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Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 1 of 9
DESIGN ENGINEERING LNG TERMINAL JAWA TIMUR PHASE-1
FLARE SPECIFICATION
1 Rev
04/03/2019 Date
IFB Status
ISSUED FOR BID Description
ADP/HBP Iss’d
DH/VIC IM Chck’d SENA
Apprv’d
FAP AAR Apprv’d Apprv’d PGN LNG INDONESIA
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1 Revision Date : 04-03-2019
Doc type: Specification
Discipline: Mechanical Page 2 of 9
Rev. 1
Date 04/03/2019
Page
REVISION HISTORICAL SHEET Description Issued for Bid
Status : IFB
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 3 of 9
TABLE OF CONTENTS TABLE OF CONTENTS.........................................................................................................................3 1.
INTRODUCTION ............................................................................................................................4
1.1. GENERAL.....................................................................................................................................4 1.2. SCOPE OF SUPPLY ....................................................................................................................4 1.3. REFERENCES .............................................................................................................................4 2.
DEFINITIONS .................................................................................................................................5
3.
SPECIFIC DESIGN REQUIREMENT ..............................................................................................5
3.1. GENERAL.....................................................................................................................................5 3.2. OPERATING CONDITION ............................................................................................................6 3.3. FLARE SERVICES .......................................................................................................................6 3.4. FLARE DESIGN............................................................................................................................6 3.5. PERFOMANCE.............................................................................................................................6 3.6. FLARE STACK .............................................................................................................................7 3.7. FLAME FRONT GENERATOR .....................................................................................................7 3.8. PILOT IGNITOR............................................................................................................................7 3.9. MATERIAL ....................................................................................................................................7 3.10. ELECTRICAL ................................................................................................................................7 4.
INSPECTION AND TESTING .........................................................................................................8
5.
PROTECTIVE COATING ................................................................................................................8
6.
PREPARATION FOR SHIPMENT AND STORAGE .......................................................................8
7.
SPARE PARTS ..............................................................................................................................8
8.
WARRANTY ...................................................................................................................................9
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 4 of 9
1.
INTRODUCTION
1.1. General This specification covers the minimum requirements for the design, materials, fabrication, inspection and testing, and preparation of shipment of flare including flare stack and flare tip for LNG Regasification Plant Project PT PGN LNG located in Teluk Lamong, Surabaya. This specification serves as an additional specification for Mechanical Design Basis (Document No LTJ-MEC-001). The flare required shall be designed, fabricated, and erected to the standards, codes, engineering practices, and general requirements as per Design Basis with high quality and high degree of safety in according with the contractual codes and standards, reliability, and engineering standard as far as possible. 1.2. Scope of Supply Supplier shall supply the following: 1. Supplier shall responsible for all necessary design, analysis, procurement and fabrication to supply a flare package system according to this specification and datasheet for flare (Document No LTJMEC-014) and Process Safety Design Basis (Document No LTJ-PSY-001). 2. Providing technical representative at the jobsite to assist during installation, start up, testing, and to ensure safe and satisfactory operation of the flare system. 3. Supplier shall provide information regarding foundation requirement, which will be built by Purchaser. 4. Detailed description of pilot, monitor, and ingition system. 5. Flare gas and pilot gas pressure required for reliable operation. 6. Ground area required for flare equipment plus additional area required for personnel protection. 7. Detailed drawings on Electrical Wiring 8. Detailed procedures for installation, testing, operation, and maintenance. 9. Detailed list of recommended spare parts for a one year period. 1.3. References The latest revision of applicable sections of the codes, standards, and specifications listed below (including agenda, and documents incorporated by reference) shall be considered an integral part of this specification. Where two or more references define requirements for the same subject, the more restrictive reference shall govern. AISC, Specification for the Design Fabrication and Erection of Structural Steel for Building ANSI A58.1, American National Standard Building Code Requirements for Minimum Design Loads in Buildings and other Structures ANSI B31.3, Chemical Plant and Petroleum Refinery Piping ASME Boiler and Pressure Vessel Codes; Section V, Non Destructive Examination; Section VIII, Rules for Construction of Pressure Vessels Division I; Section IX, Welding and Brazing Qualifications NEMA, Industrial Standards of National Electrical Manufactures Association NEC Standards NFPA 70 National Electric Code API 537, “Flare Details for Petroleum, Petrochemical, and Natural Gas Industries” API 521, “Guide for Pressure-Relieving and Depressuring Systems”
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 5 of 9
2.
