Engineering Procedure

SAEP-405 05 January 2017

Flare System Purge Gas Optimization
Document Responsibility: Flare Systems Design Standards Committee

Contents
1 Purpose ............................................................. 2
2 Scope ................................................................ 2
3 Conflicts and Deviations .................................... 2
4 Applicable Documents ....................................... 2
5 Definition ........................................................... 3
6 Purge Gas Types .............................................. 4
7 Continuous Purging Requirement ..................... 5
8 Intermittent Purging Requirements .................... 8
9 Purge Gas Optimization Methodology ............. 10
10 Utilizing Nitrogen as Purging Medium ............. 14
Revision Summary ................................................. 17

Previous Issue: New Next Planned Update: 05 January 2020

Page 1 of 17
Contact: Aldajani, Mahdi A. (aldajama) on phone +966-13-8808058

©Saudi Aramco 2017. All rights reserved.

Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

1 Purpose

The purpose of this document is to provide general guidelines and safety measures to
optimize the purge gas rate and utilize nitrogen as purge gas for Saudi Aramco upstream
and downstream facilities.

2 Scope

2.1 This procedure provides guidelines for calculating flare system minimum purge
gas requirements.

2.2 This procedure provide the methodology that should be followed in order to
optimize the purge gas flow rate without jeopardizing the safety of the flare
system.

2.3 This document covers the minimum mandatory requirements to install and
utilize Nitrogen purge with/without a Flare Gas Recovery Systems (FGRS).

2.4 This document also includes safety measures for using Nitrogen gas for an
existing Saudi Aramco facility.

3 Conflicts and Deviations

3.1 Any conflicts between this design guideline and other applicable Saudi Aramco
Engineering Standards (SAES), Standard Drawings (SASDs), or industry
standards, codes, and forms shall be resolved in writing by the Manager, Process
& Control Systems Department (P&CSD) and Manager Proponent Department.

3.2 Direct all requests to deviate from this procedure in writing to the primary
contact of this document, who shall study the request and respond as suggested
in 3.1 above.

4 Applicable Documents

The requirements contained in the following documents apply to the extent specified in
this procedure.

4.1 Saudi Aramco References

Saudi Aramco Engineering Standards

SAES-F-007 System Design Criteria of Flares
SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping, and Process Equipment
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Saudi Aramco Materials System Specification

32-SAMSS-022 Manufacture of Components for Flare Systems

4.2 Industry Codes and Standards

American Petroleum Institute

API STD 521 Pressure-Relieving and Depressuring Systems,
6th ed., 2014
API STD 537 Flare Details for General Refinery and
Petrochemical Service, 2nd ed., 2008

International References
AICHE/CCPS Guidelines for Pressure Relief and Effluent
Handling Systems, Centre for Chemical Process
Safety (CCPS), American Institute of Chemical
Engineers (AICHE), March, 1998

Process Industry Practices

PCIGN200 General Instrument Purge Details, January 2008

5 Definition

Acid Gas: A gas containing H2S and/or CO2, with a lower heating value of
18,600 kJ/scm (500 BTU/scf) or less.

Air Ingress: Air infiltration into the flare system through flare tip, flanged or corroded
piping.

BTU: British Thermal Unit

Cover Gas: Fuel gas that is added to relief gas prior to the flare burner or at the point
of combustion in order to raise the heating value.

Flare Gas Recovery System (FGRS): A system to recover the daily normal
continuous flare gas, and direct it back to the processing facility using a compressor.

Flare Header Contraction: Shrinkage of gases inside the flare header that result in
creating vacuum in the header.

Flare Pilot: Small, continuously operating burner that provides ignition energy to
ignite and/or stabilize combustion of the flared gases.

Flare Stack: Mechanical device upon which an elevated flare burner is mounted.

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Flare System: Includes all piping, valves, pressure vessels and devices downstream of
relief/depressuring outlet block valves, to and including flare tip(s).

