elevated flares.
6.16.6 Pipe-type flares shall employ a retention device to minimize flame lift-
off and blow-out. Proprietary tip designs, which achieve the same
objectives, may be used.

Page 25 of 38
6.16.7 Multi-tip, multi-stage flares shall be designed to minimize air

ingression. The need for inert purging of multi-tip multi-stage flares
shall be evaluated.
6.16.8 Single tip flare tips shall be flanged to allow removal for repairs.
Headers to individual stages of multi-tip, multi-stage flares shall be
flanged where necessary to allow inspection and cleaning.
6.16.9 The mechanical design, fabrication, materials and inspection of flare

tips and ancillaries connected to the flare tip, including pilots, barrels,
steam piping, steam jets, and nozzles where applicable, shall be in
accordance with 32-SAMSS-022.
6.16.10 Refractory shall be in accordance with SAES-N-100 “Refractory

Systems.” When outside refractory is specified, inside refractory must
also be specified.
6.17 Flare Stacks
6.17.1 Flare stacks shall be designed to drain to main flare knockout drums or
liquid seal.
6.17.2 Aviation obstruction lighting/marking shall be provided if required by

SAES-B-063.
6.17.3 A hanger system shall be used that will allow the top-most set of lights
to be lowered away from the tip when the flare is in operation.
6.17.4 A minimum 762 mm (30 in) diameter manway at the base of the stack
shall be provided for inspection and maintenance. In cases where the
diameter of the stack is too small to accommodate a 762 mm (30 in)
minimum inside diameter manway, the largest size manway down to
457 mm (18 in) or inspection openings for smaller sizes shall be
specified. Additional manway(s) shall be provided for inspection and
cleaning of internal components of the flare stack as needed such as the
inside portions of integral seal drums. The minimum sizes shall be in
accordance with the design Codes. All manways shall comply with the
requirements of SAES-D-001.
6.17.5 Elevated flare stacks can be self-supported, guy-wired or derrick

supported. For design of elevated flare stacks refer to API STD 521
Section 5.7.4.2 and API STD 537 Section A.1.2.1 unless otherwise
specified in this standard or in 32-SAMSS-022 specification.
Page 26 of 38
6.18 Pilots
6.18.1 Continuous pilots shall be required and shall be designed to ignite the
flare gas over the entire operating range of flares and wind speeds.
6.18.2 Pilot lines downstream of fuel gas filter to flare tip shall be
manufactured from 316 stainless steel.
6.18.3 Pilots and upper sections of pilot gas lines shall be constructed of
materials selected in accordance with paragraph 6.16.9.
6.18.4 Pilot Gas Conditioning and Redundancy
6.18.4.1 Pilot gas systems shall be designed to supply clean, dry, and
solids-free gas. Gas flows shall be assured under any single
contingency, including plant startup or during shutdown.
6.18.4.2 To achieve the proper pilot gas condition, filtration, heat

tracing and knock-out drums might be required as
applicable. In some cases, if the gas is normally clean and
coming off a KO drum upstream, a liquid collection boot
along with Y-type strainer in addition to heat tracing might
be sufficient to make sure the gas is liquid free without
installing an additional filter or KO drum.
6.18.4.3 Redundant fuel gas supplies should be provided for non-

maintenance flares for large process facilities such as
Refineries and Gas Plants in addition to some critical
remote areas like offshore or on-shore gas facilities.
6.18.4.4 Pilot gas redundancy in offshore production platforms can

be achieved through use of conditioned raw gas together
with dedicated Propane Cylinders. Conditioning of raw gas
is required through liquid removal via knock-out drum,
filtration and heat tracing.
6.18.5 In facilities where production trap gas must be used, aspirators shall be
located at or near grade for maintenance accessibility.
6.18.6 Pilot detection systems should be reliable and redundant for major non-
maintenance flares. The main pilot detection system should be using
Thermocouples. Back-up pilot detection systems can use Ionization
and Acoustic Systems as applicable and recommend by vendor.
A flame-out alarm and separate indication for each pilot shall be
included. The indication shall be in a constantly attended area.