DEFINITIONS
Refer to applicable code and standard for definitions cited in this specification.
3.
SPECIFIC DESIGN REQUIREMENT
3.1. General 1. Design and Construction shall comply with all applicable codes and with the ordinates of the governing agencies in the area where the new flare system to be installed. 2. Supplier shall provide flare package which has been in service as a proven technology when run continuously and it has been applied successfully, safely, and reliably and efficiently, in typical Gas and LNG plants in the world and meet the environment regulation. 3. The flare is used for cryogenic service. 4. Flare tip shall be designed for smokeless operation. The flare shall have capability in operation for emergency blow-down during process start-ups or upsets conditions, with maximum combustion flow, as specified in the datasheet. 5. The design life of equipment shall be 25 years as a minimum, except for flare components, which shall be designed, for minimum 4 years service life. 6. The flare tip shall be designed for minimum maintenance (minimizing the potential damage to the tip). The objective is no maintenance required between plant overhauls / maintenance, or a period of four years continuous operation. 7. The design of flare tip shall include the change out system for facilitating easy removal and replacement of flare tip. 8. In general, smokeless dry flares system shall be provided with all equipment and auxiliaries, including but not limited to the following: −
The flare tip shall be designed for smokeless operation with non-assisted type.
−
Vendor shall responsible for all necessary design, analysis, procurement and fabrication to supply
9. The new flare package system shall be suitable to fit in the LNG Regasification Plant PT PGN LNG Project’s area according to the P&ID (Document No LTJ-PRC-004) & Plot Plan (Document No LTJGEN-001). 10. The new smokeless flare tip shall be designed to keep purging to a minimum. The vendor shall provide sweep gas flow and velocity requirements to prevent any back flow of air in wind conditions up to 42 km/hour (25 mph). The normal sweep gas flow is 2-3 fps. 11. One thermocouple per pilot, to detect flameout, shall be provided, wired to the electrical junction box. 12. The new flare tip system shall be complete with all materials components, accessories and appurtenance necessary, including studs, nuts, lugs and interconnecting fuel gas and flame front piping for straight forward field erection. 13. Electrical wiring and conduit shall be installed where appropriate to suit the unit breakdown for shipment. Lengths of cable to connect remote control boxes shall be shipped loose. 14. Vendor shall provide design details, sizes, template and other pertinent information to allow the purchaser to erect the new flare tip system under the guidance of vendor's field representatives. 15. Sizing of flare tip for design flow rate at a specified allowable pressure drop. Maximum pressure drop allowable that can with maximum combined seal and tip differential pressure is 0.5. kg/cm2 at maximum flow given in datasheets. 16. Flare radiation shall be less than 1,600 btu/hr-ft2 at ground distance as specified in Process Safety Design Basis (Document No LTJ-PSY-001).
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 6 of 9
3.2. Operating Condition 1. Refer to flare package system datasheet (Document No LTJ-MEC-014) for detailed data regarding operating parameter of the flare. 2. Utilities available are as follows: Instrument air 8.0 kg/cm2 @30oC Electricity 380 VAC, 50 Hz 3.3. Flare Services 1. The flare is running continuously to service the regasification plant. 2. The dry flare is used for cryogenic service. All relief valve vented gas is burned by a flare stack system. 3.4. Flare Design 1. The new smokeless flare tip design shall not cause any flameout problem. Vendor shall provide flame protection sufficiently. At least three separate pilots/flare tip shall be provided. Multi continuous igniters/pilot shall be provided. Vendor shall provide heat protected multi thermocouples at tip. 2. New smokeless flare tip design should not exceed the maximum opacity measured by opacity meter 20% opacity all time. 3. Flow rate of the relieved gas is 37,051.03 kg/hr (46,734.4 m3/hr) 4. The flare tip design shall not cause any flame out with the seep gas flow. 5. New smokeless flare tip design noise should not exceed 85 dB level at flare ground base at all times with the gas flow specified in the datasheet. 6. New smokeless flare tip thermal radiation or heat flux should not exceed 1,600 btu/hr-ft2 radiation zone from the flare base. Vendor is to confirm their radiation zone is meet with the existing flare tip radiation zone as states in the datasheet. 7. Flare tip shall not create any vibration to the flare facilities / system at the flow rate as states in the datasheet. 