Zink Proposal

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A

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NOTES: 1. HT CABLE FOR KEP-100 IGNITION & DETECTION SUPPLIED BY JZ 2. DRAIN ALL LOW POINTS.

1

DRG. No.

1

2 x KEP-100

CLIENT

JOHN ZINK BE

BE

2

2 PILOT B

CLIENT

JOHN ZINK

PILOT C

KEP-100 PILOT IGNITION & DETECTION PANEL BAH

BAH

3

3 PILOT A ON

XA

PILOT FAIL COMMON ALARM

BAL

PILOT A OFF HS

PILOT A MANUAL IGNITE

REMOTE START/STOP

HS

PILOT B ON BAL

PILOT B OFF HS

NOTE 1

PILOT B MANUAL IGNITE

NOTE 1

HS

4

4 PILOT A AUTO/OFF MANUAL

POWER SUPPLY 240V 1ph 50Hz

CLIENT

PILOT B AUTO/OFF MANUAL

JOHN ZINK PCV

5 1"

1"x

1/ 2 "

5

PI

1/ 2 "x

1"

1"

INLET

0

21.11.05

REV

DATE

ISSUED FOR TENDER

NDP DRN.

DESCRIPTION

PROCESS

ENG.

PROJ. ENG.

THIS INFORMATION IS CONFIDENTIAL AND THE PROPERTY OF JOHN ZINK AND IS RELEASED ON CONDITION THAT NONE OF THE INFORMATION SHALL BE DISCLOSED TO ANY THIRD PARTY OR REPRODUCED IN WHOLE OR PART WITHOUT THE PRIOR CONSENT IN WRITING OF JOHN ZINK

HP INLET 10" 150# RFWN 6

CLIENT

JOHN ZINK

Division of the Koch Chemical Technology Group Limited Dolphn House 140 Windmill Road Sunbury-on-Thames Middlesex, TW16 7HT England Tel: (01932) 769830 Fax: (01932) 787471 ISSUE STAMP

CLIENT ORDER No.

. PROJECT

6

KALDAIR JOB No.

TITLE

PRELIMINARY PIPING & INSTRUMENTATION DIAGRAM KEP-100 PILOT IGNITION SYSTEM SCALE

NONE

A

B

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DRG. No. H

JOHN ZINK® KOCH CHEMICAL TECHNOLOGY GROUP LIMITED

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 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

JOHN ZINK Koch Chemical Technology Group

TABLE OF CONTENT 1.

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

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8

SCOPE OF SUPPLY........................................................................................................................ 4 PACKING ..................................................................................................................................... 10 CONTROL AND INSPECTION ....................................................................................................... 11 TECHNICAL NOTES AND CLARIFICATIONS ................................................................................. 12 EXCLUSIONS FROM THE SUPPLY ............................................................................................... 13 ADDITIONAL SERVICES .............................................................................................................. 13 STORAGE LIMITATION ................................................................................................................ 14 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




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.




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. 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

Provision of any utilities has a




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-PRDAT-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. JOHN ZINK TODD COMBUSTION BROWN FINTUBE KALDAIR



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-0001rev 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.




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 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 KEP-100 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.




HP 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-9-12 comprising: Inlet flange 18” Class 150 RFWN in material AISI 316L Lower Body in material AISI 310 9 arms in material AISI 310 9 quantity 12” Diameter variable slot Tulip assemblies in material AlSI 310 3 off KEP-100 Pilot(s), in material AISI 310 2. One (1) guy support stack in material carbon steel to provide an overall height of 45m 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. LP 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 KEP-100 Pilot(s), in material AISI 310 2. One (1) self support stack in material carbon steel to provide an overall height of 45m 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.




AP Flare - Kaldair Multi-point Indair with FFG pilots The Flare System will be comprised of the following components: 1. One (1) Flare tip, model EEF-U-42 comprising: Inlet flange 42” Class 150 RFWN in material AISI 316L Upper Body in material AISI 310 Lower Body in material AISI 310 4 off KEP-100 Pilot(s), in material AISI 310 2. One (1) self support stack in material carbon steel to provide an overall height of 45m 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. 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. JOHN ZINK TODD COMBUSTION BROWN FINTUBE KALDAIR



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




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.




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.




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.




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.




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.




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.




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,




5.

Packing,

6.

Guarantees




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;




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.




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.” JOHN ZINK TODD COMBUSTION BROWN FINTUBE KALDAIR



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.




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



INDAIR SPECIFICATION KMI -2-12WB JOHN ZINK

JZ REF: 200803-8213

CLIENT: PARSON

200803-8213- 103

DATA SHEET No. REV.

0

PROJECT:

DATE

31-Mar-08

KHAZZAN/MAKERAM

BY

NDP

SOUR FLARE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

DESIGN CASES Amin Buah mmscfd 50 50.0 mmscfd PURGE g/mole 24.20 23.51 °C 0 0
GAS STREAM MAX FLOW MIN M.W. TEMPERATURE SMOKELESS INLET PRESS.

UTILITY CONSUMPTION FUEL GAS / PILOT 1.85 Nm³/hr Fuel Gas 2.25 Nm³/hr PURGE GAS N2 2.01 Nm³/hr PILOTS QUANTITY 2 TYPE: KEP-100 THERMOCOUPLES No TYPE: DIMENSIONS LENGTH mm 3.0m WIDTH mm 0.5m WEIGHT kg 450 kg MANIFOLD UPPER BODY LOWER BODY WIND DEFLECTORS FLAME RETENTION LIFTING LUGS PILOT PILOT NOZZLE SEAL

MATERIALS AISI 310 AISI 310 AISI 310 AISI 310 AISI 310 AISI 310 AISI 310 AISI 310 The drawing is typical only This offer may not include all items shown above.

SURFACE FINISH

NATURAL

DESCRIPTION FLARE GAS INLET

SIZE 10 ''

PILOT GAS INLET

1 ''

TERMINAL POINTS RATING ASME16.5 CLASS 150 RFWN

AISI 316L

ASME16.5 CLASS 150 RFWN

AISI 316L

PIPE2_1

MATERIAL

NOISE DATA FREQUENCY PWL dB SPL dB PWL dB SPL dB

COMMENT Noise at stack base

dBA 62.5 125 151 101.0

250 500

1K

2K

4K

8K

REMARKS

FILE:PIPE_DS2

Wind Speed: 17.1 m/s Wind Direction: 0 degrees

-70

Flare and contour key

-50

1 2 3 4 5 6 7

-30

Elevation (m).

1

Btu/hr.ft2 500.00 700.00 900.00 1100.00 1500.00 2200.00 3000.00

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94 9.46

-10

7 6 5 4 3 10

2

Flare 1 Wt. KMI-2-12

Flow

Mol.

50 MMSCFD

22.32

30

50

70 -60

-40

-20

0 Distance (m).

20

40

60

RADIATION PLOT

Sweet Flare

RFQ: 2008-8213

JOHN ZINK Doc:

By: Nigel Philpott Rev: 0

31/03/2008


JZ REF: 200803-8213

CLIENT: PARSON

200803-8213- 104

DATA SHEET No. REV.

0

PROJECT:

DATE

31-Mar-08

KHAZZAN/MAKERAM

BY

NDP

SWEET FLARE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

DESIGN CASES Max mmscfd 50 mmscfd PURGE g/mole 22.32 °C 0



SURFACE FINISH

NATURAL


SIZE 8 ''

PILOT GAS INLET

1 ''


AISI 316L


AISI 316L

PIPE2_1

MATERIAL



dBA 148 96

62.5 125

250 500

1K

2K

4K

8K

REMARKS

FILE:PIPE_DS2


-80 6


5

5 -60 1 2 3 4 5 6 7

-40

7

Elevation (m).

-20

Btu/hr.ft2 500.00 700.00 900.00 1100.00 1500.00 2200.00 3000.00

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94 9.46

4

0 6 20


5

Flow

Mol.

280 MMSCFD

19.08

40 3

4

2

60

1

80 -60

-10

40

Distance (m).

RADIATION PLOT RFQ: 2008-8213

By: Nigel Philpott

HP Flare Composition JOHN ZINK Doc:

Rev: 0

31/03/2008


JZ REF: 200803-8213

CLIENT: PARSON

200803-8213- 105

DATA SHEET No. REV.

0

PROJECT:

DATE

31-Mar-08

KHAZZAN/MAKERAM

BY

NDP

HP FLARE X-171 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

DESIGN CASES Max Cont mmscfd 280 200.0 mmscfd PURGE g/mole 19.08 19.08 °C 23-60 23-60



SURFACE FINISH

NATURAL


SIZE 18 ''

PILOT GAS INLET

1 ''


AISI 316L


AISI 316L

PIPE2_1

MATERIAL



dBA 62.5 125 159 114

250 500

1K

2K

4K

8K

REMARKS

FILE:PIPE_DS2


-70


-50

1 2 3 4 5 6 7

Elevation (m).

-30

Btu/hr.ft2 500.00 700.00 900.00 1100.00 1500.00 2200.00 3000.00

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94 9.46

-10

7 6 10

5 4 3 2

1


Flow

Mol.

22 MMSCFD

33.93

30

50

70 -60

-40

-20

0 Distance (m).

20

40

60

RADIATION PLOT

LP Flare Composition

RFQ: 2008-8213

JOHN ZINK Doc:


31/03/2008


-70


-50

1 2 3 4 5 6 7

Elevation (m).

-30

Btu/hr.ft2 500.00 700.00 900.00 1100.00 1500.00 2200.00 3000.00

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94 9.46

-10

7 6 10

5 4 3 2

1


Flow

Mol.

22 MMSCFD

33.93

30

50

70 -60

-40

-20

0 Distance (m).

20

40

60

RADIATION PLOT

LP Flare Composition

RFQ: 2008-8213

JOHN ZINK Doc:


31/03/2008

PIPE FLARE SPECIFICATION EEF-U- 42 JOHN ZINK

JZ REF: 200803-8213

CLIENT: Workey Parsons

200803-8213- 107

DATA SHEET No. REV.

0

PROJECT:

DATE

1-Apr-08

Khazzan/Makarem

BY

NDP

AP FLARE X-193 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59

PROCESS DATA Max Cont MMSCFD 28.00 20 MMSCFD PURGE g/mole 35.16 35.16 °C 20-120 20-120

GAS STREAM MAX FLOW MIN M.W. TEMPERATURE INLET PRESS.

mbar 0.17 GAS COMPOSITION SEE CUSTOMERS DATA SHEET

UTILITY CONSUMPTION 1.85 Nm³/hr FUEL GAS / PILOT Fuel Gas 39.00 Nm³/hr PURGE GAS N2 30.11 Nm³/hr PILOTS QUANTITY 3 TYPE: KEP THERMOCOUPLES TYPE: Cr/Al DIMENSIONS LENGTH(LA): 3.00m WIDTH(LB): APPROX. WT.: 1500kg MATERIALS BODY UPPER AISI 310 BODY LOWER AISI 316 PILOT AISI 310 PILOT NOZZLE AISI 310 PILOT MANIFOLD AISI 316 IGNITION MANIFOLD AISI 310 FLAME STABILIZER PURGE SEAL AISI 316 LIFTING LUGS AISI 316 WIND DEFLECTORS AISI 310

1.35m

This offer may not include all items shown above.

SURFACE FINISH

NATURAL

DESCRIPTION FLARE GAS INLET PILOT INLET

SIZE 42 '' 1"

TERMINAL POINTS RATING ANSI CLASS 150 RF FLANGE ANSI CLASS 150 RF FLANGE

PIPE2_1

MATERIAL AISI 316 AISI 316

NOISE DATA FREQUENCY PWL dB SPL dB

COMMENT Noise level at 0m from flare

dBA

62.5 125

250 500

1K

2K

4K

8K

<85

REMARKS

FILE:PIPE_DS2


-70

Flare and contour key -50

Btu/hr.ft2 1 500.00 2 700.00 3 900.00 4 1100.00 5 1500.00 6 2200.00

-30

Elevation (m).

-10

65 43 2

10

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94

1

30

Flare 1 Wt. EEF-U-42

50

Flow

Mol.

33.4 MMSCFD

35.16

70

90

110 -60

-40

-20

0

20

40

60

Distance (m).