Page 27 of 38
For operating flares in major process facilities, consider using grade

mounted infrared detector for monitoring of the main flame on
elevated flares. If steam/air control is used for assisted flares;
then, infrared detectors shall be used. CCTV camera with Zoom-in
capability can be additionally used to monitor the condition of the main
flame. For CCTV design and use, refer to SAES-T-555.
6.18.7 Thermocouples shall be located in a thermowell inside pilot heads to

protect against flame impingement. Retractable thermocouples shall
be installed for operating flares in new facilities. Pilot flame-out shall
be indicated if a thermocouple fails.
6.18.8 Each pilot shall be provided with a thermocouple. Each thermocouple

shall be dual-element type. One element of each thermocouple shall be
used, with the other terminated at the grade junction box and available
as a spare.
6.18.9 The minimum number of pilots shall be in accordance with the

Table 2. The flare tip manufacturer should specify additional pilots if
he deems necessary.
6.19 Ignition Systems
6.19.1 Refer to API STD 537 Section 4.8 on pilot ignition systems unless
otherwise specified. A remote operated flame front generator (FFG)
ignition system shall be used. Ignition controls shall be located outside
of the 1500 BTU/hr-ft² (4.7 kW/m²) radiation zone. For a flame front
ignition system, the distance between the flare and the flame front
generator shall be minimized. Other types of ignition systems like
High Energy Ignition System (HEI) are used as back-up only, see
paragraph 6.19.9. HEI ignition system may be used, however, as a
standalone for maintenance flares.
6.19.2 Ignition lines from the flame front generator panel to the flare tip shall
be manufactured from type 316 stainless steel. The tip mounted
section of the ignition system shall be constructed of materials selected
in accordance with paragraph 6.16.9.
6.19.3 One type 316 stainless steel fuel gas supply line is required for each
pilot burner. A filter shall be installed between carbon steel fuel gas
supply lines to the stainless steel fuel gas supply lines to pilots.
6.19.4 Pilot lines and ignitor lines shall be piped separately between the
proximity of flame front generators and flare tips.
Page 28 of 38
Table 2 - Minimum Recommended Number of Pilots

Number
Tip Diameter
of Pilots
Up to 8 inches (203 mm) 2
Pipe-type Acid-gas
10 inches (254 mm) to 40 inches (1016 mm) 3
Flares
42 inches (1067 mm) and above 4
Up to 8 inches (203 mm) 1
Other Pipe-type 10 inches (254 mm) to 18 inches (457 mm) 2
Flares 20 inches (508 mm) to 46 inches (1,168 mm) 3
48 inches (1,219 mm) and above 4
6.19.5 Piping shall be flanged at the flame front generator and the bottom of
tip assemblies to facilitate the removal of flare tips.
6.19.6 All controls required shall be provided to ensure that each pilot can be
ignited individually.
6.19.7 Ignitor gas shall be dry and clean (with respect to liquids and solids)
and shall be either fuel gas or bottled gas.
6.19.8 Flame front ignition piping shall be designed to minimize low points.
Low points, if required, are to be at ignition panels and/or at the flare.
Drains and boots shall be provided and located at all necessary low
points.
6.19.9 Back-up ignition systems shall be installed on new continually

operating (non-maintenance) flares and Offshore Platforms.
High Energy Ignition System (HEI) are used as the back-up system for
FFG. However, if HEI are used, they shall be put in running service
while the more reliable FFG is used as a back-up in case the HEI
system fails or need to be maintained.
6.19.10 Compressed-air flame front generator shall be used unless Instrument

Air is not readily available such as in remote areas. In this case,
self-inspiriting flame front generator can be used.
6.20 Flashback Protection Systems
6.20.1 A flashback protection system, by means of a gas purge, is required to

prevent the accumulation of explosive mixtures of gas and air in a flare
system whenever the waste gas flow rate to a flare tip is less than the
required purge rate.