8. The flare tip shall be fabricated from a suitable heat and oxidation resistant materials. This shall include a "seal" device to prevent waste gas back flow. 9. Supplier shall provide sufficient windshield design to the flare tip. 10. Supplier shall supply a knocked down, packaged flare system to meet the operating requirements, given in the completed datasheet, to safely burn natural gas vapors. 11. Flare shall be equipped with flame retention rings, flare windshields, a flanged connection and lifting lug. 12. Upper portions of the windshield and other flare tip components in close proximity to the flame shall be fabricated from Stainless Steel 310. 13. Flares shall be properly designed for all applicable conditions, temperature, corrosion, wind, earthquake, dead load and vibration effects. 14. All design calculations shall be submitted to purchaser for review and comments before construction starts. 3.5. Perfomance 1. Supplier shall guarantee the performance as indicate in their performance datasheet for the flare tip. 2. Supplier shall guarantee that the flare tip should not cause any flame flickering or flame out problem. 3. Supplier shall perform performance test to the flare tip based on their performance guarantee figures. All the performance should be based on that there is no any flame flickering or any flame out problems.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 7 of 9
3.6. Flare Stack 1. Structural design of the flare stack system as a whole, and any of its component elements, shall be based on conditions of loading that produces the highest overturning moments, or highest stress in any individual member or connection. 2. Vendor shall calculate the temperature of the product piping and the structure. The calculation for the maximum stack and derrick metal temperature shall be based upon the flare operating at the maximum design condition together with ambient temperature of 37oC. 3. Stack deflection due to static wind load shall not be exceed 150 mm (6 inches) per 30 m (100 feet) of stack height. 4. Dynamic design analysis shall determine the flare stack's critical wind velocity. 5. The entire vibrating structure, including the foundations, must have sufficient damping capability to absorb the cyclic energy input at the critical wind velocity to keep the load stresses (due to deflection amplitude) below the maximum allowed by codes. 6. Lifting lugs shall be appropriately designed and the stack adequately stiffened, if necessary, for the lifting load when the stack is rotated from the horizontal to the vertical position. 3.7. Flame Front Generator 1. All metal , tubing fittings, connectors, (such as hinges, nuts, and bolts), valves and all components subject to atmospheric corrosive attack shall be fabricated from an austenitic stainless steel. 2. An electrical junction box shall be mounted on the side of the console. It shall meet the requirements of the area electrical classification and be watertight, or be provided with a roof to give protection from rain. 3. Conduit to and from the junction box shall enter through its bottom side to feed into the bottom side of the console. 4. An alarm shall be mounted on the console to indicate flameout at each pilot. 3.8. Pilot Ignitor 1. A manually operated ignitor shall give dependable pilot ignitor under adverse weather conditions. 2. Component of the ignitor, including piping, electrical devices, valves and instruments, shall be mounted on a stainless steel. 3. Ignitor shall be capable of operation from outside the 1,600 btu/hr-ft2 radiation zone from the flare stack. 4. Pilot shall be fabricated from heat resistant material (Stainless Steel 310 or similar). 5. Supplier shall supply piping for site installation by purchaser from the ignitor to the flare system. 3.9. Material 1. 2. 3. 4. 5.
Flare tip material shall be stainless steel 310. Flare stack material shall be stainless steel 304. Flare tip design internal shall be provided with refractory material. Materials shall be suitable for temperature as low as -157oC. All intended construction materials, which are not specified in this specification or in datasheets, shall be subject to approval by the purchaser.
3.10. Electrical 1. Electrical components and installation procedure shall meet the requirement of a Class 1, Group D, Division II classification. 2. Controls and instruments shall be intrinsically safe wherever applicable. 3. Conduit and pulled wire shall be installed and shipped attached to the structure to the greatest extent possible.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 8 of 9
4. Pull boxes shall be installed at point of field connection rather than terminal junction. Enough wire shall be left free to provide unbroken wiring from a set of terminals at the base of the structure to each electrical device or light. 5. Wire and cable shall be provided for field installation from console or to the flare system junction box.
4.
