Flare System

Flare Systems
Hydrocarbons are released in from land fills, oil wells, mines and petrochemical industries. These include ethylene,
methane, propane, propylene, butadiene, butane and other sulphur containing compounds. Instead of releasing them
directly into the atmosphere they are burnt in high temperature oxidation reaction in combustion chambers called the
flare stack to release Carbon-di-oxide and water vapor that are relatively less harmful.

Purpose of flaring
Emergency flaring: In the case of fire
outbreak, valve breakage, compressor
failure an emergency blow down of large
volumes is required, hence they are flared
in short time, usually thousands of m3/hr.
Production flaring: drilling for oil there is
possibility for unrecoverable trapped gases
that has to be gotten rid of, this is achieved
by flaring.
Process flaring: During operation purged
and wasted gases, vented gases from
furnaces require to be flared, generally
flared in low volumes of few m3/hr.
P&ID of a Flare Stack
Process Flow Diagram of a Flare Stack Gas/Liquid released from tanks, pressure vessels,
heat exchangers due to pop up of PSVs, PRDs or
from blow down valves, pressure control devices
are routed to the KOD-Knock Out Drum through a
flare header which is upstream of the Flare Stack.
The KOD is a gas liquid separator that directs the
gas alone into the flare stack for oxidation.

The KOD are of two types, horizontal and vertical.

The horizontal are usually preferred as their
elevation determines the vent line elevation of the
pressure relief valves. Reason being the slope that
is to be maintained by the flare header connecting
the vent line to the KOD.

The flare stack consists of the pilot at the top that

is burning at all times to support emergency
operation, the gases are burnt and released into
the atmosphere. The stack is steam or air flushed
to ensure smokeless burning and the flashback
prevention system curbs ambient air from
entering the stack and causing a flashback.
 3 3

2 1
Piping Standards for Flare Lines

• A minimum slope of 1:450 is to be maintained in flare headers as per API 521.

• 45 degree elbows are used to connect the vent lines with latrolets to the flare header.
• Lines must be designed for minimal pressure drop and can have only 2D loops.
• Potential dead legs and liquid traps should be avoided.
• The header should have minimal valves, they should be car sealed open.
• The header must be equipped for purging to prevent entry of any explosive gases into the flare system during
start up or operation.