Page 29 of 38
6.20.2 A liquid seal drum may be used in addition to purge gas as flashback
protection for flare headers and for in-plant piping.
6.20.3 Flare systems shall be swept with inert gas prior to plant start-up and
operation.
6.20.4 The flare system should be provided with a purge gas system.
These purges should enter the headers at their far upstream ends and be
controlled by a flow regulator with flow indicator.
6.20.5 If a vacuum could occur, purge gas on pressure control shall be

provided upstream of the liquid seal drum to maintain positive
pressure. Purge gas shall be provided downstream of the seal drum to
provide the purge rates specified at the flare tip.
6.20.6 A flame arrestor shall not be used as flashback protection.
6.20.7 Clean (with respect to solids and liquids) and oxygen-free combustible
gas, or low oxygen content inert gas, shall be used for purge gas.
6.20.8 Gas flow shall be assured during any single contingency. The maximum
allowed oxygen limit in inert gas must be determined separately for each
installation.
6.20.9 The flow of flare purge gas shall be independent of all other users and
shall not be subject to failure due to a single contingency.
6.20.10 For flares with liquid seals, an automatic liquid re-seal system is
required following a major release from the process where the liquid
seal will be broken. In this case, external or internal emergency seal
liquid storage has to be provided as specified by the Design Engineer
and Flare Vendor.
6.21 Purge Gas Rates
6.21.1 Refer to SAEP-405 on purge gas optimization and determination for

flare systems. When dry gas seals are used, the minimum purge gas
rate to prevent air ingression below the seal shall be that recommended
by the seal vendor. The Saudi Aramco Engineer may specify a higher
rate.
6.21.2 For vertical pipe flares without a dry gas seal, the purge system shall
be able to provide at least ½-ft/s (0.15 m/sec) velocity at the tip.
Page 30 of 38
6.21.3 For horizontal pipe flares, the purge system shall be able to provide at
least 1 ft/s (0.30 m/sec) velocity at the tip, when using a combustible
purge gas, even if the tip has a dry gas seal.
6.21.4 The minimum purge gas rate for multi-tip, multi-stage flares or other
proprietary flares shall be specified by the Flare Manufacturer and
approved by the Saudi Aramco Engineer.
6.21.5 Purge rates higher than those specified in this standard may be required
after flaring a hot gas or condensable vapor.
6.22 Liquid Seal Drums
6.22.1 Liquid seal drums shall be located as close as possible to flares (limited
by the thermal radiation constraints). For elevated flares, the drum
may be an integral part of the flare stack base.
6.22.2 The critical vapor velocity used in the design of a gravity separation
liquid seal drum shall be no greater than 11.5 ft/s (3.5 m/sec). A Flare
Manufacturer's proprietary design, with internals, may be used.
6.22.3 The ends of inlet pipes into drums shall be designed, or drum internals
provided, to minimize flame pulsation.
6.22.4 The filling rates of seal liquid shall be sufficient to re-establish the seal
within 5 minutes if a seal is broken. An alarm, located in the control
room, shall indicate if the seal is broken.
6.22.5 Seal liquid shall be protected from freezing down to the minimum flare
gas or ambient temperature, or a glycol solution may be used.
6.22.6 Liquid seals may be incorporated into a knockout drum in special

circumstances or both functions may be contained in separate
compartments in a single vessel.
6.22.7 For liquid seals handling H2S-bearing gas, the liquid shall be disposed
via a closed system and in an environmentally acceptable manner.
7 Mechanical and Structural Design
7.1 Mechanical design and material selection shall be in accordance to

32-SAMSS-022 and API STD 537 unless otherwise specified. If the there is a
conflict between 32-SAMSS-022 and other L-series standards;
then, 32-SAMSS-022 shall be used unless otherwise specified by Saudi Aramco
Engineer.