INSPECTION AND TESTING
1. All shop welds of structural, load-bearing shall be visually inspected during the procedure, and on its completion. Further requirement are: 2. All welds shall be given an NDT examination in conformity with ASME Section V. Acceptance standards for each test and material shall conform to the requirements of ASME Section VIII. 3. Type of examination to be applied is at the discretion of the inspector to suit the weldment circumstances. 4. If not designated otherwise, all structural examinations shall use the liquid penetrant techniques. 5. 10% of all welds not designated for examination by the purchaser's inspector shall be chosen at random for PT examination. 6. Prior to final acceptance by the purchaser, the flare system shall be performance tested after installation at the site. The system as a whole and its components shall demonstrate that they are fully functional in accordance with the requirement of this specification and datasheet.
5.
PROTECTIVE COATING
1. Adequate protection of material surface exposed to the humid, salt laden atmosphere is of the utmost importance. 2. The paint shall be applied in the vendor's fabrication facilities. 3. Only surface of stainless steel do not need to be coated for corrosion protection. 4. For all structural member and component surface to be coated, the required paint system shall be designated in the datasheet or other material requisition documents and Specification for Surface Preparation & Coating (Document No LTJ-PIP-006). 5. Adequate quantities of each coat, in suitable containers and clearly marked, shall be included as part of the shipment, to facilitate coating damage repairs after erection.
6.
PREPARATION FOR SHIPMENT AND STORAGE
1. It is intended that each flare tip system be created in an assembled state that is as complete as practical. This shall be at the discretion of a Supplier, with an aim to minimize re-assembly upon installation at the job site.
7.
SPARE PARTS
1. In the bid proposal, Supplier shall give enough information on spare parts and tools, with pricing, to allow purchaser to select a set of equipment for maintenance needs. The list shall include, but not limited to the following: 2. Assembled and exploded view for flare package. 3. Bill of material for flare package. 4. Suggested spare parts for regularly scheduled maintenance over two years. 5. Suggested spare parts for a major overhaul. 6. Suggested specialty and maintenance tools.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 9 of 9
7. Price lists for all suggested items, except for spares for start up and specially tools, which are part of the supply, itself.
8.
WARRANTY
1. Supplier shall warranty that the service lifecycle is at least 4 year service life before inspection. There is no maintenance before inspection period. 2. Supplier shall warranty that new smokeless flare tip system shall be safe, reliable, and efficient to be operated continuously.
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 1 of 9
DESIGN ENGINEERING LNG TERMINAL JAWA TIMUR PHASE-1
FLARE SPECIFICATION
1 Rev
04/03/2019 Date
IFB Status
ISSUED FOR BID Description
ADP/HBP Iss’d
DH/VIC IM Chck’d SENA
Apprv’d
FAP AAR Apprv’d Apprv’d PGN LNG INDONESIA
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1 Revision Date : 04-03-2019
Doc type: Specification
Discipline: Mechanical Page 2 of 9
Rev. 1
Date 04/03/2019
Page
REVISION HISTORICAL SHEET Description Issued for Bid
Status : IFB
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 3 of 9
TABLE OF CONTENTS TABLE OF CONTENTS.........................................................................................................................3 1.
INTRODUCTION ............................................................................................................................4
1.1. GENERAL.....................................................................................................................................4 1.2. SCOPE OF SUPPLY ....................................................................................................................4 1.3. REFERENCES .............................................................................................................................4 2.
DEFINITIONS .................................................................................................................................5
3.
SPECIFIC DESIGN REQUIREMENT ..............................................................................................5
3.1. GENERAL.....................................................................................................................................5 3.2. OPERATING CONDITION ............................................................................................................6 3.3. FLARE SERVICES .......................................................................................................................6 3.4. FLARE DESIGN............................................................................................................................6 3.5. PERFOMANCE.............................................................................................................................6 3.6. FLARE STACK .............................................................................................................................7 3.7. FLAME FRONT GENERATOR .....................................................................................................7 3.8. PILOT IGNITOR............................................................................................................................7 3.9. MATERIAL ....................................................................................................................................7 3.10. ELECTRICAL ................................................................................................................................7 4.
INSPECTION AND TESTING .........................................................................................................8
5.
PROTECTIVE COATING ................................................................................................................8
6.
PREPARATION FOR SHIPMENT AND STORAGE .......................................................................8
7.
SPARE PARTS ..............................................................................................................................8
8.
WARRANTY ...................................................................................................................................9
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 4 of 9
1.
