S-19-1357-101_3a

REFINERY UNIT V BALIKPAPAN

PT. JGC INDONESIA

Doc.No.

S-19-1357-101

Rev.

PN Doc. No.

DS-19-013-001-A4

Job Code

0-0584-00-0000

PN Job Code

E15300-09-01

3A

10-Jan-12

Sheet

1 of 9

AS BUILT

DATA SHEET FOR FLARE STACK V-219-03

REVIEW CODE A- APPROVED CODE B - APP'D WITH MINOR COMMENT CODE R - APPROVED WITH COMMENT CODE N - NOT APPROVED

NAME : DATE :

DISTRIBUTION

PMN

PM Eng Center

PM PPM EM DHT PROCESS

PENAMBAHAN UNIT SOUR WATER STRIPPING DI AREA HCC (SWS PROJECT)

CIVIL

JIND JKT

MECH

PT. PERTAMINA (PERSERO) REFINERY UNIT V BALIKPAPAN

ROT PIPING INSTR ELECTR SCH CONTR. COST CONTR ADMIN

Rev.

Date

Page

Description

Prepared

Checked

Approved

1B

8-Oct-10

All

Issued for Approval

SH

ARN

WS

CM

1C

24-Nov-10

2,3,4,6

Issued for Approval

MA

ARN

WS

FEM

2A

10-Jan-11

2,4,5,6

Issued for Construction

MA

ARN

WS

QC

2B

8-Mar-11

6,8,9

Issued for Construction

MA

ARN

WS

HSE

2C

4-Apr-11

3,6

Issued for Construction

MA

ARN

WS

3A

10-Jan-12

3,4,6

As Built

MA

ARN

WS

SWS Project Job Code 0-0584-00-0000 Data Sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN Doc. No. DS-19-013-001-A4 Sheet 2 of 9 Rev. 3A

GENERAL Type of Flare Stack No. of Flare Stack to be installed Major Components of Flare Stack: Flare Tip Gas Seal Water Seal Drum Stack Riser Platform & Ladder Stack Supporting System Ignition System Pilot Ignition System Aircraft Warning Light System Area Classification Design Code & Standard: Flare Stack Sizing Stack Supporting System Flange Rating: 24" and smaller Material (Pressure parts)

Guy Wire or Derrick Structure Supported One (1)

(Note 4)

Required (Note 2) By Vendor N/A Required Required By Vendor (Note 4) Required Required Required (Refer to Aviation Codes, Standard & Regulation) Class I, Zone 2, Group IIB or Class I, Div 2, Group C Latest Edition of API RP 521 5th Edition 2007 and API 537 AISC, UBC 1997 ASME B16.5 ASME or equivalent

PROCESS DATA FLARE GAS CONDITIONS

Relieving Capacity Pressure Temperature Compositions : H2 CH4 C2H6 C3H8 i-C4H10 n-C4H10 i-C5H12 n-C5H12 C6+ N2 H2S CO2 NH3 H2O

Case-1

Case-2

Gas Treating Facility Trip

Incinerator F-7-01 Trip

Case-3 PSV-036A/B (Power Failure)

Nm3/h

1000

648

12794

kg/cm2G

0.4

0.35

0.35

77.5

80.0

120.1

1.7 1.3 1.7 3.3 3.5 3.6 15.5 1.4 41.5 26.6

6.45 2.29 17.12 34.96 39.10

0.50 2.70 96.80

o

C % mol

SWS Project Job Code 0-0584-00-0000 Data Sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN Doc. No. DS-19-013-001-A4 Sheet 3 of 9 Rev. 3A

DESIGN AND PERFORMANCE DATA Stack Height Flare Tip Size Diameter Height Smokeless Firing: Smokeless Capacity (% of Design Load) Method of Smoke Suppression Tip Exit Gas Velocity at Design Load Pressure Drop:

mm

70000 (min.)

inch mm

By Vendor By Vendor

N/A N/A Mach No. 0.2 ~ 0.5

%

kg/cm2G

Tip

2

Gas Seal Riser Wind Velocity for Radiation Calculation Emissivity Factor

(Note 2)