Page 31 of 38
7.2 Piping
7.2.1 The mechanical design of piping, valves, and fittings required for flare
systems shall be specified by the Design Engineer in accordance with
Saudi Aramco's L-series Engineering Standards.
7.2.2 The material selection, fabrication and Inspection of piping, valves,

and fittings required for flare systems shall be specified by the Design
Engineer in accordance with Saudi Aramco's 01 and 02 series
Materials System Specifications.
7.2.3 The construction of piping shall be specified by the Design Engineer in

accordance with SAES-L-350.
7.2.4 The mating flange of pressure safety relief valves (PZV's) shall comply
with the requirements of API STD 526.
7.3 Vessels
7.3.1 The mechanical design of knockout drums and liquid seal drums shall
be specified by the Design Engineer in accordance with SAES-D-001.
7.3.2 The material selection, inspection and fabrication of vessels shall be

specified by the Design Engineer in accordance with 32-SAMSS-004.
7.4 Stacks
7.4.1 For mechanical and structural design of flare stacks, refer to

32-SAMSS-022 specification and API STD 537 Section 5.
7.4.2 The flare stack will be normally designed using structural steel
standard, ASME STS-1. However, in case the liquid seal drum is
integrally deigned with the flare stack, pressure vessel design codes
according to SAES-D-001 shall apply for the drum portion only.
7.4.3 The design of Chevron’s and internals at the bottom of the flare stack
shall be provided by vendor in accordance with 32-SAMSS-022.
7.5 Refractory and External Insulation
7.5.1 The design of refractory and external insulation shall be specified by the
Flare Vendor and Design Engineer in accordance with 32-SAMSS-022,
SAES-N-001, and SAES-N-100.
7.5.2 The installation of castable refractory shall be specified by the Design

Engineer in accordance with SAES-N-110.
Page 32 of 38
Commentary Note:
The use of external refractory for flare tips was deemed not practical by
the industry for many years now. Use of internal refractory inside the
barrel of the flare tips is also being abandoned in new designs offered
by flare tip vendors. As such, the above standard sections are used for
repair in existing tips with refractory or in case a new tip designs will
have refectory installed as required by the flare vendor.
7.6 Painting
7.6.1 The selection of the type of paints and coatings shall be in accordance
with SAES-H-001.
7.6.2 The Approved Protective Coating Systems (APCS) shall be selected

from SAES-H-101V and specified on the data sheets together with the
applicable Class 09 Saudi Aramco Materials System Specification for
the surface preparation and painting systems.
7.7 Structural
7.7.1 The Design Engineer shall determine the basic wind speed
corresponding to the Saudi Aramco site in accordance with
SAES-A-112. The basic wind speed shall be specified on the data
sheets.
7.7.2 The Design Engineer shall determine the earthquake zone, soil
coefficient and effective peak acceleration ratio (Av) corresponding to
the Saudi Aramco site in accordance with SAES-A-112. The earthquake
zone and site soil coefficient shall be specified on the data sheets.
7.8 Fireproofing
Fireproofing of equipment shall be in accordance with SAES-B-006.
7.9 Emergency and Isolation Valves
Emergency, isolation, shutdown, and depressurizing valves shall be determined