Flare Tip: Part of the flare where fuel and air are mixed at velocities, turbulence, and
concentration required to establish and maintain proper ignition and stable combustion.

Flash Back Protection System: A system to prevent a flame front from traveling back
to the upstream piping and equipment. Normally, flash back is caused when air
(oxygen) inadvertently introduced into the flare system.

HIC Resistant: Hydrogen Induced Cracking Resistant

Ignitions System: A system use to ignite the flare of flare systems.

Liquid Seal Drum: A horizontal or vertical vessel in which a liquid (usually water)
level is used to maintain a positive pressure in the relief system upstream of the seal
drum, under conditions of no flow. Also, used for staging between flares or a flare gas
recovery system and a flare.

Main Flare Header: A main line (normally off-plot) which receives vapor or gas
discharge from the unit headers or unit knockout drums and terminates at a flare or the
base of the flare stack. The main flare knockout drum and/or liquid seal drum is in the
main flare header unless they are located at the base of the flare stack.

Main Flare Knockout Drum: A vessel, located in either a main flare header or at the
base of a flare stack, which removes liquids that condense in or are carried over into the
flare system.

Purge Gas: Fuel gas or non-condensable inert gas added to the flare header.

Purge Gas Reduction Device: Device used to minimize or eliminate the intrusion of
air back into the riser from the exit.

Stack Purge: Purge gas sent directly to the flare stack to prevent air ingress.

Sweeping: Removing any contaminants from the flare header by sending a continuous
flow of sweet gas.

6 Purge Gas Types

Purge gas is one of the most important safety features of flare systems. It is required to
maintain positive pressure in the flare system and prevent air ingress to the flare system.
Purge gas also acts as a sweeping medium to prevent accumulation of liquids and sour
gases in the flare header. Purge gas can be classified as follows:

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Figure 1 - Classification of Purge Gas

7 Continuous Purging Requirement

Continuous purging of the flare system usually constitute the smaller percentage of flare
system purge gas consumption. It is required for the following reasons:

7.1 Air Ingress

Air will enter the flare system in the absence of any positive pressure in the flare
header and the flare tip. This may be as a result of wind forces, difference in
density at the tip or leakages through flanges and corroded piping. The flare
system is purged with inert gas or process fuel gas to maintain positive pressure
and avoid air ingress into the system. The quantity of stack purge gas is
dependent on the size of the flare tip, gas composition in the flare system and the
presence of a purge reduction seal.

7.1.1 The minimum purge gas rate for open barrel flare tips can be
determined as follows:
1. SAES-F-007 requires the purge gas to maintain a minimum velocity
of 0.5 ft/s at the flare tip.
2. In the presence of a purge gas reduction device, the minimum
required velocity at the flare tip shall be advised by the flare vendor
based on the tip’s design. In the absence of data, the below general
guideline may be applied:
a. Velocity seal normally require a velocity of 0.06 ft/s
b. Molecular seal normally require a velocity of 0.02 ft/s

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Refer to Table 1 for Saudi Aramco recommended minimum purge

requirements to prevent air ingress. This table includes the following
assumptions:
a. Safety margin of 100% for molecular seal
b. Safety margin of 50% for velocity seal
c. Standard conditions

Table 1 - Recommended Purge Gas Rates for Air Ingress Criteria

Purge rate for flares
Flares equipped with Flares equipped with
Line Diameter (in) without a purge
molecular seal (MSCFD) velocity seal (MSCFD)
reduction seal (MSCFD)
4.00 3.770 0.151 0.452
6.00 8.482 0.339 1.018
8.00 15.080 0.603 1.810
10.00 23.562 0.942 2.827
12.00 33.929 1.357 4.072
14.00 46.181 1.847 5.542
16.00 60.319 2.413 7.238
18.00 76.341 3.054 9.161
20.00 94.248 3.770 11.310
22.00 114.040 4.562 13.685
24.00 135.717 5.429 16.286
26.00 159.279 6.371 19.113
28.00 184.726 7.389 22.167
30.00 212.058 8.482 25.447
32.00 241.274 9.651 28.953
34.00 272.376 10.895 32.685
36.00 305.363 12.215 36.644
38.00 340.234 13.609 40.828
40.00 376.991 15.080 45.239
42.00 415.633 16.625 49.876
44.00 456.159 18.246 54.739
46.00 498.571 19.943 59.828
48.00 542.867 21.715 65.144
50.00 589.049 23.562 70.686
54.00 687.066 27.483 82.448
58.00 792.624 31.705 95.115
62.00 905.721 36.229 108.687
66.00 1026.358 41.054 123.163
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Purge rate for flares

Flares equipped with Flares equipped with
Line Diameter (in) without a purge
molecular seal (MSCFD) velocity seal (MSCFD)
reduction seal (MSCFD)
70.00 1154.535 46.181 138.544
74.00 1290.252 51.610 154.830
78.00 1433.509 57.340 172.021

7.1.2 The required purge rate for other types of flare tips shall be advised by
the flare tip vendor.

7.2 Flare Header Sweep

Flare headers are a big network of piping which receive relieved gases across
the plant. This increases the chances of accumulating contaminants in the
system, resulting in high corrosion rate and possibly pluggage if not mitigated
properly. The amount of purge rate required to sweep the system may be
determined as follows:

7.2.1 Flare headers shall be designed to meet the following requirements:

1. Adequate slopes and drainage arrangements at low points to prevent
liquid accumulation as required by SAES-F-007.
2. HIC resistant piping if the process fluid has more than 50 ppmw
of H2S in aqueous conditions to prevent corrosion as required by
SAES-L-133.

7.2.2 Flare headers are normally provided with fuel gas purge points at the
start of each flare header and sub-header. This allows the introduction of
sweep gas to prevent any corrosive products accumulation.

7.2.3 Flare header sweep requirements vary depending on the condition of the
flare system, as defined in 32-SAMSS-022, and shall be decided based
on the operational experience of the header. Consider optimizing the
sweeping rate based on the following velocity criteria in the largest
diameter portion of the flare header:
1. Headers with sweet service (H2S concentration < 1.0 mol %)
exceeding a velocity of 0.3 ft/s at the main flare header.
2. Headers with sour service (H2S concentration ≥ 1.0 mol %)
exceeding a velocity of 0.5 ft/s at the main flare header.

7.2.4 The sweep gas requirement may be higher depending on the corrosion
rate and liquid accumulation in the flare header. In this case, the sweep
rate should be maintained to minimize corrosion or liquid accumulation
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

in the header and to satisfy any operational requirement based on the

plant operational experience.

8 Intermittent Purging Requirements

These requirements are usually significant and not required on a continuous basis.
Optimization of intermittent purge always result in a significant purge gas rate
reduction. This may be achieved by providing proper control systems for purge flow
rate. Intermittent purge gas is required based on the following criteria:

8.1 Flare Header Contraction

Cooling of the flare header due to ambient cooling or rapid cooling of the gases
after a hot release may result contraction of gases in the flare system, which
creates a vacuum condition in the header and allows air into the system.
Vacuum can also be created while draining the flare knock out drum.
This phenomena is usually mitigated by introduction of additional purge gas
after a hot release. This is independent of air ingress purge requirement due to
their different objectives. Optimization of intermittent purge rate to avoid
contraction can be done based on the following:

8.1.1 Reduction in flare header contraction purging requirement can be

achieved through the provision of an instrumented control system, which
is cascaded with the flare system pressure and temperature. The system
shall be designed to provide the minimum flow rate calculated from
Equation 1. Refer to Figure 2 for an example of an instrumented control
system installed in Haradh Gas Plant.

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

Figure 2 - Purge Gas Instrumented Control System at Haradh Gas Plant HP Flare System,
refer to drawing (BA-415091, sheet 001)

8.1.2 In the absence of an instrumented control system, continuous flow of

purge gas shall be maintained in the header. The minimum purge gas
requirement to prevent flare system contraction can be calculated
through the following equation (Assuming a cooling rate of 8°F/min).
Equation 1 - Simpson's formula

Where Q: Required purge rate, SCFM

V: Total volume of the flare header, ft3
Reference: Guidelines for Pressure Relief and Effluent Handling Systems,
Centre for Chemical Process Safety, American Institute of Chemical Engineers

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

8.2 Low BTU/Sour Gas

Flare tips are designed for a minimum heating value of flared gas. A supplement
cover gas is added if the flared gas BTU is below the design (e.g., acid gas) so that
overall heating value meets the minimum tip design heating value.

8.2.1 Saudi Aramco requires a lower heating value of 500 BTU/SCF to be

maintained in flare header at all time.

8.2.2 The required amount of cover gas can be determined as per the amount
of gas required to maintain a lower heating value as required by 8.2.1.

9 Purge Gas Optimization Methodology

The following steps shall be followed to conduct a purge gas optimization study.

Figure 3 - Methodology of Conducting Purge Gas Optimization

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 Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

9.1 Flare System Survey

A comprehensive survey on the flare system shall be conducted to understand its

configuration, as follows:

9.1.1 Review P&IDs to identify configuration of flare system and purge

stations. The following information should be obtained:
1. Diameter of flare headers and sub-headers
2. Location of purge points
3. Type and details of purge stations

9.1.2 Conduct a field survey to verify the information obtained from P&IDs.

9.1.3 It is recommended to develop a simple sketch of the system with

HNGL HP Flare Monitoring System FMS Valves Behavior
information obtained in the survey, refer to Figure 4 as an example.
GC II B66 NGL I B66 NGL II B66 NGL III
-PV-041 41-PV-574 43-PV-574
42-PV-574

41-HV-315 RO 3/16" 42-HV-315 RO 3/16" RO 3/16" 43-HV-315

RO 3/16"
##### ##### #####
# 41-E-101 42-E-201 43-E-301
#####
24"-RL-0219-1CC2P2

##### ##### #####

20"-B-20002-A1A1

18"-B-20028-A1A1

PV-017
6"-B-27001-A1A1

##### ##### 43-PV-861

41-PV-861 42-PV-861
RO 3/16"
41-K-0110A 42-K-0210A 43-K-0310A
43-HV-316
24"-B-13001-A1A1

41-HV-316 42-HV-316
# ##### #####
63-K-101C #####
41-D-104 A/E 42-D-204 A/E 43-D-304 A/E
PV-031 ##### #####
41-PV-387 ##### 42-PV-387 43-PV-387
##### ##### #####
41-K-0110B 42-K-0210B 43-K-0310B
42"-B-28001-A1A1 48"-B-28001-A1A1 ##### ##### 50"-B-28001-A1A1
90-FI-001
## Z89-V-1
##### #####
41-D-105 42-D-205 43-D-305
3"-B-14001-A1A1
24"-B-20001-A1A1

##### HP Flare
HNGL HP Flare Monitoring System FMS Valves Behavior

GC
PV-041II B66 NGL I B66 NGL II B66 NGL III
25-PV-015
3-PV-041 32-PV-019 A 41-PV-574 31-PV-019 A 42-PV-574 D-101 HP FLARE K.O DRUM
43-PV-574

41-HV-315 42-HV-315 43-HV-315

## ##### ##### ##### 25-D-107 A/B
## ##### ##### RO41-E-101
3/16"
#####
RO#####
3/16"
42-E-201
##### HP Flare Summery Table
43-E-301
PV-017 ##### 25-PV-025 DFV
##### ##### ##### FV YTD
-PV-017 32-PV-019
##### B 31-PV-019 B 43-PV-861
41-PV-861 42-PV-861 ##### HP Purge Rate
#### 41-K-0110A 42-K-0210A 43-K-0310A
## ##### 25-K-102A HP Accounted Flared ##### ##### #####
61-K-101A 41-HV-316 42-HV-316 43-HV-316
##### ##### ##### HP FMS Flaring
##
63-K-101C ##### #####
25-PV-054 ##### ##### #####
PV-031 41-D-104 A/E 42-D-204 A/E 43-D-304
Flaring A/EMeter
per Flow
-PV-031 RO 3/16" 31-C-101 ##### ##### #####
##### 32-C-201 ##### 42-PV-387
#####
43-PV-387
41-PV-387 ##### HP Unaccounted Flaring
##### ##### #####
41-K-0110B 25-K-102B
43-K-0310B
### 42-K-0210B
30"-F-1001301-AB1
##### #####
FV : Flare 60"-F-1001310-AB1
Rate (MMSCFD)
90-FI-001
### Z02-V-14
##### #####
CI B65 Gas Treat II B65
41-D-105Gas Treat I B64 42-D-205
Inlet Area DFV : Daily Flared
43-D-305 Volume (MMSCFD)
YT D : Year To Date (MMSCF)
HP Flare
Figure 4 - Simplified Flare System Sketch with Details of Purge Gas
#####Stations

-PV-041 25-PV-015
32-PV-019 A 31-PV-019 A D-101 HP FLARE K.O DRUM

## ##### ##### 25-D-107 A/B

##### ##### Saudi #####
Aramco: Company General Use HP Flare Summery Table
-PV-017 25-PV-025
FV Page
DFV 11
YTDof 17
32-PV-019 B 31-PV-019 B
HP Purge Rate
####
## ##### 25-K-102A HP Accounted Flared ##### ##### #####
61-K-101A ##### #####
25-PV-054 HP FMS Flaring ##### ##### #####
-PV-031
Flaring per Flow Meter ##### ##### #####
32-C-201 31-C-101
Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

9.2 Data Collection

The following data shall be collected:

1. Flare system inspection history
2. Flare tip datasheet
3. Purge gas station datasheet
4. Purge gas composition and condition
5. Flare system isometrics

9.3 Calculate Existing Purge Rate and Develop a Velocity Profile

The amount of existing purge rate shall be calculated based on the data collected
during from the survey. A velocity profile of the flare system shall be
developed, refer to Figure 5 as an example.
8"-RL-(J87)0501
Flow Rate (MSCFH) 0.61
HNGL HP FlareVelocity
Monitoring System FMS
3"-FG-0130

FI-0136 (ft/s) 0.485 Valves Behavior

B68 SGCNote
II 1 B66 NGL I B66 NGL II B66 NGL III
64-PV-041 63-PV-041 J87
41-PV-574 42-PV-574 43-PV-574
0.61 MSCFH 41-HV-315 42-HV-315 43-HV-315
#####
##### ##### ##### 41-E-101 Flow Rate #####
(MSCFH) 42-E-201 12.55 J89FIC0002.pv##### 43-E-301
#####
##### ##### #####
64-PV-017 63-PV-017 ##### 43-PV-861
41-PV-861 42-PV-861 #####
PIC-356 41-K-0110A 42-K-0210A 43-K-0310A
FI-0106 FCV0002
2"-FG-0342 ##### 2"-FG-0019 43-HV-316
41-HV-316 42-HV-316
##### ##### ##### #####
Flow Rate (MSCFH) 5 64-K-101D
64-PV-031 63-PV-031
HNGL 3"-FG-0129
63-K-101C
HP Flare#####Monitoring
41-D-104 A/E System FMS
42-D-204 A/E 43-D-304 A/E Valves Behavior Flow Rate (MSCFH) 18.16435
##### #####
Velocity (ft/s) 0.44 0 MSCFH Flow Rate (MSCFH)
41-PV-387 5.61##### 42-PV-387 43-PV-387 Actual Velocity (ft/s) 0.657685
36"x24" PC B68 SGC II B66 NGL I
41-K-0110B
#####
Velocity (ft/s)
#####
0.203
42-K-0210B
B66 NGL 36"-RL-102
II 43-K-0310B
B66 NGL III
#####