INTRODUCTION
1.1. General This specification covers the minimum requirements for the design, materials, fabrication, inspection and testing, and preparation of shipment of flare including flare stack and flare tip for LNG Regasification Plant Project PT PGN LNG located in Teluk Lamong, Surabaya. This specification serves as an additional specification for Mechanical Design Basis (Document No LTJ-MEC-001). The flare required shall be designed, fabricated, and erected to the standards, codes, engineering practices, and general requirements as per Design Basis with high quality and high degree of safety in according with the contractual codes and standards, reliability, and engineering standard as far as possible. 1.2. Scope of Supply Supplier shall supply the following: 1. Supplier shall responsible for all necessary design, analysis, procurement and fabrication to supply a flare package system according to this specification and datasheet for flare (Document No LTJMEC-014) and Process Safety Design Basis (Document No LTJ-PSY-001). 2. Providing technical representative at the jobsite to assist during installation, start up, testing, and to ensure safe and satisfactory operation of the flare system. 3. Supplier shall provide information regarding foundation requirement, which will be built by Purchaser. 4. Detailed description of pilot, monitor, and ingition system. 5. Flare gas and pilot gas pressure required for reliable operation. 6. Ground area required for flare equipment plus additional area required for personnel protection. 7. Detailed drawings on Electrical Wiring 8. Detailed procedures for installation, testing, operation, and maintenance. 9. Detailed list of recommended spare parts for a one year period. 1.3. References The latest revision of applicable sections of the codes, standards, and specifications listed below (including agenda, and documents incorporated by reference) shall be considered an integral part of this specification. Where two or more references define requirements for the same subject, the more restrictive reference shall govern. AISC, Specification for the Design Fabrication and Erection of Structural Steel for Building ANSI A58.1, American National Standard Building Code Requirements for Minimum Design Loads in Buildings and other Structures ANSI B31.3, Chemical Plant and Petroleum Refinery Piping ASME Boiler and Pressure Vessel Codes; Section V, Non Destructive Examination; Section VIII, Rules for Construction of Pressure Vessels Division I; Section IX, Welding and Brazing Qualifications NEMA, Industrial Standards of National Electrical Manufactures Association NEC Standards NFPA 70 National Electric Code API 537, “Flare Details for Petroleum, Petrochemical, and Natural Gas Industries” API 521, “Guide for Pressure-Relieving and Depressuring Systems”
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 5 of 9
2.
DEFINITIONS
Refer to applicable code and standard for definitions cited in this specification.
3.
SPECIFIC DESIGN REQUIREMENT
3.1. General 1. Design and Construction shall comply with all applicable codes and with the ordinates of the governing agencies in the area where the new flare system to be installed. 2. Supplier shall provide flare package which has been in service as a proven technology when run continuously and it has been applied successfully, safely, and reliably and efficiently, in typical Gas and LNG plants in the world and meet the environment regulation. 3. The flare is used for cryogenic service. 4. Flare tip shall be designed for smokeless operation. The flare shall have capability in operation for emergency blow-down during process start-ups or upsets conditions, with maximum combustion flow, as specified in the datasheet. 5. The design life of equipment shall be 25 years as a minimum, except for flare components, which shall be designed, for minimum 4 years service life. 6. The flare tip shall be designed for minimum maintenance (minimizing the potential damage to the tip). The objective is no maintenance required between plant overhauls / maintenance, or a period of four years continuous operation. 7. The design of flare tip shall include the change out system for facilitating easy removal and replacement of flare tip. 8. In general, smokeless dry flares system shall be provided with all equipment and auxiliaries, including but not limited to the following: −
The flare tip shall be designed for smokeless operation with non-assisted type.
−
Vendor shall responsible for all necessary design, analysis, procurement and fabrication to supply
9. The new flare package system shall be suitable to fit in the LNG Regasification Plant PT PGN LNG Project’s area according to the P&ID (Document No LTJ-PRC-004) & Plot Plan (Document No LTJGEN-001). 10. The new smokeless flare tip shall be designed to keep purging to a minimum. The vendor shall provide sweep gas flow and velocity requirements to prevent any back flow of air in wind conditions up to 42 km/hour (25 mph). The normal sweep gas flow is 2-3 fps. 11. One thermocouple per pilot, to detect flameout, shall be provided, wired to the electrical junction box. 12. The new flare tip system shall be complete with all materials components, accessories and appurtenance necessary, including studs, nuts, lugs and interconnecting fuel gas and flame front piping for straight forward field erection. 13. Electrical wiring and conduit shall be installed where appropriate to suit the unit breakdown for shipment. Lengths of cable to connect remote control boxes shall be shipped loose. 14. Vendor shall provide design details, sizes, template and other pertinent information to allow the purchaser to erect the new flare tip system under the guidance of vendor's field representatives. 15. Sizing of flare tip for design flow rate at a specified allowable pressure drop. Maximum pressure drop allowable that can with maximum combined seal and tip differential pressure is 0.5. kg/cm2 at maximum flow given in datasheets. 16. Flare radiation shall be less than 1,600 btu/hr-ft2 at ground distance as specified in Process Safety Design Basis (Document No LTJ-PSY-001).
