NRL REFINERY FLARE PACKAGE SYSTEM
FLARE PACKAGE SYSTEM
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
NUMALIGARH REFINERY LTD
Client
AFG COMBUSTION PVT LTD. (Formerly Known as Airoil Flaregas Pvt Ltd.)
PMC
ENGINEERS INDIA LTD
Location
NUMALIGARH INDIA
Project Scope
The Greenfield project scope comprises of Detail engineering of Piping, comprehensive 3D modelling, Piping stress analysis and Civil and Structural engineering for the Refinery Hydrocarbon Flare System with KO drum, Water seal drum, Molecular seal and Flare tip along with supporting structure.
Development and finalization of engineering deliverables for procurement, fabrication, construction, and commissioning activities.
The flare system in the project comprises of Flare Knock-Out (KO) Drums, KOD Pumps, Water Seal Drum, Flare Riser, Molecular Seal, Flare Tip, and Flare Headers from battery limits (B/L) to KO drums and from KO drums to the water seal drum, with a maximum header size of 86 inches for 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 86 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 flare system, designed for both functionality and safety to withstand environmental loads such as wind and seismic forces also trussell supports are designed to support large diameter flare header.
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 Refinery Hydrocarbon Flare System.
The project covers multiple flare networks including KO drums, KOD pumps, Water seal drum, Flare riser, Molecular seal and flare tip along with flare headers size 86” from battery limits to KO drums and water seal drum.
Developed intelligent 3D models ensuring: Clash-free interdisciplinary design, Optimized routing of large bore piping (up to 86”) with improved constructability and space utilization
Performed comprehensive pipe stress analysis, considering: Thermal expansion and sustained loads, Wind and Seismic loads, Occasional and emergency operating conditions.