Flare Light Up and Shut Down Procedure

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Created By: Rachid Ghileb
 GABON OPERATIONS
PRC
Flare Light Up/Shut Down Procedure

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REVISION INDEX
Revision Date Description of Changes Revised By
0 Jan 09 Initial release Rachid Ghileb

COPYRIGHT © 2008 EXTERRAN HOLDINGS, INC. Paper copies of this document are uncontrolled. This copy is valid only at the time of printing. The
controlled version of this document is stored on the Exterran intranet Web site.

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 GABON OPERATIONS
PRC
Flare Light Up/Shut Down Procedure

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TABLE OF CONTENTS
1.0 INTRODUCTION.............................................................................................................................4
2.0 PURPOSE..........................................................................................................................................4
3.0 SAFETY CONSIDERATIONS........................................................................................................4
4.0 OPERATION.....................................................................................................................................5
4.1 Pre Start-Up Checklist.........................................................................................................................................5
4.2 System Purge.......................................................................................................................................................5
4.3 Operating Summary............................................................................................................................................5
4.4 Controls Summary...............................................................................................................................................6
4.5 Initial Settings......................................................................................................................................................6
4.6 Customer Alarms.................................................................................................................................................7
4.7 Schedule of Alarms.............................................................................................................................................7
4.8 Schedule of Operators and Indicators.................................................................................................................7
4.9 System Operation................................................................................................................................................8
4.10 System Shutdown................................................................................................................................................9
5.0 APPENDIX 1: FLARE STACK piD..................................................................................................9

COPYRIGHT © 2008 EXTERRAN HOLDINGS, INC. Paper copies of this document are uncontrolled. This copy is valid only at the time of printing. The
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 GABON OPERATIONS
PRC
Flare Light Up/Shut Down Procedure

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1.0 INTRODUCTION

The purpose of the Flare Header and equipment is to contain vented fluids from various sources, flare
the gases and pump the liquids to the Closed Drains Header.
All vented fluids are routed either to atmosphere or the Flare System. That vented to the flare system
are routed via the flare header, along with a small continual flow of sweep gas, to the Flare Knockout
Drum V-21664.
This is a large empty vessel which can absorb the variations in compositions and flow imposed on it
by its various users. Any liquids in the fluids fall to the bottom of the vessel from where they are
intermittently pumped by the duty Flare KO Drum Pumps P-21665 A/B to the Closed Drain system.

As the liquid may sit in the vessel boot for a period of time a heating coil containing hot flushing
water is included in the liquid boot to prevent wax formation.
Any gas passing through the vessel is routed to the flare stack A-21663 and burnt.

Main Equipment within this package includes:

 HP Flare K.O. Drum V-21664

 Flare K.O. Drum Pumps P-21665 A/B
 Flare Stack A-21663
 Stack Air Blower K-216171

2.0 PURPOSE

The purpose of this procedure is to detail and clarify the efficient and safe manner to light up, Shut
down and operate the flare stack

3.0 SAFETY CONSIDERATIONS

GENERAL COMMENTS FOR SAFETY DURING FLARE OPERATION

CAUTION! Safety during flare operation requires that there is not an air / gas mixture in the
flare system at any time. Purge gas, which can consist of either inert gas (preferred), fuel gas or
waste gas, should be used in such quantities as to avoid the entry of air into the flare system. A
purge of the flare should occur prior to the release of waste gas into the system and before the
ignition system is turned on. Explosion hazards can exist during the operation of a flare system
only if the ignition system has been initiated and before the flare is purged.
Therefore the ignition system must not be operated until the system is thoroughly purged, and
the flare system is absolutely gas tight.
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Flare Light Up/Shut Down Procedure

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4.0 OPERATION
4.1 Pre Start-Up Checklist

The following items should be checked before starting the flare:

 Verify that all electrical devices are connected to the proper power sources.
 All system lines should be dry and free of dirt and foreign matter.
 Confirm all drain and vent valves are closed and that all drain and vent plugs are tightly
secured.
 Check all control valves for proper function.
 Purge the flare for 10 volumes of the flare and flare header
 Turn the ignition system on and confirm a spark in the FFG combustion chamber sight
glass.
 Add pilot gas to the pilots, light the pilots using the FFG, and check for suitable ignition
of pilots.
 Leave the ignition system on at all times.
4.2 System Purge

There is danger of severe explosion in the flare system if the flare is ignited before the flare
system has been purged from the beginning of the system all the way to the flare with a
volume of non-condensable gas equal to ten times the volume of the flare system. The flare
system includes all piping from relief valves toward the flare and riser to the elevation of the
flare at the point of combustion.

Suitable purge gases include natural gas, propane, nitrogen, inert gas, carbon dioxide or
butane, if temperature level is 32°F or above. Steam, as purge volume is not recommended for
two reasons. The first is that the steam is at an elevated temperature and the steam content of
the flare will shrink as the steam cools and condenses to draw air back into the flare system.
The second is that as the steam condenses, water will be present in the flare system partially
blocking the system, which presents a freezing hazard. In addition, the condensation
encourages accelerated corrosion.

The flare should be ignited only after the “SYSTEM PURGE” is complete as outlined above and
preferably as the purge gas is being admitted. If the purge gas is combustible, the burning of
the purge gas at the flare will be proof of ignition.

4.3 Operating Summary

The operating summary outlines the critical information related to the Model 300 Flame Front
Generator control system. The following sections will help the system operator become familiar
with the controls, initial settings, and general operation of the system. System purge must be
completed prior to any ignition or waste gas combustion.
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Flare Light Up/Shut Down Procedure

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4.4 Controls Summary

The Model 300 Flame Front Generator control system was designed by FII to provide reliable
ignition of the flare system. By design, the control system will operate with minimal user input.
The following is a list of the major components used to control flare ignition:

 Ignition Transformer – Generates high energy spark to light pilots

 Model 245 pilots – Provides a reliable stable flame to ignite waste gas flow.

