Zink Proposal

WRITING OF JOHN ZINK

INFORMATION SHALL BE DISCLOSED TO ANY THIRD PARTY OR REPRODUCED IN WHOLE OR PART WITHOUT THE PRIOR CONSENT IN

THIS INFORMATION IS CONFIDENTIAL AND THE PROPERTY OF JOHN ZINK AND IS RELEASED ON CONDITION THAT NONE OF THE

TITLE

SCALE

ISSUE STAMP

KALDAIR JOB No.

PROJECT

CLIENT ORDER No.

CLIENT

ENG.

PROJ.PROCESSDESCRIPTIONDATEREV

DRG. No.

A B C D E F G H

A B C D E F G H

5

4

3

2

6

1 1

2

3

4

5

6

ENG.

NONE

PIPING & INSTRUMENTATION DIAGRAM

0 21.11.05 ISSUED FOR TENDER NDP

DRN.

DR

G.

No.

KEP-100 PILOT IGNITION SYSTEM

NOTES:

1. HT CABLE FOR KEP-100 IGNITION & DETECTION SUPPLIED BY JZ

2. DRAIN ALL LOW POINTS.

.

PRELIMINARY

Dolphn House

140 Windmill RoadSunbury-on-Thames

Middlesex, TW16 7HTEngland

Tel: (01932) 769830Fax: (01932) 787471

Division of the Koch Chemical

Technology Group Limited

JOHN ZINK

PILOT B

BAH

PILOT AON

BAL

PILOT BOFF

HS HS

MANUAL

AUTO/OFF

MANUAL

HSHS

KEP-100

CLIENT JOHN ZINK

INLET

PI

XA

1"1"

NOTE 1

BAH

PILOT BON

OFFPILOT A

BAL

IGNITE

PILOT BPILOT AMANUAL

IGNITE

PILOT A PILOT B

PCV

POWER SUPPLY240V 1ph 50Hz MANUAL

AUTO/OFF

ALARMCOMMON

PILOT FAIL

CLIENT JOHN ZINK

NOTE 1

BE BE

PILOT C

REMOTESTART/STOP

CLIENT JOHN ZINK

"1/ 21"x x 1""1/ 2

PILOT IGNITION & DETECTION PANEL

HP INLET

10" 150# RFWN

2 x KEP-100

JOHN ZINK®KOCH CHEMICAL TECHNOLOGY GROUP LIMITED

JOHN ZINK �� TODD COMBUSTION �� BROWN FINTUBE �� KALDAIR

Registered Address: Dolphin House � 140 Windmill Road � Sunbury-on-Thames � Middx TW16 7HT � England Telephone: +44 (0) 1932 769830 � Fax +44 (0) 1932 787471 / 789916

VAT No. GB 785 4178 88 � Registered in England � Registration No. 3321082

Sheet 1

Worley Parsons Worley Parsons

P.O Box-795

Postal Code-133

Muscat

Sultanate of Oman 2 April 2008

JZ Ref: 200803-8213-A

Client Ref: CON-BPXO-07-0007 Flares

Subject: Flare System Khazzan / Makarem Project

To the attention of : Sunil Nayyar

Dear Sunil,

In response to your valued enquiry, we are pleased to submit our technical and

commercial quotation for the equipment as described in the attached proposal. We

apologise for the delay in responding.

We would draw your attention to the advantages of selecting a sonic solution for

your high pressure flares in our Introduction on sheet 4 of the proposal. Individual

data sheets for the tips offered are located in the Apendix at the end of the proposal

document. The Commercial section, including pricing starts on sheet 17.

Should you have any questions or require additional information, please do not

hesitate to contact the undersigned.

There are many other new products in our range as well as the traditional products.

For full details on everything, please visit our Website on www.johnzink.com

Thank you for your interest in John Zink combustion products. We trust the attached

information is in accordance with your requirements and hope to have the privilege

of working with you on this project.

Very truly yours,

Nigel Philpott

Applications Engineer

JOHN ZINK Koch Chemical Technology Group




Sheet 2

TABLE OF CONTENT

1. TECHNICAL OFFER – SCOPE OF SUPPLY ......................................................................... 4

1.1 SCOPE OF SUPPLY........................................................................................................................ 4 1.2 PACKING ..................................................................................................................................... 10 1.3 CONTROL AND INSPECTION ....................................................................................................... 11 1.4 TECHNICAL NOTES AND CLARIFICATIONS ................................................................................. 12 1.5 EXCLUSIONS FROM THE SUPPLY ............................................................................................... 13 1.6 ADDITIONAL SERVICES .............................................................................................................. 13 1.7 STORAGE LIMITATION ................................................................................................................ 14 1.8 GUARANTEE................................................................................................................................ 15

2. COMMERCIAL OFFER ............................................................................................................. 17

2.1 PRICING ....................................................................................................................................... 17 2.2 COMMERCIAL TERMS ................................................................................................................. 19 2.2.1 GENERAL TERMS AND CONDITIONS ....................................................................................... 19 2.2.2 VALIDITY OF OUR OFFER ......................................................................................................... 19 2.2.3 TERMS OF PAYMENT ............................................................................................................... 19 2.2.4 DELIVERY TERMS (INCOTERMS 2000).................................................................................... 20 2.2.5 DELIVERY DATE ....................................................................................................................... 20 2.2.6 LIMITATION OF LIABILITY.......................................................................................................... 20 2.2.7 DOCUMENTATION .................................................................................................................... 21 2.2.8 INTELLECTUAL PROPERTY RIGHTS ........................................................................................ 21 2.2.9 FORCE MAJEURE..................................................................................................................... 21 2.2.10 TITLE AND RISK ..................................................................................................................... 21 2.2.11 NON-PAYMENT ...................................................................................................................... 22 2.2.12 ADDRESS WHERE TO PLACE THE ORDER ............................................................................. 23





Sheet 3

KOCH INTERNATIONAL / JOHN ZINK Division

Proposal prepared for

WORLEY PARSONS / BP OMAN

REVISION 0

KHAZZAN / MAKAREM PROJECT

Client Reference : CON-BPXO-07-0007 Flares

Koch International/John Zink Reference : 200803-8213-A

Part 1 (Technical - Scope of Supply)

PROPRIETARY INFORMATION NOTICE

All information supplied herewith, including without limitation technical or financial data, know-how,

formulae, processes, designs, photographs, drawings, specifications, software programs and samples

and any other material bearing or incorporating any information relating to John Zink's products or

systems is proprietary information belonging to John Zink. Such information shall not be copied,

reproduced, used or disclosed, (in whole or in part) without the prior consent of John Zink for any

purpose other than that for which it has been supplied

Please note that John Zink will enforce its intellectual property rights in any of its proprietary

information to the maximum extent permissible at law, without further notice.





Sheet 4

1. TECHNICAL OFFER – SCOPE OF SUPPLY

1.1 Scope of supply

INTRODUCTION

For this application we would propose to utilize our Indair High Pressure flare

technology wherever the pressures are available. This would apply to the Sweet

flare as well as the HP and LP flares.

This solution allows us to provide for smokeless operation to less than Ringelmann 1

over the whole flaring range of each flare as well as maximizing air entrainment to

improve atmospheric dispersion.

There are distinct cost advantages to operating your system at high pressure. These

are:

• Reduced stack height and weight. The stack height calculated for radiation

will be approximately half that required for a low pressure system.

• Reduced header sizes, reduces weight of header pipework and support

structure

• Smaller K.O. Drums, less cost, less weight

• No steam, air or water assistance required. Provision of any utilities has a

long term power consumption impact.

• No special materials required to prevent sea water corrosion from water

injection.

• Improved tip life. Staging of the multi nozzles reduces wear and tear on tip by

limiting low trickle flows to one nozzle.

• High pressure flares are more stable and less susceptible to weather

conditions.

• KMI has lower purge requirements than an open pipeflare and less

susceptibility to internal burning.

• High pressure flares have better dispersion characteristics than low pressure

flares. The KMI tip in particular is very efficient due to the quantity of air it

entrains.

• KMI has a more efficient burn than a low pressure flare





Sheet 5

The design we have offered presents the opportunity for you to make significant cost

savings both in the sizing of the flare stack, risers and KO drums as well as

eliminating the need for any additional equipment for utility supply. In addition there

is a long term operational saving both in the reduction in utility usage and reduced

maintenance costs.

For the Sour Service we are concerned about the low LHV. While we consider that

given the current composition a high pressure flare tip could be used, we anticipate

that over time the LHV of the field production will reduce due to inert gas re-injection

and therefore an HP flare tip would become unstable. Therefore for this application

we would offer a utility pipeflare.

For the AP service there is not enough pressure available to take advantage of a

high pressure flare tip design and therefore for this application we would propose a

utility pipeflare.

John Zink are able to offer a comprehensive after sales service package including

assistance with installation, commissioning and training as well as spare parts

holdings. John Zink are an International combustion specialist with over 80 years

experience in supplying flare systems. John Zink have main manufacturing and

service facilities in Tulsa Oklahoma and Luxembourg along with service centres

throughout the world. John Zink employ over 1000 people worldwide. Scope Wellhead Flare Systems Reference Document: Wellhead Flare Functional Specification KM-5000-WP-PR-

DAT-0008 – rev 0 Sour Gas Flare

The current composition of the sour well head gases would be suited to use a KMI

type flare tip but the LHV levels are marginal and would not be high enough to

ensure burner stability for the KMI style flare tip as the field matures. We understand

that the Sour flare will be operated at exploration and early production phase and

therefore would not be subject to future dilution from reinjection. In this case we

would propose to use a high pressure KMI solution.

For this application we propose a KMI-2-12 high pressure flare tip (2 each 12"

Coanda tips) operating at 5 barg. We have included for a 75m high flare stack. Such

a flare would easily meet both the noise and radiation requirements defined in the

Wellhead Flare Functional Specification KM-5000-WP-PR-DAT-0008-rev 0.

Sweet Gas Flare

The sweet gas composition is approximately 900 BTU/SCF which is enough to

support a KMI style burner. Even so, if inert re-injection is planned, then at some

point in the future burner stability may become an issue. An estimate of future LHV

trends would be useful in selection of the best solution.





Sheet 6

For this application we propose a KMI-2-12 high pressure flare tip (2 each 12"

Coanda tips) operating at 5 barg. We have included for a 30m high flare stack. Such

a flare would easily meet both the noise and radiation requirements defined in the

Wellhead Flare Functional Specification KM-5000-WP-PR-DAT-0008-rev 0.

We would propose that, subject to satisfactory dispersion analysis these two flares

are located in a common structure to take advantage of some of the economies such

an arrangement can offer.

Central Processing Facility Flares Reference Document: Flare Functional Specification KM-5000-WP-PR-DAT-0001-

rev 0

This document relates to a central gas processing facility. There are 3 flares

involved in this system: HP, LP and AP. HP Flare X-171 We have designed this flare as a KMI-9-12 (9 each 12" Coanda tips) operating at 5

barg. Reference document indicates a minimum stack height of 25m. We have

based our proposal on a height of 45m, however we would recommend this height is

calculated based on SO2 and H2S dispersion.

LP Flare X-170 We have designed this flare as a KMI-2-12 (2 each 12" Coanda tips) operating at

2.25 barg. Reference document indicates a minimum stack height of 20m. We have

based our proposal on a height of 25m, however we would recommend this height is

calculated based on SO2 and H2S dispersion.

AP Flare X-193 Reference document indicates minimum LHV sent to flare will be below 400

BTU/SCF. This gas will require some enrichment to elevate the LHV to allow it to

support stable combustion. Assuming methane is used as enrichment, the required

flow is approximately 5.5 MMSCFD to enrich 28 MMSCFD to 400 BTU/SCF. This

flare would require a 42 inch utility flare tip to maintain flame stability at

400 BTU/SCF. Reference document indicates a minimum stack height of 100m.

We have based our proposal on a height of 100m, however we would recommend

this height is calculated based on SO2 and H2S dispersion.





Sheet 7

Scope of work Sour Flare - Kaldair Multi-point Indair with FFG pilots

The Flare System will be comprised of the following components:

1. One (1) Flare tip, model KMI-2-12 comprising:

Inlet flange 10” Class 150 RFWN in material AISI 316L

Lower Body in material AISI 310

2 arms in material AISI 310

2 quantity 12” Diameter variable slot Tulip assemblies in material AlSI

310

2 off EEP-210 Pilot(s), in material AISI 310

2. One (1) self support stack in material carbon steel to provide an overall

height of 30m to the top of the tip, complete with riser, ignition lines, tip

access platform, full height ladder and rest platforms located at 9m intervals.

3. One (1) Ignition / monitoring panel, suitable for hazardous area location.

Sweet Flare - Kaldair Multi-point Indair with FFG pilots







310

2 off KEP-100 Pilot(s), in material AISI 310









Sheet 8

HP Flare - Kaldair Multi-point Indair with FFG pilots







310


2. One (1) guy support stack in material carbon steel to provide an overall




LP Flare - Kaldair Multi-point Indair with FFG pilots







310










Sheet 9

AP Flare - Kaldair Multi-point Indair with FFG pilots


1. One (1) Flare tip, model EEF-U-42 comprising:


Upper Body in material AISI 310







Our proposal includes for documentation, packing and delivery to point FOB.

HP Flare Technology We have attached a short paper with this proposal which describes the development

of high pressure flares and details the various flare tip technologies available. The

section on KMI flare tips describes the KMI tip and discusses some of the

advantages of selecting this type of technology.

LP Utility Flare Tips

We have attached a short paper which describes the John Zink Utility Pipeflare tip

and some fo the key features incormporated in its design.

Flare Ignition

For this application we have selected the KEP Inition / monitoring system. We have

selected this type of system due to its fast response time when monitoring. In the

event of a pilot failure the unit responds immediately to try to reignite the pilot.

Ignition is instantaneous from the panel with no special maintenance required prior to

ignition.

For H2S service we would recommend a duel ignition / monitoring system. As an

option we can combine the KEP system with a conventional flame front type ignition

system. In this system the KEP would be the primary ignition source with the FFG as

a backup.

We have attached a short paper describing the KEP ignition system.





Sheet 10

1.2 Packing

The different parts of the supply will be packed as per the following table:

Items to be packed Packing type

Flare tip Case

Pilot(s) Packed with the tip





Sheet 11

1.3 Control and Inspection

The material will be fabricated and controlled in compliance with the norms and

codes as stated in your inquiry and our offer.

Item Type of Inspection

Flare tip Radiography 100%

Pilot(s) Radiography 100%

The control procedures and certificates will be included in the final documentation.

We have included for the requirements of PED.





Sheet 12

1.4 Technical notes and clarifications

1. We have not provided any purge gas seals on the high pressure flare tips as

these are not required for the type of tip we are proposing.

2. Due to the proprietary nature of shop detail drawings and design calculation,

these information cannot be provided.

3. John Zink is currently accredited to ISO 9001. Therefore, any material

fabricated in our Luxembourg shop will follow the procedure of ISO 9001.

4. Dispersion analysis is completed on our own simple in house model to assist in

prediction of flare stack heights. Should accurate results be required for the

purpose of presentation to certifying or inspection authorities then we

recommend that a specialist environmental consultant is employed.

5. The ignition cable for the KEP is a special construction specifically designed for

KEP applications. We will supply the stack height plus 100m of this cable for

each pilot within our scope. The cable is armoured type.





Sheet 13

1.5 Exclusions from the supply

The following material and/or services are NOT included in our scope of supply:

1. Installation and pre-commissioning of the equipment,

2. Equipment startup,

3. Piping insulation,

4. Interconnecting pipeworks between the ignition panel and the flare base,

5. Hydrostatic pressure testing of flare tips.

6. Spare parts for commissioning or normal operation,

7. Third Party Inspection and authority approvals.

8. Generally speaking, anything that is not positively described in this offer.

1.6 Additional Services

Our technicians can assist the Customer during the time of erection and/or startup.

A copy of our Service Rates is attached.





Sheet 14

1.7 Storage Limitation

John Zink shop has a certain storage capability for Customer’s goods already

delivered Ex-works.

In any case, the maximum acceptable storage, if required in due advance time, is of

30 calendar days.

After this period we reserve the right to apply a fee of 50 Euro/day or to ask the

Customer to immediately evacuate his goods from the shop.

It is understood that, in no circumstances, the storage will postpone the invoicing of

the goods after positive release from the Customer or waiving of his final inspection.