in accordance with SAES-B-058.
8 Flare and Relief System Design Development
8.1 General
8.1.1 As being critical to the safety of an operating plant, the flare system
shall be continuously available and capable of its intended
performance through all operating-plant emergency conditions,
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including a site-wide general power failure.
8.1.2 As stipulated in API STD 521 Section 5.3.1, the process of developing
disposal system design loads can be complex requiring input from
different parties and various engineering disciplines. The governing
process design loads, conditions and composition of relieving streams
will also dictate other design aspects such as mechanical and radiation
exposure. As such, clear and verifiable evidence of design intent, and
verification of design and functional performance will need to be
provided by the Design Engineer to be reviewed and approved by
Saudi Aramco Engineer. Native files of process models, data sheets,
design narratives and calculation sheets need to be provided throughout
the various design stages for verification and evergreening of flare
system design. Requirements for design development are listed
sections 8.2 to 8.4 below in line with Saudi Aramco Capital Project
Management System (CMS) and Front Engineering Loading (FEL)
Process as specific to each project type as per SAEP-360.
8.1.3 The Design Engineers shall complete all required design data as
specified on Saudi Aramco Forms SA-7305, SA-9543, SA-9544,
SA-9547, SA-9548, SA-9549, SA-9561, and SA-9562 for both new
and modified flare system. Additional requirements in API STD 537
sections 4.2 and 4.3 shall also be provided if not covered in these data
sheets.
8.1.4 When a new flare system is integrated into an existing flare system, a
complete detailed evaluation of the relief/flare system is required to
ensure there is no negative impact on the existing relief/flare system.
This evaluation will be conducted by the project team or contractor
who is connecting to or making changes to the existing system.
A study is also required when a new equipment relief connection is
connected to the flare system to ensure there is no negative impact on
the existing equipment relief system during global relief scenarios.
8.2 DBSP/Business Case Phase (FEL-1-2)s
During this phase, the objective is to develop the business case and define the
main elements of the project scope of work, as such the following is required:
8.2.1 List, size and brief description of main flare system equipment to be
installed including headers, knock-out drums, pumps, stacks/tips and
FGRS systems if applicable. Also, the various types of flare systems
and broad segregation of flare systems in terms of pressure, rating,
material and composition is required as applicable. These can include
High Pressure (HP), Low Pressure (LP), Acid Gas (AG), Cold Flare
Page 34 of 38
designation for flare systems. In addition, requirements for Burn Pits,

Ground Flares, Boom Flares and liquid recovery systems will be
specified as needed.
8.2.2 Expected pressure ratings and materials of construction should be also

provided.
8.2.3 The major relief rates and conditions expected will have to be
estimated. Pro-rating of similar facilities can be used together with
licensor’s estimates if any in addition to making some rough
calculations for the estimated relief loads as needed.
8.3 Project Proposal Phase (FEL-3)
At this stage, as the heat and material balances should be completed and process
systems and utilities configuration are more detailed, a much more accurate
level of design development for the flare and relief system is required.
Licensor estimates or proration of existing units/equipment will not be accepted
at this stage. Instead, an appropriate level of deign development will be required
along with evidence for verification of design The assumptions made on flare
system equipment sizes and configuration at DBSP stage will be also verified.
The following is required during this stage:
8.3.1 Required Documents
PFDs and P&IDs and Relief/Flare System Analysis Report as per

Section 8.3.4 below. In addition PZV, Instrument, and flare system
data sheet as per paragraph 8.1.3 above.
8.3.2 Relief/Flare System Analysis and Report
The flare and relief system analysis is an essential part of design

development and includes but not limited the flare report and models.
This analysis and report should serves as a design basis for new or
modified facilities.
The report outlines all failure modes, effects and sizes of pressure
relief, depressurizing valves and flare systems to prevent any failure.
The relief analysis and report shall include the following:
1) Equipment which may be overpressured due to abnormal operating
conditions and determine the location of depressuring valves.
2) Relief loads resulting from various contingencies and the
disposition of relief discharges.

Page 35 of 38
3) The maximum (controlling) relief load for each PZV, the PZV
type and size along with hydraulic analysis and maximum back
pressures developed. Back pressure calculations should start
from relief source such as PZV’s and control valves and not
using arbitrary point like the back pressure on the knock out
drum.
4) The report should include the flare system and over pressure
protection philosophy in addition to overall ESD and control
narrative.
5) Adequate details for utility system configuration and supply
related to or serving the flare system such as cooling water,
Instrument Air and Electrical Power Supply which may be
needed to estimate relief loads form process units.
6) Relief scenarios identification and rational should be conducted
in accordance with SABP-Z-079. Relief rate calculation and
relief device and system sizing should be also conducted.
Native files for these analyses should be provided for Saudi
Aramco Engineer approval.
7) The scope of the report shall include each unit which is
discharging into the flare system. Additionally, the report shall
specify total loads into each flare system from various units
connected to the flare. The report should also integrate all design
packages relief loads served by the same flare.
8) If the project is making changes or interacting with an existing
process facility flare system, as stated in paragraph 8.1.2 above;
then, the Design Engineer should perform a complete analysis of
the affected system using actual relief loads and conditions to
evaluate the real impact on the existing systems and identify
project deliverables to handle such an impact.
9) If the project proposal contactor is not able to conduct part or all
these design development steps; then, the Design Engineer
should hire a third party consultant to execute the missing steps
as recommended by Saudi Aramco Engineer.
8.3.3 Flare Schematic Diagrams
The Design Engineer shall prepare a schematic diagram for the flare
system from pressure relief and vapor depressuring valves to flare
tip(s). This schematic diagram shall cover all vessels, pumps, and
equipment in a flare system, and include the following information:
Page 36 of 38
1) Flare line sizes and line slope