##### #####
64-PV-041
##### 63-PV-041
##### 41-PV-574 42-PV-574 Flow Rate43-PV-574
(MSCFH) 5.6190-FI-001
##### #####
FI0003
41-D-105 42-D-205 Actual Velocity (ft/s) 43-D-305
0.203
41-HV-315 42-HV-315 43-HV-315
#####
#####
##### #####
Flow Rate (MSCFH) 5 ##### 41-E-101 ##### #####
43-E-301
J89-F-101
42-E-201 HP Flare
J88-D-311 Velocity (ft/s) ##### 0.20
J89-D-101 #####
FI-0323
64-PV-017 63-PV-017 #####
#####
##### #####
##### 43-PV-861
J89
##### 41-PV-861 42-PV-861
2"-FG-0343

41-K-0110A 42-K-0210A 43-K-0310A

#####
62-PV-041 61-PV-041 2"-FG-0020 43-HV-316
Flow Rate (MSCFH) 5 ##### ##### 41-HV-316 42-HV-316 25-PV-015
##### #####
63-K-101C 32-PV-019 A ##### 31-PV-019 A D-101 HP FLARE K.O DRUM
Velocity (ft/s) 64-K-101D
0.20 J88
64-PV-031 63-PV-031
41-D-104 A/E
FCV0005
42-D-204 A/E
#####
43-D-304 A/E Flow Rate (MSCFH) 2.00
##### ##### #####
#####
41-PV-387 ##### ##### 42-PV-387
##### 25-D-107 A/B 43-PV-387 Actual Velocity (ft/s) 0.072309
#####
41-K-0110B
#####
##### ##### #####
43-K-0310B
HP Flare Summe ry Table
62-PV-017 61-PV-017 42-K-0210B 25-PV-025
#####J89FIC0005.pv ##### FV DFV YTD
##### ##### 32-PV-019 B Flow Rate (MSCFH)
31-PV-019 B 2.00 Flow Rate (MSCFH) 090-FI-001
#####
HP Purge Rate #####
##### ##### 41-D-105 42-D-205 Actual Velocity (ft/s) 0.000
43-D-305
##### 25-K-102A HP Accounted Flared ##### ##### #####
##### ##### J89-F-102
62-K-101B ##### 61-K-101A ##### ##### HP Flare
25-PV-054 HP FMS Flaring #####
##### ##### #####
62-PV-031 61-PV-031
Flaring per Flow Meter ##### ##### #####
32-C-201 31-C-101
#####

62-PV-041
##### 61-PV-041
#####
Figure 5 - RTR J-89 Velocity Profile #####
25-PV-015
25-K-102B
HP Unaccounted Flaring

FV :HP
Flare Rate K.O
(MMSCFD)
32-PV-019 A 31-PV-019 A D-101 FLARE DRUM
B68 SGC I B65 Gas Treat II B65 Gas Treat I B64 Inlet Area DFV : Daily Flared Volume (MMSCFD)
##### ##### ##### ##### ##### 25-D-107 A/B YT D : Year T o Date (MMSCF)
##### ##### HP Flare Summe ry Table
62-PV-017 61-PV-017 25-PV-025

9.4 Calculate Required Purge Rate #####

#####
#####
#####
32-PV-019 B 31-PV-019 B

##### 25-K-102A
HP Purge Rate
HP Accounted Flared
FV DFV

##### ##### #####

YTD

62-K-101B 61-K-101A ##### #####

25-PV-054 HP FMS Flaring ##### ##### #####
62-PV-031 61-PV-031
Flaring per Flow Meter ##### ##### #####
32-C-201 31-C-101

The required purge rate can be calculated based on the guidelines provided in
##### #####
##### 25-K-102B
HP Unaccounted Flaring

FV : Flare Rate (MMSCFD)

B65 Gas Treat II B65 Gas Treat I B64 Inlet Area
sections 7 andB68
8.SGCFollowing
I DFV : Daily Flared Volume (MMSCFD)

requirements shall be conformed: YT D : Year T o Date (MMSCF)

1. The purge gas requirement shall be calculated and reported for each of the
criteria.
2. Facilities with Instrumented Control System for intermittent purge is
required to maintain the continuous purge requirements only. The rate
should be considered as the highest of air ingress and sweeping only.
3. Facilities without Instrumented Control System for intermittent purge is
required to maintain the intermittent and continuous purge requirements on

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

continuous bases. The rate should be considered as the highest of air

ingress, sweeping, contraction and low BTU value.
4. Any instrumented control system should be adequately sized to provide the
minimum intermittent rate identified in Section 8.
5. Leakages from control valves may be included in the purge rate provided:
a. A leak survey is conducted
b. An accurate flare flowmeter is available
6. The amount of purge in each sub-header should be determined to meet the
following:
a. Velocity in the main header meets the requirement specified in paragraph
0 of this procedure.
b. Enough purge gas is available to prevent accumulation of corrosive
materials in sub-headers. The velocity in sub-headers may be lower
than 0.3 ft/s or higher than 0.5 ft/s depending on the condition of the
sub-header.

9.5 Develop a Report with an Implementation Plan

The findings of the study should be documented in a report along with an

implementation plan. The report should consist of the following sections:
1. Overview of the Flare System: This section should include an overview of
the flare system and purging points configuration. This must include any
intermittent purge gas control system.
2. Study Basis: This section should include all the data collected through the
survey. A list of purge points shall be provided in this system along with
details
3. Current Purge Rate and Velocity Profile: Purge rate from each purge point
shall be estimated and listed in this section. A velocity profile of the system
shall be developed. Any corrosion issue which was identified during the
survey must be documented in this section.
4. Recommended Purge Rate: The recommended purge rate for each of the
criteria must be calculated, listed, and analyzed in this section.
5. Recommendations and Implementation Plan: Recommendations to adjust
the purge rate such as, provide an intermittent purge rate controller, redesign
purge station in accordance with PIP PCIGN200, etc., shall be provided in
this section. An implementation plan shall also be provided in this section.

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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

It should include a list of purge points along with the recommended flow rate.
6. Plant flare purge gas adjustments are to be implemented per Saudi Aramco
Safety Management System (SMS), Element 5, and Management of Change
(MOC) to properly review and document the changes.

9.6 Continuous Monitoring and Optimization

1. It is recommended to develop a monitoring sheet for purge gas rate to ensure
the optimum flow is always achieved, refer to Figure 6 for an example. If it
is not possible to monitor the purge rate through DCS or PI, a check list
might be developed to monitor the flow rate during each shift.

Figure 6 - KGP Purge Gas DCS Monitoring Screen

2. The purge gas optimization study shall be reviewed and validated on annual
basis by plant Process Engineering group.

10 Utilizing Nitrogen as Purging Medium

Nitrogen may be utilized as purge gas on partial or full basis depending on the
configuration of the flare system.

10.1 Facilities with Flare Gas Recovery System

Facilities with a flare gas recovery system may achieve near zero flaring by
utilizing nitrogen as the main purging medium with fuel gas as back-up
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

downstream of the staging device. This will result in extenuating the tip flame
when relieved gases are routed to the recovery system. When the seal is broken,
gases going to the flare tip will displace nitrogen and will be ignited by the
pilots. Therefore, the following must be considered prior to introducing
nitrogen to the system:
1. Ensure that the pilots are compatible to function in a nitrogen rich
environment: When purging with nitrogen, pilots are essential to ensure
ignition of relieved gases when the seal drum is broken. Therefore, it is
recommended to ensure that the number of pilots are in accordance with
SAES-F-007 requirements and are in working order. It is also recommended
to consult the flare vendor to ensure existing pilot’s ability to withstand a
nitrogen rich environment.
2. Two functioning pilot monitoring systems should be available (main and
back-up): Pilot monitoring system is essential to ensure pilots are ignited at
all times. Thermocouples are the most common monitoring system.
However due to the thermocouple’s low life span, a back-up system shall be
provided. A flame-out alarm and separate indication for each pilot in a
constantly attended area shall be included, as required by SAES-F-007.
3. Two pilot ignition systems must be available (main and back-up):
SAES-F-007 requires each flare system to have a functioning Flame Front
Generator package. When purging with nitrogen, a back-up system shall be
provided.
4. Design the purge station to admit nitrogen in a control manner with
logic to automatically switch to fuel gas in case of interruption in
nitrogen supply: The purge gas station shall be designed to minimize the
need of operator intervention. A logic of automatic switching to fuel gas
shall be present to ensure adequate flow of purge is present at all times.
5. Provide a dedicated nitrogen generation package for flare purging
requirement with a minimum purity of 98%: This is to ensure a reliable
nitrogen supply, which is not affected by operational issues, is available at
all times.