Vendor to verify

kg/cm G

Vendor to verify

kg/cm2G m/s -

Vendor to verify 35 Vendor to advise

Solar Radiation

kW/m 2

1.26

Heat Intensity (at 43 m from stack base include Solar Radiation) Noise Level Max. Noise at normal operation at 0 m from stack base Utility Consumption Fuel Gas For Pilot Burner For Purge For Ignition (FFG)

kW/m 2

1.58

dB(A)

85

Air for Ignition (FFG) Electrical Power For Ignition (FFG)

(Note 1) (Note 2)

kg/h kg/h kg/h

By Vendor By Vendor By Vendor

Nm 3/h

By Vendor

kW

By Vendor

MECHANICAL DESIGN Flare Tip Assembly Flare Tip: Type Dimensions: Diameter Height Thickness Design Condition: Temperature Pressure

Non-Smokeless in mm mm o

(Note 9)

By Vendor By Vendor By Vendor

C

154

kg/cm2

3.5

Gas Temperature Minimum Maximum Material Tip Wind Shield Inlet Flange Inlet Connection for Pilot Gas: Flange Size Flange Rating Pilot and Igniter: Number of Pilot Type of Ignition Number of Igniter Material : Pilot Assembly Igniter Assembly

o

C

49.1

o

C

120.1 Type 310 SS (Upper half) ; Type 304 SS (Lower half) Type 310 SS Type 304 SS

in

By Vendor ANSI 150# RFWN By Vendor Front Flame Generator (FFG) By Vendor (1 igniter per pilot) Type 309 SS or 310 SS Type 309 SS or 310 SS

SWS Project Job Code 0-0584-00-0000 Data Sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN Doc. No. DS-19-013-001-A4 Sheet 4 of 9 Rev. 3A

MECHANICAL DESIGN Pilot Flame Detector Type Number of per pilot Number per of tip Sheath Material of Thermocouple Weight of Tip Assembly for Erection Water Seal Drum Dimensions: Diameter Length (TL-TL) Corrosion Allowance for carbon steel Shell Thickness Design Condition: Temperature Pressure Material Shell / Head Internal Inlet/Outlet Connection Size Weight For Erection Stack Riser Dimensions: Diameter Length (Total including Flare Tip) No. of Division Length (each div.) Corrosion Allowance for carbon steel Shell Thickness Design Condition: Temperature

kg

mm mm mm mm o

N/A N/A N/A N/A

C

kg/cm

N/A 2

in mm sets mm mm mm o

By Vendor By Vendor By Vendor By Vendor 3 for Carbon Steel By Vendor

C

kg/cm

Temperature

o

154 2

C

kg/cm

N/A N/A N/A N/A N/A

in kg

Pressure Operating condition:

Pressure Material: Shell Gas Inlet Connection: Flange Size Flange Rating Intermediate Connection: Riser sections Drain Pot Connection Weight: per Each Section Riser Total Stack Supporting System Type Design Conditions Wind Design Basis Maximum Wind Speed Wind Importance Factor Exposure Category Seismic Design Basis Seismic Zone Seismic Importance Factor

Thermocouple - Type K 1 (one) By Vendor Inconel or Equivalent By Vendor N/A

3.5 49.1 / 120.1

2

0.35 / 0.4 By vendor

in

By Vendor ANSI 150# RFWN Flange Connections By Vendor By Vendor By Vendor Vendor to propose (Note-4)

km/hr

UBC 1997 125 1.15 C UBC 1997 2A 1.25

(Note 1) (Note 1)

SWS Project Job Code 0-0584-00-0000 Data Sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN Doc. No. DS-19-013-001-A4 Sheet 5 of 9 Rev. 3A

DESIGN AND PERFORMANCE DATA Ignition System Type Operation (Auto. / Manual) Ignition Local Control Panel Type of Panel Enclosure

Front Flame Generator (FFG) Manual NEMA 4x or Eq. (Class I, Zone 2, Group IIB or Class I, Div 2, Group C) Vendor Standard

Panel Design Code & Standard Indicator on Panel: Power ON/OFF Each Pilot Flame ON/OFF Switch on Panel: Power ON/OFF Ignition Lamp Test Panel Voltage Rating Cable provided with Flare Stack Instrument Cable for Pilot Flame Detector / Thermocouple

Yes Yes Yes Yes Yes 120 VAC / 1 Ph / 50 Hz Required

(Note 7)

Fuel Gas Properties Parameters Temperature Pressure

o

C 2

kg/cm G

H2 Rich

Average

CO2 Rich

40

40

40

5.72

5.72

5.72

79.19 0.14 0.4 0.14 5.37 1.9 4.5 2.54 2.51 0.58 0.29 2.44 100

60.74 0.16 0.48 0.07 23.32 1.49 5.29 3.09 3.04 1.45 0.6 0.27 100

70.07 1.01 7.47 11.57 2.26 2.06 0.5 0.5 0.8 0.95 2.71 100

Composition H2 N2 CO2 CO H2S C1 C2 C3 i-C4 n-C4 i-C5 n-C5 C6 Total

vol %

Molecular Weight

MW

10.934

13.297

12.619

kcal/kg

13,371.6 0.3775

12,656.3 0.4597

9,971.9 0.4372

LHV Specific Gravity (water = 1)

SWS Project Job Code 0-0584-00-0000 Data Sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN Doc. No. DS-19-013-001-A4 Sheet 6 of 9 Rev. 3A

REMARKS 1. Vendor to design the flare stack diameter consider to both below conditions: a. Allowable heat radiation at 43 m from stack base is 1.58 kW/m2. The intensity of solar radiation is 1.26 kW/m2 shall be considered in the total radiation computation. b. Dispersion study for H2S, NH3, SO2, CO, and NO2 based on flare gas condition for case-1, case-2 and case-3. Vendor to calculate dispersion study based on maximum wind velocity 35 m/s and minimum wind velocity 12.5 m/s. The requirement of ground concentration (Ambient Air Quality) considering the existing air quality as shown in attachment-3 plus flare dispersion shall not exceed the requirement of attachment-1 and attachment-2. 2. Vendor to advise type of flare tip. The velocity at the flare tip should design for Mach Number 0.2 to 0.5. Vendor shall provide "Flow vs Pressure" profile through tipand liquid level inside water seal drum. 3. Deleted. 4. Vendor to propose and design the best flare supporting system guyed wire or derrick structure type consider to available flare area and economical design. 5. Vendor shall ensure stable and reliable operation of flare for full range of flare load specified. 6. Vendor shall guarantee : 6.1 Thermal design and mechanical design of the flare system. 6.2 Total flare gas pressure drop flare inlet to flare tip exit. 6.3 Heat Radiation not exceeding 1.58 kW/m2 at ground level 43 m from stack base at design flare capacity plus solar radiation. 6.4 Continuous safe operation of pilot burner under specified flare capacity and wind velocity. 6.5 Continuous safe operation of flare tip for full ranges from purge operation to design flare capacity. 6.6 Flaring design capacity. 6.7 Proper function of Flame Front Generator (FFG) 6.8 Stack gas emission 6.9 Noise level 6.10 Utility Consumption - Fuel gas for pilot burner - Fuel gas for purge - Fuel gas for FFG - Fuel gas for assist gas - Utility air for ignition - Electrical power for FFG 7. High temperature resistant extension cable to the junction box located at stack base shall be supplied by vendor. The extension cable shall as a minimum be 304SS braided, teflon insulated color coded chrome-alumel cable. 8 Vendor shall ensure necessity of assist gas (fuel gas) to be introduced in sour gas due to low heating value for complete combustion and vendor shall estimate fuel gas consumption in case assist gas is required. Vendor to consider minimum net heating value of the sour gas shall be 200 BTU/scf. 9 Vendor shall verify flare tip type smokeless or non-smokeless refer to all flare design case. 10 Steam tracing to be provided up to dry gas seal. The requirement of steam tracing refer to specification for steam tracing (Doc.No.S-00-1360-005). 11 Flare stack material shall comply to NACE MR.0175 .

SWS Project Job Code 0-0584-00-0000 Data sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN. Doc. No. DS-19-013-001-A4 Sheet 7 0f 9 Rev. 3A ATTACHMENT-1

SWS Project Job Code 0-0584-00-0000 Data sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN. Doc. No. DS-19-013-001-A4 Sheet 8 0f 9 Rev. 3A ATTACHMENT-2

SWS Project Job Code 0-0584-00-0000 Data sheet for Flare Stack V-219-03

Doc. No. S-19-1357-101 PN. Doc. No. DS-19-013-001-A4 Sheet 9 0f 9 Rev. 3A ATTACHMENT-3