2) Equivalent lengths of line sections
3) Vessel equipment numbers and their relative locations
4) Safety relief/depressuring valve numbers
5) Identity of those valves which could simultaneously contribute to
the maximum continuous, and maximum instantaneous flaring
used to design main header(s), knockout drum(s) and flare(s)
6) Maximum and allowable back pressures at each valve.
8.3.4 Radiation Map
A radiation map shall be prepared and show the radiation intensity

contours at 500 BTU/hr-ft² (1.6 kW/m²), 1,000 BTU/hr-ft²
(3.2 kW/m²), 1,500 BTU/hr-ft² (4.7 kW/m²), and 3,000 BTU/hr-ft²
(9.4 KW/m²). The radiation intensities shall be calculated at grade
(or offshore platform levels) and at higher operating platform levels in
the vicinity of the flare. Flaresim software will be used to determine
the radiation exposure at this stage.
8.4 Detailed Design (Execution Phase)
During this phase, all the steps in Project Proposal phase design development
Section 8.3 will have to be further detailed with the addition of the below steps.
Detailed engineering contactor should conduct in this case the required design
development. No final design for construction will be acceptable without this
development. Similar to Project Proposal phase, if the contractor is not able to
conduct part or all these design development steps; then, a third party consultant
should be hired to complete required steps. The name, scope, and conclusions
of required third party work shall be approved by Saudi Aramco Engineer.
The third party consultant work is to augment the detailed Design Engineer
scope in some specialty engineering areas and the detailed design contractor is
still responsible for verifying and implementing required design scope ensuring
safe design in line with this standard requirements. Additional requirements for
detailed engineering phase design development and deliverables include the
following in addition to the items listed in Section 8.3:
1) Integrated and native PS PPM software files including all units and flare
networks or approved alternative by Saudi Aramco Engineer. Excel sheets
and non-approved software will not be accepted.
2) Integration of multiple EPCs sharing the same flare by the respective EPC
contactor for the flare system if separate. The flare system EPC contactor
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can obtain the various model and relief system design work for each
contactor but he needs to integrate all in one model and feedback changes to
each EPC until design is finalized. If this task cannot be handled by the
flare system EPC; then, a third party consultant with access to all EPC relief
work and data shall perform this job. For Mega-projects with multiple
EPCs, a third party consultant shall be hired at early stages of deign prior to
the 30% design stage to assist with the integration and design verification
work.
3) For radiation analysis, the design contactor can utilize the selected Flare
Vendor propriety methods to determine the final radiation isopleths and
superimpose on the facility plot plans. The Flare Vendor has to guarantee
this radiation analysis. Prior to vendor selection, Flaresim shall be used.
8.5 Electronic Documentation
Electronic documentation shall be provided by the Design Engineer to the