Before any ignition sequences begin, the flare should be checked and fully purged as described
in section 4.2.

Startup begins by switching the MAIN POWER OFF/ON switch to the ON position. During this
time, the ignition transformer will generate a high-energy spark when needed by simply
pressing the MANUAL SPARK pushbutton located on the FFG XFMR BOX enclosure. When pilot
fuel gas is supplied to the Model 245 pilots, this high-energy spark will ignite the fuel air/gas
mixture at the Flame Front Generator and light the pilots. This Model 300
Flame Front Generator is a manual ignition system and is supplied without automatic re-
ignition.

Upon pilot failure, re-ignition is achieved by manually relighting the system for ignition of the
associated pilot.

4.5 Initial Settings

All system controls and regulator valves have been properly adjusted before shipment and
come ready for operation. The following settings are to be used for information only and should
only be used for modification in the event of necessary adjustment.

Tag # Component Set Point

 PCV100 Flame Front Generator Ignition Air 8-10 psig

 PCV200 Flame Front Generator Ignition Fuel 8-10 psig
 TC-100 Temperature Controller, Pilot 1 250°F
 TC-200 Temperature Controller, Pilot 2 250°F
 TC-300 Temperature Controller, Pilot 3 250°F
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Flare Light Up/Shut Down Procedure

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4.6 Customer Alarms

Alarms are used to communicate data between the flare’s control system and the existing
EXTERRAN controls. These alarms typically communicate critical information such as pilot
failure notification, liquid level status, or various service pressures. This system is not
interlocked, as it is shipped from the factory.
Use of any system alarms is ultimately at the Exterran’s discretion and responsibility.

The following alarms have been provided with this system:

Interlock Description Point of Connection

Model 245 Pilot 1 ON TBA-190130
Model 245 Pilot 2 ON TBA-190131
Model 245 Pilot 3 ON TBA-190132

4.7 Schedule of Alarms

Alarm Associated Tag # Cause Effect

Component

Model 245 Model 245 TE100 Temperature Controller • Customer Alarm contacts
Pilots ON Pilot TE200 has reached 250°F energized
Thermocouples TE300 (preset) • PILOT ON indicator is lit at
MAIN CONTROL PANEL

4.8 Schedule of Operators and Indicators

This section provides a description of the operators and indicators located on the main control
panel. One should become familiar with the meaning and effect of each component prior to any
attempt at operating the system.

Item Operator or Function

Indicator

Switches and Pushbuttons

1 Main Power Off/On • Controls main power for entire control system
• Must be in the ON position to operate system

2 Bulb Check • Verifies illumination of main control panel lights

3 Manual Spark • When pressed, a spark will be generated at the Combustion

Chamber by the Ignition Transformer for the purpose of lighting the pilots.
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Flare Light Up/Shut Down Procedure

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Indicators

Item Operator or Function

Indicator
1 Power On • Indicates the system is energized and available for pilot ignition.
2 Pilot #1 On • Indicates Pilot 1 is operational
3 Pilot #2 On • Indicates Pilot 2 is operational
4 Pilot #3 On • Indicates Pilot 3 is operational

4.9 System Operation

The following procedure describes the operation of the flare control system. This system is a
manual ignition system by design. Before any operations are conducted, the flare should be
fully purged. See section 4.2 for a review of safety precautions when operating the system.

1 Turn the MAIN POWER OFF/ON switch to the ON position.

2 Open the valves to release ignition air and ignition fuel to the Flame Front Generator
system (BV-101 and BV-201). Confirm that the pressure shown at the pressure
gauges of each valve train are 8 psig. Some adjustment may be necessary the first
time the FFG is used in its new location.
3 Open any valves required to release pilot fuel to the Model 245 Pilots.
4 Open the first valve on the ignition side of the Flame Front Generator (BV-100). Be
sure BV-200 and BV-300 are closed. Wait approximately one minute for every 100’
of distance between the Flame Front Generator and the Model 245 Pilot, including
the height of the flare (50’).
5 Press and immediately release the MANUAL SPARK button on the ignition
transformer box to fire the Flame Front Generator. There should be a momentary
blue flash visible through the sight glass in the Combustion Chamber (34-BE-001).
6 Upon verification that the first pilot is lit, open BV-200, close BV-100, and repeat
steps 4 and 5 for BV-200.
7 Confirm second pilot has ignited.
8 Repeat procedure a third time; open BV-300, close BV-200, and repeat steps 4 and
5 for BV-300.
9 Close all ball valves after ignition is complete. This includes BV-100, BV-200, BV-300
as well as BV-101 and BV-201. These valves should remain closed while pilots are in
operation.
10 Any valves supplying fuel gas to the pilots should remain open.
11 The flare system is now ready to accept waste gas flow.

4.10 System Shutdown

Caution:
The system should only be shutdown if the flare is intended for intermittent use.
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Flare Light Up/Shut Down Procedure

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THIS IS NORMALLY DURING MAJOR SHUT DOWN

Only the Operations Superintendent or his designated cover will allow Flare Shut down and
Ignition.

Once the system has been shutdown, any system monitoring will end.

1 Verify that waste gas flow has ceased and that the corresponding waste gas control
valves are fully closed.

2 Close all valves controlling the pilot fuel gas. This will extinguish the Model 245
pilots.

3 Turn the MAIN POWER OFF/ON switch to the OFF position. The POWER ON indicator
will de-energize indicating the system has been shutdown.

5.0 APPENDIX 1: FLARE STACK PID

 GABON OPERATIONS
PRC
Flare Light Up/Shut Down Procedure

Revision: 0 Number: Revised: