IOCL REFINERY FLARE PACKAGE SYSTEM
FLARE PACKAGE SYSTEM
Delivered integrated Piping, Civil & Structural engineering, intelligent 3D modelling and Piping stress analysis solutions to ensures safe, reliable, and construction-ready execution for the Refinery Hydrocarbon Flare System.
Owner
IOCL REFINERY LTD
Client
AFG COMBUSTION PVT LTD. (Formerly Known as Airoil Flaregas Pvt Ltd.)
PMC
TOYO ENGINEERING INDIA LTD
Location
BARAUNI, INDIA
Project Scope
The Brownfield project scope comprises Detail engineering of Piping, comprehensive 3D modelling, and Piping stress analysis, Civil and Structural engineering for the Refinery Hydrocarbon Flare System.
Development and finalization of engineering deliverables for procurement, fabrication, construction, and commissioning activities.
The flare system in the project comprises following systems:
• Primary Hydrocarbon Flare System
• Secondary Hydrocarbon Flare System
• Sour Gas Flare System
Each system is engineered with dedicated or common headers, ensuring safe segregation, controlled disposal of hydrocarbons, and efficient handling of varying pressure and composition streams.
At the core of the project lies Piping engineering and highly detailed 3D model, that serves as a single source of truth for all engineering disciplines.
The piping scope includes design of large-bore flare headers (up to 76 inches) from battery limits to KO drums and onward to flare stacks, ensuring proper slope for drainage, minimal pressure drop, and accessibility for operation and maintenance and Integration with civil, structural, E&I systems using 3D modelling for efficient coordination.
Engineering activities include piping routing, piping layout development, critical line stress analysis, utility integration and multidisciplinary coordination.
Given the extreme conditions in flare systems, detailed stress analysis is a critical component to take care of Thermal Expansion, various load considerations like Sustained, occasional and dynamic loads with support optimization and code compliance.
The project includes a common derrick structure supporting multiple flare systems, designed for both functionality and safety to withstand environmental loads such as wind and seismic forces also trussell support and Piperack are designed to support large diameters flare headers.
Access Platforms, Stairs & Ladders are designed for safe operation, access for inspection and maintenance at elevated heights.
Key Highlights
Detail engineering of Piping, Civil & Structural engineering, 3D modelling of complete facility and Piping stress analysis of system of plot area 35200 m2 for Refinery Hydrocarbon Flare System.
The project covers multiple flare networks including Primary and Secondary Hydrocarbon flare and Sour gas flare and headers up to 76’’, with Flare Knock-Out (KO) Drums, KOD Pumps, Water Seal Drum, Flare Risers, Molecular Seals, Flare Tips.
Developed intelligent 3D models ensuring: Clash-free interdisciplinary design, Optimized routing of large bore piping (up to 76”) with improved constructability and space utilization
Performed comprehensive Piping stress analysis, considering: Thermal expansion and sustained loads, Wind and Seismic loads, Occasional and emergency operating conditions.