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 6 of 9
3.2. Operating Condition 1. Refer to flare package system datasheet (Document No LTJ-MEC-014) for detailed data regarding operating parameter of the flare. 2. Utilities available are as follows: Instrument air 8.0 kg/cm2 @30oC Electricity 380 VAC, 50 Hz 3.3. Flare Services 1. The flare is running continuously to service the regasification plant. 2. The dry flare is used for cryogenic service. All relief valve vented gas is burned by a flare stack system. 3.4. Flare Design 1. The new smokeless flare tip design shall not cause any flameout problem. Vendor shall provide flame protection sufficiently. At least three separate pilots/flare tip shall be provided. Multi continuous igniters/pilot shall be provided. Vendor shall provide heat protected multi thermocouples at tip. 2. New smokeless flare tip design should not exceed the maximum opacity measured by opacity meter 20% opacity all time. 3. Flow rate of the relieved gas is 37,051.03 kg/hr (46,734.4 m3/hr) 4. The flare tip design shall not cause any flame out with the seep gas flow. 5. New smokeless flare tip design noise should not exceed 85 dB level at flare ground base at all times with the gas flow specified in the datasheet. 6. New smokeless flare tip thermal radiation or heat flux should not exceed 1,600 btu/hr-ft2 radiation zone from the flare base. Vendor is to confirm their radiation zone is meet with the existing flare tip radiation zone as states in the datasheet. 7. Flare tip shall not create any vibration to the flare facilities / system at the flow rate as states in the datasheet. 8. The flare tip shall be fabricated from a suitable heat and oxidation resistant materials. This shall include a "seal" device to prevent waste gas back flow. 9. Supplier shall provide sufficient windshield design to the flare tip. 10. Supplier shall supply a knocked down, packaged flare system to meet the operating requirements, given in the completed datasheet, to safely burn natural gas vapors. 11. Flare shall be equipped with flame retention rings, flare windshields, a flanged connection and lifting lug. 12. Upper portions of the windshield and other flare tip components in close proximity to the flame shall be fabricated from Stainless Steel 310. 13. Flares shall be properly designed for all applicable conditions, temperature, corrosion, wind, earthquake, dead load and vibration effects. 14. All design calculations shall be submitted to purchaser for review and comments before construction starts. 3.5. Perfomance 1. Supplier shall guarantee the performance as indicate in their performance datasheet for the flare tip. 2. Supplier shall guarantee that the flare tip should not cause any flame flickering or flame out problem. 3. Supplier shall perform performance test to the flare tip based on their performance guarantee figures. All the performance should be based on that there is no any flame flickering or any flame out problems.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 7 of 9
3.6. Flare Stack 1. Structural design of the flare stack system as a whole, and any of its component elements, shall be based on conditions of loading that produces the highest overturning moments, or highest stress in any individual member or connection. 2. Vendor shall calculate the temperature of the product piping and the structure. The calculation for the maximum stack and derrick metal temperature shall be based upon the flare operating at the maximum design condition together with ambient temperature of 37oC. 3. Stack deflection due to static wind load shall not be exceed 150 mm (6 inches) per 30 m (100 feet) of stack height. 4. Dynamic design analysis shall determine the flare stack's critical wind velocity. 5. The entire vibrating structure, including the foundations, must have sufficient damping capability to absorb the cyclic energy input at the critical wind velocity to keep the load stresses (due to deflection amplitude) below the maximum allowed by codes. 6. Lifting lugs shall be appropriately designed and the stack adequately stiffened, if necessary, for the lifting load when the stack is rotated from the horizontal to the vertical position. 3.7. Flame Front Generator 1. All metal , tubing fittings, connectors, (such as hinges, nuts, and bolts), valves and all components subject to atmospheric corrosive attack shall be fabricated from an austenitic stainless steel. 2. An electrical junction box shall be mounted on the side of the console. It shall meet the requirements of the area electrical classification and be watertight, or be provided with a roof to give protection from rain. 3. Conduit to and from the junction box shall enter through its bottom side to feed into the bottom side of the console. 4. An alarm shall be mounted on the console to indicate flameout at each pilot. 3.8. Pilot Ignitor 1. A manually operated ignitor shall give dependable pilot ignitor under adverse weather conditions. 2. Component of the ignitor, including piping, electrical devices, valves and instruments, shall be mounted on a stainless steel. 3. Ignitor shall be capable of operation from outside the 1,600 btu/hr-ft2 radiation zone from the flare stack. 4. Pilot shall be fabricated from heat resistant material (Stainless Steel 310 or similar). 5. Supplier shall supply piping for site installation by purchaser from the ignitor to the flare system. 3.9. Material 1. 2. 3. 4. 5.
Flare tip material shall be stainless steel 310. Flare stack material shall be stainless steel 304. Flare tip design internal shall be provided with refractory material. Materials shall be suitable for temperature as low as -157oC. All intended construction materials, which are not specified in this specification or in datasheets, shall be subject to approval by the purchaser.
3.10. Electrical 1. Electrical components and installation procedure shall meet the requirement of a Class 1, Group D, Division II classification. 2. Controls and instruments shall be intrinsically safe wherever applicable. 3. Conduit and pulled wire shall be installed and shipped attached to the structure to the greatest extent possible.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 8 of 9
4. Pull boxes shall be installed at point of field connection rather than terminal junction. Enough wire shall be left free to provide unbroken wiring from a set of terminals at the base of the structure to each electrical device or light. 5. Wire and cable shall be provided for field installation from console or to the flare system junction box.
4.
INSPECTION AND TESTING
1. All shop welds of structural, load-bearing shall be visually inspected during the procedure, and on its completion. Further requirement are: 2. All welds shall be given an NDT examination in conformity with ASME Section V. Acceptance standards for each test and material shall conform to the requirements of ASME Section VIII. 3. Type of examination to be applied is at the discretion of the inspector to suit the weldment circumstances. 4. If not designated otherwise, all structural examinations shall use the liquid penetrant techniques. 5. 10% of all welds not designated for examination by the purchaser's inspector shall be chosen at random for PT examination. 6. Prior to final acceptance by the purchaser, the flare system shall be performance tested after installation at the site. The system as a whole and its components shall demonstrate that they are fully functional in accordance with the requirement of this specification and datasheet.
5.
PROTECTIVE COATING
1. Adequate protection of material surface exposed to the humid, salt laden atmosphere is of the utmost importance. 2. The paint shall be applied in the vendor's fabrication facilities. 3. Only surface of stainless steel do not need to be coated for corrosion protection. 4. For all structural member and component surface to be coated, the required paint system shall be designated in the datasheet or other material requisition documents and Specification for Surface Preparation & Coating (Document No LTJ-PIP-006). 5. Adequate quantities of each coat, in suitable containers and clearly marked, shall be included as part of the shipment, to facilitate coating damage repairs after erection.
6.
PREPARATION FOR SHIPMENT AND STORAGE
1. It is intended that each flare tip system be created in an assembled state that is as complete as practical. This shall be at the discretion of a Supplier, with an aim to minimize re-assembly upon installation at the job site.
7.
SPARE PARTS
1. In the bid proposal, Supplier shall give enough information on spare parts and tools, with pricing, to allow purchaser to select a set of equipment for maintenance needs. The list shall include, but not limited to the following: 2. Assembled and exploded view for flare package. 3. Bill of material for flare package. 4. Suggested spare parts for regularly scheduled maintenance over two years. 5. Suggested spare parts for a major overhaul. 6. Suggested specialty and maintenance tools.
Document No. LTJ-MEC-006
Contract No :
FLARE SPECIFICATION
Revision : 1
Status : IFB
Revision Date : 04-03-2019 Doc type: Specification
Discipline: Mechanical Page 9 of 9
7. Price lists for all suggested items, except for spares for start up and specially tools, which are part of the supply, itself.
8.
WARRANTY
1. Supplier shall warranty that the service lifecycle is at least 4 year service life before inspection. There is no maintenance before inspection period. 2. Supplier shall warranty that new smokeless flare tip system shall be safe, reliable, and efficient to be operated continuously.
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