DE-MOUNTABLE FLARE SYSTEM PACKAGE
SYSTEM PACKAGE
Delivered integrated Piping, Civil & Structural engineering, intelligent 3D modelling and Piping stress analysis solutions to ensures safe, reliable, and construction-ready execution for the Refinery Hydrocarbon Flare System.
Owner
HPCL RAJASTHAN REFINERY LTD (HRRL)
Client
AFG COMBUSTION PVT LTD. (Formerly Known as Airoil Flaregas Pvt Ltd.)
PMC
ENGINEERS INDIA LTD
Location
PACHPADRA, BARMER, INDIA
Project Scope
The Greenfield project scope comprises Detail engineering of Piping, comprehensive 3D modelling, and Piping stress analysis, Civil and Structural engineering for the Refinery Hydrocarbon Flare System, including Low Pressure (LP) and High Pressure (HP) flares, DFCU LP Flare System, Polymer LP Flare System, C4 Acetylene Flare System, and Sour Acid Flare System.
Development and finalization of engineering deliverables for procurement, fabrication, construction, and commissioning activities.
The flare system in the project comprises following systems:
• Low Pressure (LP) and High Pressure (HP) Flare System.
• Delayed Fluid Coker Unit (DFCU) LP Flare System
• Polymer Flare System
• C4 Acetylene Flare System
• Sour Acid Gas Flare System
Each system is engineered with dedicated or common headers, ensuring safe segregation, controlled disposal of hydrocarbons, and efficient handling of varying pressure and composition streams.
At the core of the project lies Piping engineering and highly detailed 3D model, that serves as a single source of truth for all engineering disciplines.
The piping scope includes design of large-bore flare headers (up to 100 inches) from battery limits to KO drums and onward to flare stacks, ensuring proper slope for drainage, minimal pressure drop, and accessibility for operation and maintenance and Integration with civil, structural, E&I systems using 3D modelling for efficient coordination.
Engineering activities include piping routing, piping layout development, critical line stress analysis, utility integration and multidisciplinary coordination.
Given the extreme conditions in flare systems, detailed stress analysis is a critical component to take care of Thermal Expansion, various load considerations like Sustained, occasional and dynamic loads with support optimization and code compliance.
The project includes a common derrick structure supporting multiple flare systems, designed for both functionality and safety to withstand environmental loads such as wind and seismic forces also trussell support and Piperack are designed to support large diameters flare headers.
Access Platforms, Stairs & Ladders are designed for safe operation, access for inspection and maintenance at elevated heights.
Key Highlights
Detail engineering of Piping, Civil & Structural engineering, 3D modelling of complete facility and Piping stress analysis of system of equipment Refinery Hydrocarbon Flare System.
The project covers multiple flare networks including: LP & HP Flare Systems, DFCU LP Flare System, Polymer LP Flare System, C4 Acetylene Flare System, Sour Acid Flare System with Flare Knock-Out (KO) Drums, KOD Pumps, Water Seal Drum, Flare Risers, Molecular Seals, Flare Tips.
Developed intelligent 3D models ensuring: Clash-free interdisciplinary design, Optimized routing of large bore piping (up to 100”) with improved constructability and space utilization.
Performed comprehensive Piping stress analysis, considering: Thermal expansion and sustained loads, Wind and Seismic loads, Occasional and emergency operating conditions.