10.2 Facilities without Flare Gas Recovery System

Facilities with no Flare Gas Recovery System should consider partial utilization
of nitrogen in purging the flare system. Full utilization is prevented by leakages,
which if not burned at the tip will have a detrimental impact on environment and
safety of the operation. The amount of nitrogen purge should be calculated
based on the continuous purge rate only to maintain constant flame at the tip.
Leakages should be addressed through replacement of valves. The following
shall be considered prior to introducing nitrogen to the system.
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

1. To ensure safe operation of flares, nitrogen purging for acid flare

systems should not be considered: Acid gas has a low lower heating value.
Introducing nitrogen will reduce the heating value further and may result in
releasing unburned toxic gases to the atmosphere.
2. Completion of purge gas optimization study: Completing a purge gas
optimization study and implementing the study recommendations is essential
to identify any opportunity to reduce purge gas. This in turn will result in
less requirement of nitrogen.
3. Ensure that the pilots are compatible to function in nitrogen rich
environment: Pilots are an important layer of protection against any possible
flame out in case of fuel gas supply interruption. Therefore, it is
recommended to ensure that the number of pilots are in line with SAES-F-007
requirements and are in a working order. It is also recommended to consult
the flare vendor to ensure the ability of existing pilots to withstand a nitrogen
rich environment.
4. Two functioning pilot monitoring systems should be available (main and
back-up): Pilot monitoring system is essential to ensure that the pilots are
ignited at all times. Thermocouples are the most common monitoring
system. However, due the thermocouple’s low life span, a back-up system
must be provided. A flame-out alarm and a separate indication system for
each pilot in a constantly attended area shall be included, as required by
SAES-F-007.
5. Two pilot ignition systems must be available (main and back-up):
SAES-F-007 requires each flare system to have a functioning Flame Front
Generator package. When purging with nitrogen, a back-up system shall be
provided.
6. Design the purge gas control system to satisfy the following:
a. Automatically control the heating value of the purge gas mixture to
maintain a minimum of 500 BTU/SCF. The amount of nitrogen
required to reach a heating value of 500 BTU/SCF can be confirm
through the use of simulation tools. The purge gas station must be
designed to minimize the need of operator intervention. A ratio
controller must be provided to ensure a minimum heating value of
500 BTU/SCF is always met.
b. Design for minimum requirement of a constant fuel gas purge to
satisfy the vendor specification for flare tip requirement. Providing a
fixed amount of fuel gas through a restricted orifice will guarantee the
vendor recommended purge to prevent air ingress into the flare system in
case of a nitrogen purge failure.
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Document Responsibility: Flare Systems Design Standards Committee SAEP-405
Issue Date: 05 January 2017
Next Planned Update: 05 January 2020 Flare System Purge Gas Optimization

7. Provide a dedicated nitrogen generation package for flare purging

requirement with a minimum purity of 98%: This is to ensure a reliable
nitrogen supply, not affected by operational issues, is available at all times.

Revision Summary
05 January 2017 New Saudi Aramco Engineering Procedure to provide general guidelines and safety
measures to optimize the purge gas rate and utilize nitrogen as purge gas for Saudi Aramco
upstream and downstream facilities.

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