RADIATION PLOT

AP Flare

RFQ: 2008-8213

JOHN ZINK Doc:


04/01/2008


-80

Flare and contour key -60

Btu/hr.ft2 1 500.00 2 700.00 3 900.00 4 1100.00 5 1500.00 6 2200.00 7 3000.00

-40

Elevation (m).

-20

0

7 6 5

KW/m2 1.58 2.21 2.84 3.47 4.73 6.94 9.46

4 2 3 1

20


Flow

Mol.

50 MMSCFD

23.51

40

60

80 -60

-40

-20

0 20 Distance (m).

40

60

RADIATION PLOT

Sour Flare Buah Composition

RFQ: 2008-8213

JOHN ZINK Doc:


31/03/2008


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 mixi ng 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.

Unburned 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.

Aspirated Air

Aspirated Air

Aspirated Air

Aspirated Air

Small Diameter Nozzle

Large Diameter Nozzle

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 premixed 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 a nd 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 highpressure 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 conve ntional 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 crosswinds. 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 carryover 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.

Flow MM Sm3/d

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 Flare Tip barg. In flaring terms this Flow vs Pressure Curve 25.00 latter pressure is not enough to produce a 20.00 turbulent, stiff flame and 15.00 the result is a laminar diffusion flame (like a 10.00 pipeflare). The region that a Coanda flare will 5.00 give good performance 0.00 starts at about 0.2 barg is 0.0 1.0 2.0 3.0 4.0 5.0 6.0 Pressure barg fully developed by 0.8 MW= 17.00 Temp= 15.0°C 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.

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

Flow MM Sm3/d

Flare Tip There is another way to Flow vs Pressure Curve "stage" a flare, that is to 25.00 say to modify it's 20.00 flow/pressure curve so that it operates at higher 15.00 pressures at lower flows. This can only be done by 10.00 varying the discharge flow 5.00 area of the flare tip itself. The INDAIR flare lends 0.00 0.0 1.0 2.0 3.0 4.0 itself to this very well. It is Pressure barg apparent that the gas slot MW= 17.00 Temp= 15.0°C area can be changed by raising or lowering the tulip assembly within the flare tip body.

Tulip Cone

Coanda Profile Tulip Bowl Annular Slot (minimum width)

Tulip Cone

Coanda Profile Tulip Bowl Annular Slot (maximum width)

5.0

6.0

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.

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 multiarm 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.

Tulip Cone

Coanda Profile Tulip Bowl Annular Slot (maximum width) Non-Fixed (Guide Tube) Support Brackets Fixed (Welded) Support Brackets

Spring Adjustment Port

Main Body Main Body

Spring Assembly (Bellville Washers) In Compressed State

•

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.

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

Wind Speed = 65 ft/s

Vertical 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 Tip

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

INDAIR e = 0.08 - 0.10

MARDAIR e = 0.05 - 0.07

API Pipeflare e = 0.20 - 0.30

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

JOHN ZINK ® KOCH CHEMICAL TECHNOLOGY GROUP LIMITED

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 flam e reten tio n a flanged piece of seg m en ts pipe, with an ignition p ilo t source at the exit. w in d sh ield This simplest type of flare tip suffers from some poor operating characteristics. These types of flares are prone to flame liftoff, where the flame becomes unstable at high flow rates. Flame lift-off can w aste g as 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.

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: 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.

One of the most prominent wind mechanisms direction responsible for the failure of a flare tip is internal burning. air / fuel A flare tip will mixture typically experience internal burning if it operates at a low waste waste gas exit gas 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


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

Pilot Nozzle

Ceramic Rod (Electrode)

Inspirator Assembly Pilot Inlet

Ignition Inlet

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 highvoltage 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.

Kanthal Electrode (Pilot Nozzle End)

Locking Nut (Pilot Nozzle End)

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.

Ceramic Rod

Kanthal Electrode (Cable End)

Locking Nut (Cable End)

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 flo w 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

+

+ - + + - + +- + + - + + + + + + +

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. TO PILOTS

PILOT #1

PILOT #2

PILOT #3

PILOT ON

PILOT ON

PILOT ON

PILOT OFF

PILOT OFF

PILOT OFF

MAN/OFF/AUTO MAN/OFF/AUTO MAN/OFF/AUTO SELECTOR SELECTOR SELECTOR

AC POWER IN

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.

REMOTE ALARMS

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.

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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