proponent and Saudi Aramco engineer which shall include all detailed analysis
of the relief/flare system. The documentation shall be in an electronic version
that can be kept in an evergreen state by Saudi Aramco. It shall include all
details such as analyses and calculations for relief and depressurizing scenarios,
relief valves sizing, relief & flare piping, flare system components sizing, and
heat radiations analysis. Simulation files for the analyses shall be submitted to
the proponent and Saudi Aramco engineer.
9 Maintenance and Repairs
The maintenance and repair of flare systems, including replacement in-kind, shall be in
accordance with the original design modified by the Corporate Technical Alerts,
inspection history, and industry practices. The maintenance philosophy for flares
should be in line with governing Saudi Aramco Standards including SAES-F-007 and
generally follow API STD 537 guidelines in that regard. For assistance in the
incorporation of these modifications, consult the Saudi Aramco Engineer.
Revision Summary
3 May 2011 Revised the "Next Planned Update", reaffirmed the contents of the document, and reissued
with minor changes.
10 July 2011 Editorial revisions to clarify the Acceptable Flare Locations for Onshore Facilities (Figure 1) and
the required study for a new equipment relief connection to the flare.
1 January 2018 Editorial revision to modify paragraphs 6.7.6, 6.14.6, 6.15.14, and 6.19.1.
9 January 2018 Major revision, incorporate cost savings ideas reflected in VE session, and align with new
changes made in SAES-A-102. Moreover, this standard is better aligned with lessons learned
on some issues like FGRS and enables incorporation of new technologies or application like
HEI and Multi Point Ground Flares. It also provides a more structured approach for execution
of flare engineering studies and reports at various project phases.
Page 38 of 38

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Engineering Standard

SAES-F-007 9 January 2018

Previous Issue: 1 January 2018 Next Planned Update: 9 January 2021

©Saudi Aramco 2018. All rights reserved.

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-360 Project Planning Guidelines

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specifications

Saudi Aramco Standard Drawings

Saudi Aramco: Company General Use

Saudi Aramco Best Practices

Saudi Aramco Engineering Report

Saudi Aramco Forms and Data Sheets

3.2 Industry Codes and Standards

American Petroleum Institute

International Society for Measurement and Control

AIV: Acoustically Induced Vibration

CFMS: Corporate Flare Monitoring System

Elevated Flare: Refer to SAES-B-055 Section S-2.

Flaring Minimization Plan (FMP): A comprehensive Site Specific Flaring

Real-Time Flaring Monitoring System (FMS): Real-Time Flaring Monitoring

FFG: Flame Front Generator

Saudi Aramco: Company General Use

High Integrity Protective System (HIPS): High Integrity Protective System is an

Incinerator: A furnace in which a combustible material is burned and in which the

Mach Number: It is defined as the ratio of a fluid’s velocity, measured relative to

Maximum Instantaneous Flow: This flow is due to depressurization and/or an

P&ID: Piping and Instrument Diagram

PFD: Process Flow Diagram

Saudi Aramco: Company General Use

Shock Chilling Effect: The temperature of a fluid causing shock chilling.

6.1 Design Considerations

In order to ensure plant safety, flare systems shall be continuously

Flare system and flare-tip type selection shall be based on an overall

shall be involved in the initial scope development, determination of

The flare and related mechanical components shall be designed to

6.1.3 Smokeless Design for New Plants

For emergency or non-routine flaring purposes, full or partial smokeless

Saudi Aramco: Company General Use

environmental regulations. HP flares in offshore production platforms or

6.1.4 Flare Gas Recovery Systems

The need to install an FGRS for facilities with normal

6.1.4.2 For existing facilities, the requirements to install an FGRS will

6.1.4.4 For guidance on selection, design and application of FGRS

6.1.5 Flare Minimization for Existing Facilities

6.1.6 Flare Minimization for New Facilities

6.2 Flare System Components

6) Access platform for maintenance and operations.

6.3 Flare Gas Loads

6.3.1 A flare system shall be designed to handle normal continuous flows,

6.3.2 For HIPS applications, refer to SAEP-354.

6.4 Design Temperature

6.4.1 The operating temperature shall be the temperature of gas/liquid being

6.4.2 A minimum margin of 30°C (54°F) shall be added to the maximum

6.5 Design Pressure

6.5.3 The Saudi Aramco Engineer shall specify:

6.6 Horizontal Spacing and Height

6.6.2 Optimum Flare Location

6.6.2.1 For optimum location of new flares, normal wind direction

6.6.2.2 For existing flares evaluation or expansion of existing flares

Saudi Aramco: Company General Use