Sheet 15

1.8 Guarantee

1. John Zink will guarantee that the equipment supplied against order will be new,

of merchantable standards and free from defect in material and workmanship.

Any items found to be defective and not in accordance with the specification

provided prior to purchase order will be replaced free of charge and without any

delay at the same conditions of the Purchase Order.

2. John Zink guarantee that the material offered comply with all performance and

hardware requirements called in the requisition and comply with the conditions

given in the data sheets, except where specified in the attached quotation,

provided the equipment are correctly operated in accordance with the John Zink

operating and maintenance manual. The material are designed to provide

trouble free operation and minimize erosion, plugging and corrosion.

3. The performance and mechanical guarantees stated above shall cover a period

of twelve (12) months "Normal Operation" or for eighteen (18) months after

completion of delivery whichever occurs first.

4. Running Test. Any eventual running test must be required within 3 months from

the first start-up of the flare, but no later than 6 months from delivery from our

shops. After this time, John Zink reserves the right to check the current status of

all material.

5. The material good storage and maintenance before the startup are at

Customer's care and responsibility in order to keep the guarantee's validity. All

our guarantees commit only for the indicated period to repair or replace some

items and/or devices that will be recognized as defective, and NO indirect or

consequential damage will be accepted other than the repair or replacement of

these parts.

The above repair or replacement cannot, in any way, postpone the guarantee

period.

All replaced parts or devices will be rendered at the same conditions of the

Purchase Order.

The maximum total Vendor's liability, in any case or circumstances, will not

exceed the value of the Purchase Order.





Sheet 16

KOCH INTERNATIONAL / JOHN ZINK Division

Proposal prepared for

WORLEY PARSONS / BP OMAN

REVISION 0

KHAZZAN / MAKAREM PROJECT

Client Reference : CON-BPXO-07-0007 Flares

Koch International/John Zink Reference : 200803-8213-A

Part 2 (Commercial)

PROPRIETARY INFORMATION NOTICE

All information supplied herewith, including without limitation technical or financial data, know-how,

formulae, processes, designs, photographs, drawings, specifications, software programs and samples

and any other material bearing or incorporating any information relating to John Zink's products or

systems is proprietary information belonging to John Zink. Such information shall not be copied,

reproduced, used or disclosed, (in whole or in part) without the prior consent of John Zink for any

purpose other than that for which it has been supplied

Please note that John Zink will enforce its intellectual property rights in any of its proprietary

information to the maximum extent permissible at law, without further notice.





Sheet 17

2. COMMERCIAL OFFER

2.1 Pricing

For the following scope of supply:

1. Sour Gas Flare System €426600.00

2. Sweet Gas Flare System €156500.00

3. HP Flare System €414700.00

4. LP Flare System €155300.00

5. AP Flare System €503700.00

6. Documentation included

7. Export packing included

For this scope of we advise our price as follows:

TOTAL PRICE (Ex works)………………………………………. €1,656,800.00

Option: Budget for FFG duel ignition add approximately €15000.00 per pilot.

Our prices include:

1. All material as described in the "Scope of supply" section of this proposal

2. All documents as described in the "Commercial" section of this proposal

3. Flare process design,

4. Flare mechanical design,





Sheet 18

5. Packing,

6. Guarantees





Sheet 19

2.2 Commercial Terms

2.2.1 General Terms and Conditions

The General Terms and Conditions issued with the enquiry are not acceptable in

their entirety and the following are additional items which we would suggest adding to

the terms. Mutually acceptable terms shall be negotiated prior to placement of

purchase order.

2.2.2 Validity of our offer

Except as otherwise noted in this proposal, the prices quoted are valid for 60 days

from the date of the proposal. However, due to recent significant and adverse

worldwide fluctuations in the price and availability of both steel and steel containing

components, prices and delivery schedules stated herein are subject to adjustment at

the time of order placement.

Should material prices increase and availability of steel changes during the execution

of the order, further price adjustments may be required and delivery schedules will

need to be reviewed

Please, note that we are submitting this offer and pricing with the understanding and

provision that any resulting contract shall be based on total quantities as specified in

this proposal. We reserve the right to adjust our proposal pricing if the scope of work

changes.

The prices do not include any additional cost due to stoppage of work, certified strikes,

etc…, or any other reason out of John Zink control, including Force Majeure.

2.2.3 Terms of Payment

We propose the following terms of payments based on a Letter of Credit.

10% of the contract price upon acceptance of the Seller’s quotation and

issuance of the contract;

20% of the contract price upon initial submittal of general arrangement

drawings;

35% of the contract price six weeks after initial submittal of general

arrangement drawings;





Sheet 20

and

35% of the contract price upon notice of availability for shipment..

2.2.4 Delivery terms (Incoterms 2000)

Material will be delivered Ex works as per pricing schedule.

2.2.5 Delivery date

The delivery period is dependant on the factory loading at the time the order is

placed and will be confirmed immediately prior to order placement.

However, we anticipate the delivery as follows:

1. Drawings will be submitted 6 - 8 weeks after order placement and receipt of all

technical details

2. Manufacture complete 36 weeks after order.

3. Packing and FOB complete 1 weeks after completion of manufacture or final

inspection subject to shipping instructions.

All above schedule foresees two calendar weeks as Customer’s approval time, and

that the official P.O. is received within 2 weeks from the eventual fax or letter of

intent, complete of all Technical & Commercial attachments.

Note :Time for delivery is not of the essence. John Zink however recognizes the

importance of timely delivery of the equipment and documentation. Notwithstanding

anything to the contrary contained in this offer, in the event that delivery is delayed

for reasons attributable to John Zink, John Zink will pay agreed liquidated damages

up to a maximum of 10% of the contract price. Payment of liquidated damages shall

be the Buyer’s sole remedy for delay.

2.2.6 Limitation of liability

1. With the exception of death or personal injury caused by our negligence, John

Zink's maximum liability to the Buyer, how so otherwise arising, is limited to the

Contract Price.

2. John Zink will not be liable for any indirect or consequential loss or damage

including – but not by way of limitation – loss of use, loss of production, loss of

profits (whether direct or indirect), loss of contracts, and whether arising under

warranty, contract, tort (including negligence) at law or otherwise.





Sheet 21

3. We will accept penalties only in the form of liquidated damages. The Buyer’s

remedies are specifically limited to those undertakings expressly accepted in

the Contract. Such remedies shall be in lieu of all others whether implied by

statute, at law or otherwise. Liquidated damages shall be the buyers sole

remedy for late delivery.

2.2.7 Documentation

Documents will be in English language and supplied in 2 hard copies.

One copy of the electronic files (Excel, Word, Autocad…) is also available.

The following documents and/or drawings are included in the John Zink standard

package:

1. General assembly drawing of the Tips and Stack

2. Structural Calculations

3. Data Sheets

4. Installation, operating and maintenance manual

5. Spare Parts book

6. Manufacturing dossier

2.2.8 Intellectual Property Rights

John Zink retains all intellectual property rights, whether registered or un-registered,

including without limitation, copyright of all documents, drawing rights, design rights,

developed programs, software, models and other data developed in the course of

this contract. John Zink will, if so required by Buyer, grant Buyer a non-exclusive,

non-assignable royalty free license to use the same only for the purpose of operating

or maintenance of the equipment by the Buyer.

2.2.9 Force Majeure

"Force Majeure" means any circumstances beyond the reasonable control of either

party including unreasonable and unforeseen escalation of raw material prices.

Neither party will have any liability, other than for the payment of monies owing, for

their failure to perform any of their contractual obligations arising out of or in

connection with events of Force Majeure.”

2.2.10 Title and Risk

Title in the Goods shall pass to the Buyer only upon payment in full. The risk in the

goods shall pass to the Buyer upon delivery in accordance with the Contract.”





Sheet 22

2.2.11 Non-Payment

If the Buyer shall withhold payment of monies properly due and owing to the

Supplier, the Supplier shall have the right to suspend performance of the Contract

until payment is made. The time for performance of the contract and any

corresponding liquidated damages payment dates shall be extended by the period of

the suspension for non-payment. The Buyer shall be liable for interest on the

outstanding amount at the then prevailing EURIBOR rate of interest.





Sheet 23

2.2.12 Address where to place the order

You are kindly requested to place any order resulting from this offer directly to our

European Headquarters in Luxembourg at the following address:

JOHN ZINK INTERNATIONAL LUXEMBOURG SARL

Zone Industrielle Riedgen

Boîte Postale 83

L - 3401-DUDELANGE

Phone (352) 51.89.91

Fax (352) 51 86 11

Attn: Stephane Tarchala

DATA SHEET No. 103

KMI -2-12WB REV.

DATE

BY

1

2 Amin Buah

3 MAX mmscfd 50 50.0

4 MIN mmscfd

5 g/mole 24.20 23.51

6 °C 0 0

7

8 barg 5.00

9

10 SEE CUSTOMERS DATA SHEET

11

12

13

14

15 Fuel Gas

16 N2

17

18 2 TYPE: KEP-100

19 No TYPE:

20

21

22

23

24

25

26

27

28

29

30 FLAME RETENTION

31 LIFTING LUGS

32

33

34

35

36 PIPE2_1

37

38

39

40 SIZE

41 10 ''

42

43 1 ''

44

45

46

47 dBA 62.5 125 250 500 1K 2K 4K 8K

48 151

49 101.0

50

51

52

53

54

55

56

57

58

59 FILE:PIPE_DS2

ASME16.5 CLASS 150 RFWN

DESCRIPTION

SURFACE FINISH

MATERIALS

AISI 310

NATURAL

The drawing is typical only

2.25 Nm³/hr

UTILITY CONSUMPTION

200803-8213

SPL dB

This offer may not include all items shown above.

NOISE DATA

FREQUENCY COMMENT

AISI 310

PWL dB

SPL dB

PWL dB

Noise at stack base

AISI 310

AISI 310

AISI 310

AISI 310

AISI 310

LOWER BODY

WIND DEFLECTORS

SEAL

PILOT

PILOT NOZZLE AISI 310

FLOW

INLET PRESS.

NDP

TEMPERATURE

SMOKELESS

JZ REF:

PILOTS

PURGE GAS

FUEL GAS / PILOT

2.01 Nm³/hr

3.0m

0.5m

WEIGHT kg 450 kg

LENGTH mm

DIMENSIONS

PILOT GAS INLET

AISI 316LFLARE GAS INLET

MANIFOLD

UPPER BODY


JOHN ZINK

RATING

QUANTITY

THERMOCOUPLES

TERMINAL POINTS

MATERIAL

WIDTH mm

PURGE

<Ringelmann 1

GAS COMPOSITION

INDAIR SPECIFICATION

M.W.

DESIGN CASES

SOUR FLARE

PARSON KHAZZAN/MAKERAM

GAS STREAM

200803-8213-

REMARKS

0

31-Mar-08PROJECT:CLIENT:

1.85 Nm³/hr

AISI 316L

Sweet Flare

-70

-50

-30

-10

10

30

50

70

-60 -40 -20 0 20 40 60

Distance (m).

Ele

vation (

m).

RADIATION PLOT

RFQ: 2008-8213 By: Nigel Philpott

Rev: 0Doc: 31/03/2008

Wind Speed: 17.1 m/s

Wind Direction: 0 degrees

Flare and contour key

Flare Flow Mol.

Wt.1 KMI-2-12 50 MMSCFD 22.32

Btu/hr.ft2

1 500.00

2 700.00

3 900.00

4 1100.00

5 1500.00

6 2200.00

7 3000.00

KW/m2

1.58

2.21

2.84

3.47

4.73

6.94

9.46

JOHN ZINK

1

2345

67

DATA SHEET No. 104

KMI -2-12WB REV.

DATE

BY

1

2 Max

3 MAX mmscfd 50

4 MIN mmscfd

5 g/mole 22.32

6 °C 0

7

8 barg 5.00

9


11

12

13

14

15 Fuel Gas

16 N2

17

18 2 TYPE: KEP-100

19 No TYPE:

20

21

22

23

24

25

26

27

28

29

30 FLAME RETENTION

31 LIFTING LUGS

32

33

34

35

36 PIPE2_1

37

38

39

40 SIZE

41 8 ''

42

43 1 ''

44

45

46

47 dBA 62.5 125 250 500 1K 2K 4K 8K

48 148

49 96

50

51

52

53

54

55

56

57

58

59 FILE:PIPE_DS2


DESCRIPTION

SURFACE FINISH

MATERIALS

AISI 310

NATURAL


2.25 Nm³/hr

UTILITY CONSUMPTION

200803-8213

SPL dB


NOISE DATA

FREQUENCY COMMENT

AISI 310

PWL dB

SPL dB

PWL dB

Noise at stack base

AISI 310

AISI 310

AISI 310

AISI 310

AISI 310

LOWER BODY

WIND DEFLECTORS

SEAL

PILOT


FLOW

INLET PRESS.

NDP

TEMPERATURE

SMOKELESS

JZ REF:

PILOTS

PURGE GAS

FUEL GAS / PILOT

2.01 Nm³/hr

3.0m

0.5m

WEIGHT kg 450 kg

LENGTH mm

DIMENSIONS

PILOT GAS INLET


MANIFOLD

UPPER BODY


JOHN ZINK

RATING

QUANTITY

THERMOCOUPLES

TERMINAL POINTS

MATERIAL

WIDTH mm

PURGE

<Ringelmann 1

GAS COMPOSITION


M.W.

DESIGN CASES

SWEET FLARE


GAS STREAM

200803-8213-

REMARKS

0


1.85 Nm³/hr

AISI 316L

HP Flare Composition

-80

-60

-40

-20

0

20

40

60

80

-60 -10 40

Distance (m).

Ele

va

tio

n (

m).

RADIATION PLOT


Rev: 0Doc: 31/03/2008




Flare Flow Mol.

Wt.1 KMI-9-12 280 MMSCFD 19.08

Btu/hr.ft2

1 500.00

2 700.00

3 900.00

4 1100.00

5 1500.00

6 2200.00

7 3000.00

KW/m2

1.58

2.21

2.84

3.47

4.73

6.94

9.46

JOHN ZINK

12

3

44

4

5

5

5

6

6

7

DATA SHEET No. 105

KMI -9-12WB REV.

DATE

BY

1

2 Max Cont

3 MAX mmscfd 280 200.0

4 MIN mmscfd

5 g/mole 19.08 19.08

6 °C 23-60 23-60

7

8 barg 5.00 3.25

9


11

12

13

14

15 Fuel Gas

16 N2

17

18 3 TYPE: KEP-100

19 No TYPE:

20

21

22

23

24

25

26

27

28

29

30 FLAME RETENTION

31 LIFTING LUGS

32

33

34

35

36 PIPE2_1

37

38

39

40 SIZE

41 18 ''

42

43 1 ''

44

45

46

47 dBA 62.5 125 250 500 1K 2K 4K 8K

48 159

49 114

50

51

52

53

54

55

56

57

58

59 FILE:PIPE_DS2


DESCRIPTION

SURFACE FINISH

MATERIALS

AISI 310

NATURAL


8.22 Nm³/hr

UTILITY CONSUMPTION

200803-8213

SPL dB


NOISE DATA

FREQUENCY COMMENT

AISI 310

PWL dB

SPL dB

PWL dB

Noise at stack base

AISI 310

AISI 310

AISI 310

AISI 310

AISI 310

LOWER BODY

WIND DEFLECTORS

SEAL

PILOT


FLOW

INLET PRESS.

NDP

TEMPERATURE

SMOKELESS

JZ REF:

PILOTS

PURGE GAS

FUEL GAS / PILOT

9.05 Nm³/hr

3.0m

1.4m

WEIGHT kg 1800 kg

LENGTH mm

DIMENSIONS

PILOT GAS INLET


MANIFOLD

UPPER BODY


JOHN ZINK

RATING

QUANTITY

THERMOCOUPLES

TERMINAL POINTS

MATERIAL

WIDTH mm

PURGE

<Ringelmann 1

GAS COMPOSITION


M.W.

DESIGN CASES

HP FLARE X-171


GAS STREAM

200803-8213-

REMARKS

0


1.85 Nm³/hr

AISI 316L

LP Flare Composition

-70

-50

-30

-10

10

30

50

70

-60 -40 -20 0 20 40 60

Distance (m).

Ele

vation (

m).

RADIATION PLOT


Rev: 0Doc: 31/03/2008




Flare Flow Mol.

Wt.1 KMI-2-12 22 MMSCFD 33.93

Btu/hr.ft2

1 500.00

2 700.00

3 900.00

4 1100.00

5 1500.00

6 2200.00

7 3000.00

KW/m2

1.58

2.21

2.84

3.47

4.73

6.94

9.46

JOHN ZINK

1

23

4

5

67

DATA SHEET No. 107

EEF-U- 42 REV.

DATE

BY

1

2 Max Cont

3 MAX MMSCFD 28.00 20

4 MIN MMSCFD

5 g/mole 35.16 35.16

6 °C 20-120 20-120

7

8 mbar 0.17

9


11

12

13

14

15 Fuel Gas

16 N2

17

18 3 TYPE: KEP

19 TYPE: Cr/Al

20

21 3.00m 1.35m

22 1500kg

23

24

25

26

27

28

29

30

31

32

33

34

35

36 PIPE2_1

37

38

39

40 SIZE

41 42 ''

42 1"

43

44

45

46

47 dBA 62.5 125 250 500 1K 2K 4K 8K

48

49 <85

50

51

52

53

54

55

56

57

58

59 FILE:PIPE_DS2

39.00 Nm³/hr

NDP

FREQUENCY COMMENT

Noise level at 0m from flare

ANSI CLASS 150 RF FLANGE

PWL dB

SPL dB

NOISE DATA

AISI 316

LIFTING LUGS

WIND DEFLECTORS

AISI 316

AISI 310

AISI 310

AISI 316

AISI 310

AISI 310

AISI 310

AISI 316

PILOT NOZZLE

PILOT MANIFOLD

IGNITION MANIFOLD

SURFACE FINISH


NATURAL

FLOW

INLET PRESS.

PURGE

PILOTS

PURGE GAS

FUEL GAS / PILOT

TEMPERATURE

GAS COMPOSITION

FLARE GAS INLET

QUANTITY

THERMOCOUPLES

FLAME STABILIZER

PURGE SEAL

MATERIALS

BODY UPPER

BODY LOWER

PILOT

TERMINAL POINTS

DESCRIPTION RATING MATERIAL

DIMENSIONS

LENGTH(LA):

APPROX. WT.:

WIDTH(LB):

PILOT INLET

AISI 316ANSI CLASS 150 RF FLANGE

30.11 Nm³/hr

UTILITY CONSUMPTION

JZ REF:

200803-8213JOHN ZINK

PIPE FLARE SPECIFICATION

M.W.

PROCESS DATA

AP FLARE X-193

Workey Parsons Khazzan/Makarem

GAS STREAM

200803-8213-

REMARKS

0

1-Apr-08PROJECT:CLIENT:

1.85 Nm³/hr

AISI 316

AP Flare

-70

-50

-30

-10

10

30

50

70

90

110

-60 -40 -20 0 20 40 60

Distance (m).

Ele

vation (

m).

RADIATION PLOT


Rev: 0Doc: 04/01/2008




Flare Flow Mol.

Wt.1 EEF-U-42 33.4 MMSCFD 35.16

Btu/hr.ft2

1 500.00

2 700.00

3 900.00

4 1100.00

5 1500.00

6 2200.00

KW/m2

1.58

2.21

2.84

3.47

4.73

6.94

JOHN ZINK

12

34

56

Sour Flare Buah Composition

-80

-60

-40

-20

0

20

40

60

80

-60 -40 -20 0 20 40 60

Distance (m).

Ele

vation (

m).

RADIATION PLOT


Rev: 0Doc: 31/03/2008




Flare Flow Mol.

Wt.1 KMI-2-12 50 MMSCFD 23.51

Btu/hr.ft2

1 500.00

2 700.00

3 900.00

4 1100.00

5 1500.00

6 2200.00

7 3000.00

KW/m2

1.58

2.21

2.84

3.47

4.73

6.94

9.46

JOHN ZINK

1

2

3

4

567

JOHN ZINK® KOCH CHEMICAL TECHNOLOGY GROUP LIMITED

HIGH PRESSURE FLARES INTRODUCTION The use of flare tips operating at high pressure has become very much normal practice in petrochemical operations. The use of high pressure systems enables the operator to minimise line, vessel and relief valve sizes in order to save on capital cost and weight. The use of a high pressure flare does not only provide advantages in terms of capital cost but also in terms of improved flare tip performance. Typically a high pressure flare will deliver high capacity, improved efficiency, better dispersion and lower radiation. It will do this by utilising the Kinetic energy in the high pressure gas as it exits the tip, to entrain more air and create turbulence to mix that air with the flare gas. Improved aeration and mixing results in a more efficient flame which burns with a shorter and cooler flame. The result is a reduction in unburned elements in the combustion products, an increase in the proportion of entrained air allowing for improved atmospheric dispersion, and a reduction in the temperature and surface area of the flame to improve radiation levels. The art of designing the optimum flare tip is to maximise the surface area of gas exposed to air. John Zink and Kaldair have been the two world leaders in flare technology for a quarter of a century. The merger of the two companies in 2001 has yielded a range of flare tips and new technologies which is unique in the industry.

THE JOHN ZINK KSP FLARE TIP The KSP single point sonic pipeflare is the simplest form of high pressure flare tip. The KSP, originally developed by Kaldair, has been integrated into the John Zink range in its single nozzle form. The tip operates by allowing flare gas to accelerate to sonic velocity at the tip exit. For low capacity applications burning light hydrocarbon gases, this is a low cost and efficient solution for smokeless operation and reduced radiation. Single nozzle sonic flares have limitations. This type of tip is suitable for burning light hydrocarbons smokelessly, but as the hydrocarbons become heavier then more and more smoke will result at lower flows as the kinetic energy reduces and more air is required to burn heavier hydrocarbons. In addition there is a size limitation. As tip capacities increase then the exit diameter increases. As the flame envelop increases then it is more difficult for air to penetrate to the centre of the envelope. This results in unburned hydrocarbons at the centre of the flame ultimately producing smoke.

Small Diameter Nozzle Large Diameter Nozzle

Aspirated AirAspirated AirAspirated AirAspirated Air

Unb

urne

d H

ydro

carb

ons

THE JOHN ZINK HYDRA FLARE TIP To overcome the limitations of single nozzle flare tips, designers have sought to configure the tip to increase the the gas / air surface area. Designers of conventional flares have achieved this by passing the flare gas at high velocity through multiple nozzles rather than one large tip. This has the effect of increasing the surface area of gas exposed to the air and also reducing the effective diameter of the flare gas envelope allowing air to penetrate to its centre. The highly successful John Zink Hydra flare tip operates on this principle. It is a single point flare tip with multiple sonic nozzles.

The Hydra flare tip achieves a highly aerated, stiff and stable flame inspiriting significantly more air than a conventional sonic pipeflare which in turn reduces heat radiation. This stable flame is highly resistant to wind effects and flame pull down. The flame is initiated above the tip metal surface contributing to extended tip life. The Hydra is proven in service worldwide since 1989.

The phenomenon of flame lift off is common in high pressure flare tips. The unique John Zink technology used in the Hydra flare tip incorporates a small central burner which stabilises the flame and roots it to the flare tip resulting in a tip where lift off has been eliminated.

Due to its high flame stability the Hydra tip can be operated at higher pressures than other sonic flare tips. The Hydra is recommended for flaring low to medium weight saturated hydrocarbons between 1 and 15 barg. Even at high pressures the central burner holds the flame onto the centre of the tip. As many countries now are seeking to tax Emissions, there has been a trend in recent times to operate flare tips without pilots. This practice is not recommended by API as flare tips require pilot to remain stable. Most open pipe and multi nozzle flare tips will become unstable when operating without pilots. The central burner on the Hydra acts in place of the pilots to maintain stability. Although this type of flare tip has superior operational characteristics over single point flare tips, it still does not provide for smokeless flaring of heavier hydrocarbon gases at low pressure low flowrates.

Coanda Technology THE JOHN ZINK INDAIR FLARE TIP The INDAIR flare has been developed to provide a safe and reliable high efficiency flare tip to produce a smokeless, low radiation flare design without the need for outside assist media such as forced air or steam. The INDAIR flare is a pressure-assisted flare design which utilizes the internal energy within high-pressure gas streams to produce a highly aerated, turbulent flame.

The INDAIR flare utilizes the “Coanda Effect” to entrain and mix air into the hydrocarbon gas stream. High-pressure gas is ejected radially from the annular slot at the base of the INDAIR tulip. Instead of continuing horizontally, the gas adheres to the Coanda profile and is diverted through 90 degrees, entraining up to 20 times its own volume of air in the process.

The pre-mix air/gas mixture creates very efficient, 100% smokeless combustion of the flare gases. The flame produced by this efficient pre-mixed combustion is a very low radiation, low luminance flame. The flame length is less than half of that produced by a conventional flare tip. The flame is also a thin, stiff, pencil shape that is not easily distorted by crosswinds.

Flame initiation always takes place near the maximum diameter of the tulip, insuring reliable ignition of the gas by external pilots, even on sudden venting and under high wind conditions. Smokeless, low radiative combustion is achieved without the need for ancillaries such as steam, compressed air or fuel gas. Unlike other flare tips, the flame propagates from the outside and there is always a protective film of hydrocarbon gas insulating the Coanda tip. This avoids overheating of the flare tip and allows it to be manufactured from conventional alloy steels, using normal welding procedures, without the need for sophisticated materials such as ceramics.

Advantages and Operating Characteristics of the INDAIR Flare

High Pressure Operation

Since the INDAIR flare operates at elevated pressure when burning HP gas (rather than near atmospheric pressure as with a conventional flare), significant savings in header size and knock-out vessel size may be made. The primary design consideration in sizing relief headers and liquid knockout vessels is the velocity of the gas. Maintaining a high backpressure at the flare tip keeps the gas compressed in the upstream flare header. This reduces the velocity of the gas for a given relief flow rate of gas.

Efficient Air Entrainment and Mixing

The efficiency of any combustion process is largely a function of the efficiency of the fuel/air mixing. Conventional low-pressure pipeflares emit a cylinder of hydrocarbon gases that rely totally on natural diffusion of air into the flame. This produces relatively low combustion efficiency. Multi-point sonic pipeflare tip designs improve the efficiency by splitting the flow between smaller, separated cylinders of hydrocarbon gases and creating some air entrainment into the flame due to the sonic jet nozzles which are used. The unique INDAIR flare tip, based on the Coanda Effect, forms a thin film of hydrocarbon which entrains and pre-mixes air prior to combustion. The INDAIR flare, in most cases, produces combustion efficiencies in excess of 99.9%.

Smokeless Operation

INDAIR flares will provide smokeless combustion of high-pressure gas over their specified operating range. Conventional multi-point sonic flare tip designs can produce smoke when flaring heavy hydrocarbon gases, unsaturated hydrocarbon gases, or gas streams containing liquid droplets. The INDAIR flare tip, due to its unique pre-mixed turbulent flame, high air entrainment rate, and thin film combustion technique, will produce smokeless flaring of any hydrocarbon gas stream.

Low Radiation The INDAIR flare produces a highly aerated turbulent diffusion flame that radiates far less heat than the equivalent flame produced by the conventional pipeflare. The reduction in radiation is achieved without the use of ancillaries such as steam, compressed air or fuel gas. The Fraction of Heat Radiated (F), which is also often termed flame Emissivity (e), is the portion of a flame’s gross heat release that is emitted as radiation from the flame. The F-factor (or Emissivity) of INDAIR flares has been measured for a wide range of operating conditions. The value of F for INDAIR flares varies from 0.08 to 0.10. A value for F of 0.20 to 0.25 is used for an API-type pipe flare. A value for F of 0.12 to 0.15 is produced by conventional multi-point sonic flare tip designs.

Flame Length The turbulent INDAIR diffusion flame with its increased combustion intensity is far shorter than that of an equivalent conventional flare. The flame length produced by an INDAIR flare is less than half that produced by a conventional API-type pipeflare

Flame Stability In contrast to the wind sensitive flame produced by a conventional flare, the INDAIR flare produces a flame with a high directional stability which is not easily distorted by cross-winds. The flame is extremely stable; in fact, INDAIR flares have been operating successfully in the North Sea in wind speeds in excess of 100 mph.

Liquid Carry-Over Even with the best run production/separation installations, liquid carry-over to the flare line can take place. With conventional pipeflares or multi-point sonic flare tips this can be a serious potential hazard giving rise to 'flaming rain' falling and pollution affecting a wide area.

The intense shear in the INDAIR slot region ensures efficient atomization of liquids, aiding vaporization and combustion. The INDAIR flare is capable of burning 25% by weight of liquid carry-over without any fall-out or smoke production whatsoever. The INDAIR flare tip can effectively atomize liquid particles with size in excess of 1200 microns. This feature means that, in many cases, the flare may be operated without a liquid knockout drum in the HP flare line.

Stiff Directional Flame

The unique geometry and stiff directional flame allow the Indair to be mounted at an angle without any detrimental effect on the tip operation or life. This feature is particularly useful in offshore application where the flame can be angled away from the platform or FPSO in order to reduce radiation on deck.

Unique Metallurgical Design

Extensive research and development has led to recent advances in the metallurgical design of INDAIR flare tips. Flaring is a unique high temperature service in that the metal is often exposed to extreme temperature differentials across the periphery of the flare tip, thermal shock during a sudden blowdown condition, and very high temperatures during low to moderate flow rates. Conventional high nickel alloys used in many flare designs can withstand very high temperatures, but can be subject to cracking and failure when exposed to repeated cycles of thermal shock and high temperature differentials.

The INDAIR flare tip uses a special high-nickel alloy that combines high temperature strength and high ductility. All of the metal surfaces that have contact with the flame (i.e. the entire “tulip” assembly) are fabricated with this alloy. This unique design enables the INDAIR flare to easily withstand a vast array of harsh operating conditions. The unique INDAIR flare tip design can provide long, maintenance-free service life.

Reliable Ignition The INDAIR flame always initiates near the maximum tip diameter so that reliable ignition of the INDAIR flame is achieved, even on sudden venting and under high wind conditions.

Flare Capacities In general, the volumetric gas flow rate (Q) through a sonic flare tip is a function of the absolute gas pressure (P) at the exit area (A) and the specific gravity and absolute temperature of the gas (Sg, T). The multiplier K is a function of flare design and to a lesser extent gas composition.

Q = KPA (T x Sg)-0.5

For conventional sonic flare tips, the outlet area A is fixed, and turndown is largely governed by the ratio of operating pressures:

Turndown = P available/ P minimum

Where P minimum is normally around 10 psig.

With the unique variable slot (VS) INDAIR design, the area varies linearly with pressure. Much larger turndown ratios can be achieved since:

Turndown = (P available x A max) / (P min x A min)

THE FIXED SLOT INDAIR Few other devices in engineering are required to perform satisfactorily over such a wide range of operation as the flare tip. It must be able to handle all flow conditions from purge to full relief. This it can do but it is fair to say that it handles some conditions better than others. Essentially at high flow the flame is more controlled and burns away from the flare tip. Under this condition metal temperatures are low and the tip would last an almost indefinite period. However under low flow conditions flame control is lost. It burns around the tip or even inside it, metal temperatures are high and cyclical. This is the situation that burns out flare tips and unfortunately it is

the one commonly encountered on modern platforms that export or re-inject their gas. The fixed slot version of the Indair is most susceptible to damage due to continued operation at low pressures and therefore should only be considered where high flows are anticipated or where continuous purging is with nitrogen.. The tip is recommended for venting applications where high air entrainment and dilution are required to aid dispersion. It is a physical fact that the shape of the flow/pressure curve of an orifice discharging to atmosphere is such that relatively high flows are achieved at low upstream pressures i.e. if an orifice were designed to pass 23 MMSM³/D at 5 barg then it would still pass 2.8 MMSM³/D at only 0.1 barg. In flaring terms this latter pressure is not enough to produce a turbulent, stiff flame and the result is a laminar diffusion flame (like a pipeflare). The region that a Coanda flare will give good performance starts at about 0.2 barg is fully developed by 0.8 barg and carries on to 5 barg or above. So, in the case of our 23 MMSM³/D flare, this will give it's best performance from 6.5 to 23 MMSM³/D, give improving performance from 2.8 to 6.5 MMSM³/D and pipeflare like flames below 2.8 MMSM³/D. Thus in the area where it's performance is worst is just where it will operate most of the time. HL Indair A variant of the Indair is the HL which allows a separate LP case to be passed through the centre of the Indair Tulip. The efficiency of the Indair in entraining air is such that when HP and LP are firing simultaneously there is enough air entrained to allow both LP and HP streams to operate smokelessly.

Flare TipFlow vs Pressure Curve

0.00

5.00

10.00

15.00

20.00

25.00

0.0 1.0 2.0 3.0 4.0 5.0 6.0

Pressure barg

Flo

w M

M S

m3/

d

MW= 17.00 Temp= 15.0°C

VARIABLE SLOT INDAIR The only solution for providing reasonable smokeless turndown with a conventional sonic flare tip is to provide an elaborate multi-flare tip design with many flare stages separated by control valves. This type of design is therefore very expensive to install and maintain There is another way to "stage" a flare, that is to say to modify it's flow/pressure curve so that it operates at higher pressures at lower flows. This can only be done by varying the discharge flow area of the flare tip itself. The INDAIR flare lends itself to this very well. It is apparent that the gas slot area can be changed by raising or lowering the tulip assembly within the flare tip body.

The whole tulip and inner stack is allowed to move up and down in response to applied flare gas pressure. In effect we have a force balance with the tulip weight, Coanda thrust and spring force all acting downwards being opposed by the upward force caused by the internal gas pressure. The rating of the springs determines the opening characteristic which is normally to start opening at 0.7 barg and be fully open by 2.0 barg

The slot width (which determines the tip outlet area) remains at a small size during low gas flow rates and increases proportional with increase in gas flow. This design provides near infinite smokeless turndown design while maintaining high maximum flow capacities. This variable slot INDAIR design, therefore, produces 100% smokeless flaring from minimum (purge) to maximum design flow rates.

The unique variable slot INDAIR flare tip provides infinite smokeless turndown without the need for these elaborate staged multi-flare designs. A single INDAIR flare tip provides 100% smokeless flaring and high flaring capacity with a very low radiation flame. The spring-loaded mechanism is extremely reliable, with a design similar to that used in safety relief valves.

Tulip Bowl

Tulip Cone

Annular Slot(maximum width)

CoandaProfile

Tulip Bowl

Tulip Cone

Annular Slot(minimum width)

CoandaProfile

Flare TipFlow vs Pressure Curve

0.00

5.00

10.00

15.00

20.00

25.00

0.0 1.0 2.0 3.0 4.0 5.0 6.0

Pressure barg

Flow

MM

Sm

3/d

MW= 17.00 Temp= 15.0°C

THE JOHN ZINK KMI FLARE TIP The KMI is a Hybrid of the Hydra and Indair Variable slot technology. The concept of multiple Indair tips being located in an array has been used for many years however John Zink have developed a multi-nozzle flare tip which is a single point tip with multiple Indair Nozzles. This not only has provided the multi-arm advantages of the Hydra, increasing the flare gas surface area exposed to the air, but also employs the infinite turndown features of the Variable Slot Indair. In addition the turndown flexibility can be enhanced further by varying the spring rates on the individual nozzles such that the flare tip can act as a staged system in itself. Thus the tip can be set up to bring nozzles online in turn such that at low flows only one or two nozzles will have their slots open while all the others are closed. As the pressure and flow increase then slots can open in sequence until at full flow all slots are fully open. KMI Advantages

The KMI benefits from all of the advantages of single tulip Indair’s described above, but also has some key advantages:

• The large Indair tulips are a two part construction with a pressed bowl and a fabricated cone. These parts are welded together. In operation this construction does have an inherent weakness in the welds which over time can reduce the life of the tip. The small Indair tulips used in the KMI are investment cast single part construction and very robust. The ratio of bowl diameter to wall thickness is much higher for the smaller tulip and therefore the tulip is extremely stable.

• As the KMI tulips are very small they

are easily man handled. Therefore in the event that any tulips require changing, it can be done without the use of crane a crane. In addition the replacement of an investment cast small tulip is not expensive where the manufacturing cost of a large tulip is relatively high.

• The KMI design allows much more

flexibility than the single point tip. The springs on the KMI can be set at different ratios to allow slots on some arms to open earlier than slots on others. This can be used to effectively stage the flare. In this way at low flows it is possible to operate with one 1 or 2 slots open thus optimizing the pressures and saving wear and tear on other nozzles.

• The spring system is maintenance free and will give many years of trouble free

operation. Often there are concerns over the possibility of the springs failing and the tip not opening. The mechanism has a fail safe, i.e. fail open, arrangement. Our experience has been that we have not, in 30 years of supplying Indair’s, had a report of a spring failure with tips operating within their design criteria.

• Over a 20 year flare life all types of flare tip will require a certain extent of

refurbishment. For the single point Indair tip this would mean a new tulip on average every 5 to 7 years. For the multipoint we would expect this period to be much longer and only a few of the tulips may need changing if at all. Maintenance costs and down time will be reduced.

Tulip Bowl

Tulip Cone

SpringAdjustment

Port

Annular Slot(maximum width)

CoandaProfile

Spring Assembly(Bellville Washers)In CompressedState

Fixed (Welded)Support Brackets

Non-Fixed (Guide Tube)Support Brackets

MainBodyMainBody

The Variable Slot Indair has been installed in over 300 installations worldwide for nearly 30 years.

With smokeless flaring being a more important design feature in recent years the variable slot INDAIR has become the choice of most major oil and gas producers.

Advantages of angling flare tips The unique geometry and stiff directional flame allow the Indair to be mounted at an angle without any detrimental effect on the tip operation or life. This feature is particularly useful in offshore application where the flame can be angled away from the platform or FPSO in order to reduce radiation on deck. The following radiation isopleths demonstrates how the deck level radiation is reduced for a boom mounted Indair flare tip CONDAIR FLARE TIP The CONDAIR flare tip is a variation of the Indair tip which utilises the superb liquid handling ability of the Coanda effect. The CONDAIR tip can burn gases smokelessly with up to 75% entrained liquids and without liquid fall out. These flare tips are often used in well test applications where high pressure is available or in burn pit applications.

Angled TipVertical Tip

Wind Speed = 65 ft/s

MARDIAR FLARE TIP A derivative of the INDAIR, again based on the 'Coanda Effect' is the MARDAIR flare. The cross-section, shown of the MARDAIR shows the gas exiting from the slot over a Coanda surface on the inside of the flare tip drawing air from beneath the flare. The MARDAIR flare tip has many of the attributes of the INDAIR tips but the MARDAIR flare is intrinsically more efficient than the INDAIR, producing lower radiation and a less luminous flame. Even greater air entrainment is achieved by an “inwardly curved” Coanda profile. The MARDAIR, with its unique “trumpet shape” entrains air at a rate up to 25 times the gas flow rate The MARDAIR is also the quietest of all flares that operate within the sonic flow regime. Its unique low noise feature is achieved by virtue of all high velocity gases being contained within the body of the flare.

A special low noise version of the MARDAIR M-400, has been developed. With this the normally plain slot profile is replaced by a 'Shark Tooth' design which effectively reduces sonic jet noise by increasing the gas/air contact interface in exactly the same manner as low noise trim valves. This version gives a useful 3-4 dB drop in jet noise.

The low radiation characteristic of the Mardair is compared to other flare tip designs in the example below The radiation for the Indair tip can less than half that of a conventional low pressure pipeflare. The Mardair can offer radiation levels of up to half of that again.

JOHN ZINK u TODD COMBUSTION u BROWN FINTUBE u KALDAIRu KEU Registered Address: Dolphin House w 140 Windmill Road w Sunbury-on-Thames w Middx TW16 7HT w England

Telephone: +44 (0) 1932 769830 w Fax +44 (0) 1932 787471 / 789916 www.johnzink.com

INDAIRe = 0.08 - 0.10

API Pipeflaree = 0.20 - 0.30

MARDAIRe = 0.05 - 0.07

John Zink Utility Pipeflare

The John Zink Utility Flare Tip is a cost effective tip that

serves the three primary functions of a flare tip:

• Maintains Stability

• Minimizes Burn-back

• Reduces Flame Pull-down Design Basis: A pipeflare consists of

a flanged piece of

pipe, with an ignition

source at the exit.

This simplest type of

flare tip suffers from

some poor operating

characteristics.

These types of flares

are prone to flame lift-

off, where the flame

becomes unstable at

high flow rates.

Flame lift-off can

result in the flame

being extinguished, and unburned gases being released

into the atmosphere. Pipe flares have poor turndown

and short service life. The tip is not protected from

flame burning the outside or inside of the tip, and the tip

life is reduced. John Zink’s Utility flare is designed to be

a cost effective and simple low pressure flare tip

enabling stable burning and extended flare tip life.

Stability:

Pipe flares exhibit poor

combustion efficiency

and instability resulting in

flame loss. To eliminate

this problem, John Zink

provides a flame

retention device at the

tip exit to root the flame

to the tip.

Flame pull-down: As wind blows across a flare

tip, a low pressure zone is

created on the downwind side

of the flare. This low

pressure zone pulls the flame

downward, causing the gases

to impinge and burn on the

shell. A windshield protects

the flare tip by eliminating the

low pressure zone to prevent

flame impingement directly on

the tip shell in windy

conditions. This added

protection results in longer flare tip life. John Zink flare

tips greater than 8 inches are equipped with a stainless

steel windshield that surrounds the upper section of the

burner.

Internal Burning:

One of the most

prominent

mechanisms

responsible for the

failure of a flare tip

is internal burning.

A flare tip will

typically experience

internal burning if it

operates at a low

waste gas exit

velocity in windy

conditions. Under

these operating conditions, the wind will create an

internal recirculation pattern near the tip outlet creating

internal burning. Larger diameter flare tips are more

likely to experience internal burning inside the flare tip

shell. Burn-back can greatly reduce tip life by deforming

the structure and embrittling the tip material. As a

result, John Zink lines the upper section of the larger

utility flare tips with refractory. This refractory type and

thickness has proven successful in severe thermal

shock applications, and significantly increased the tip

life of large tips.

JOHN ZINK �� TODD COMBUSTION �� KALDAIR�� KEU Dolphin House � 140 Windmill Road � Sunbury-on-Thames � Middx TW16 7HT � England

Telephone: +44 (0) 1932 769830 � Fax +44 (0) 1932 787471 / 789916

www.johnzink.com

w aste gas

pilo t

w indshield

flam e retention

segm ents

waste

gas

wind

direction

air / fuel

mixture



KEP-100 Automatic Electronic Ignition Control System

John Zink are committed to the principle of pilot ignition for flares. The use of a continuous pilot is the only reliable method to guarantee flare ignition and stability. It is proven that flare tips and pilots work as a system and pilotless flare tips have a tendency to instability.

The Kaldair model KEP-100 automatic electronic pilot ignition control system is proprietary design providing many operational benefits over conventional flare pilot ignition control systems which use flame front generation for ignition or thermocouples to detect the flame. The KEP offers the following features

• Proven and reliable pilot monitoring technology

• Instantaneous recognition of pilot failure

• Fast, reliable pilot ignition / re-ignition

• Easy and flexible installation

• Simple hassle free operation

• Low capital cost

The KEP pilot draws in air with the fuel gas fed to the pilot to create a combustible mixture that is fed into the pilot burner nozzle. The burner nozzle includes a high voltage electrode that terminates directly in the burner nozzle. Upon energizing the electrode with a high AC voltage potential, a high-voltage arc is discharged creating a spark that ignites the fuel/air mixture in the burner nozzle.

The direct spark ignition achieved with the KEP-100 electronic pilot is far more reliable than conventional flame front generator ignition systems, which require a long purge of the flame front lines followed by the remote ignition of the flame front at the remote location.

InspiratorAssembly

Pilot Inlet

IgnitionInlet

PilotNozzle

CeramicRod

(Electrode)

The electrode used in the pilot nozzle is a rugged Kanthal rod design. The rod is insulated along the entire length of the pilot by a high temperature ceramic rod. The ceramic rod/electrode assembly is protected in a ½” 316 SS pipe. The electrical connection is made in a stainless steel connector box at the base of the pilot. The high voltage cable termination is made at this point using a spark plug boot-type connection to the Kanthal rod.

The specially developed KEP ignition cable has one core and a single cable is used for both ignition and monitoring.

How does Ionization Detection Work ?

In the ignition monitoring mode, the electrode is energized with a small AC potential applied between the electrode and ground. The AC current flow between the electrode and ground is then monitored by the control system.

If no flame is present, there is no path for current flow between the electrode and ground (for example, an open circuit is detected). However, if a flame is present, the pilot nozzle will contain a cloud of ionized gases in the burning flame (referred to as “Flame Ionization”). These ionized gases create a path for current flow between the electrode and ground (for example, a closed circuit is detected).

Open Circuit =Flame Out

Closed Circuit =Flame On

+-

-

- -

--

+

--

-

-+

++

++ +-+

-+

++

+

+ +

Ceramic Rod

Kanthal Electrode(Pilot Nozzle End)

Kanthal Electrode(Cable End)

Locking Nut(Pilot Nozzle End)

Locking Nut(Cable End)

The method of flame ionization monitoring is a very reliable pilot flame monitoring technique. The instant that the flame is lost, the loss is detected by the control system, allowing the control system to immediately switch to the re-ignition mode to attempt to re-ignite the pilot. Conventional pilot monitoring techniques rely on thermocouple measurements that create a considerable response time delay as the thermocouple sheath cools to the alarm set point. Thermocouples can take up to 15 minutes to recognize flame failure. Cold venting of hazardous flare gas for this period of time could be fatal.

If the first attempt is unsuccessful than the purge delay cycle is started once again. These considerable response time delays with an FFG ignition system can often leave the pilots unlit for an unacceptable, dangerous time period. The KEP system, however, provides immediate indication of pilot flame loss and nearly instantaneous re-ignition via direct spark in the pilot nozzle.

Conventional pilot monitoring systems use a thermocouple mounted in the pilot nozzle. The extreme temperature of the pilot flame makes the long-term reliability of this technique very poor. In fact it is common to burn up the thermocouple junctions upon initial startup of the pilots. When designs are modified to protect the thermocouple, response time upon loss of flame becomes very slow.

With the KEP-100 pilot ignition system all of the electronics to control the ignition and flame monitoring are housed in a remote control panel. A single high voltage cable connection is made between the control panel and each of the pilots. The standard control panel can be easily installed up to 300m from the pilots and as far as 1000 m with special modifications.

The control panel includes the high voltage transformer (6 kVA) used for pilot ignition and all of the monitoring and control electronics. The panel includes automatic mode selector, manual ignite pushbutton, flame on & flame off indicator lights for each of the pilots. Each pilot has its own dedicated monitoring and control circuits and ignition transformer for truly independent operation of each of the pilots.

PILOT ON

PILOT OFF

MAN/OFF/AUTOSELECTOR

PILOT #2

TOPILOTS

AC POWER INREMOTEALARMS

PILOT ON

PILOT OFF


PILOT #3

PILOT ON

PILOT OFF


PILOT #1

The Kaldair KEP-100 ignition control system has been in use for many years and has proven highly successful in hundreds of flaring applications from the rugged Arctic conditions of the North Slope of Alaska to the extremely high winds of the North Sea in the Atlantic. The direct spark ignition coupled with the unique flame ionization monitoring technique provides a system far more reliable than conventional flame front ignition or thermocouple monitoring systems.

Through continuous improvement and experience the KEP system has evolved over the years. Many improvements have been made to the pilot to improve its reliability and operational life. The latest pilots include high integrity systems to eliminate heat damage to the KEP cables.

The latest KEP pilot incorporates the unique technology of the KEP ignition and monitoring system into the advanced John Zink Windproof pilot which, not only reduces gas consumption by up to 50%, but also operates in winds of 160 mph and rainfall equivalent to 20 inches per hour, and will also reliably reignite in these conditions.

The KEP system can be supplied for both safe and hazardous areas. The system is certified to most international standards including ATEX. The individual requirements of most Oil and Gas Operators and Contractors specifications can be accommodated.

JOHN ZINK u TODD COMBUSTION u BROWN FINTUBE u KALDAIR Registered Address: Dolphin House w 140 Windmill Road w Sunbury-on-Thames w Middx TW16 7HT w England

Telephone: +44 (0) 1932 769830 w Fax +44 (0) 1932 787471 / 789916 www.johnzink.com

Zink Proposal

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