Prevention or creation of liquid slugs in flarelines OC 449/7This OC summarises a number of recent potentially serious incidents involving flareline systems in refineries and recommends measures to prevent their reoccurrence,
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(1) condensed hydrocarbon gases and steam which have been fed to the flare,
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(2) liquid carried over from high pressure plant when rapid acting emergency depressurisation valves are opened,
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(3) dense phase mist flows due to two phase flashing relief flow where only large liquid droplets are separated by the knock out pot,
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3 It is generally considered impractical to design the supports and restraints of flareline systems to cope with the large mechanical reaction forces which arise when liquid slugs of possibly several pipe diameters in length are driven into bends at vapour release velocities. It is therefore vital that no gross liquid slugs enter flarelines. The knock out pot facilities should therefore be designed,
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4 The conventional,
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5 If carryover is not possible then simpler drainage arrangements may be acceptable,
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(1) drainage pots and lines should be designed so that the chances of blockage are minimised,
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(2) an easily operated and effective means of checking that drain lines are free should be provided. Bleed valves are a simple way of achieving this,
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(3) inspection of drain lines should be routinely undertaken and the results formally recorded,
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7 The design codes state that it is not necessary to assume the simultaneous occurrence of 2 or more unrelated events. Additionally it may have been assumed in the design that only one relief valve would lift,
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Action by inspectors 8 Flare systems are provided as a last line of defence against a major accident. Adequate design and maintenance,
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9 Prevention of liquid accumulation is central to safe operation,
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(1) The lack of knock out pots without detailed justification,
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(2) The presence of small bore drains,
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(3) The lack of regular formal checks on drainage arrangements,
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10 It is vital that no gross liquid slugs enter flarelines,
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11 It is important that the knock out pot facilities are designed,
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12 Managers of sites with flarelines should be asked to take account of these factors when carrying out risk assessments and deciding on the appropriateness of their control measures,
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13 FCG assistance may be required particularly where knock out pots are not provided. The Chemical Manufacturing NIG,
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26 November 1993APPENDIX 1: Incidents

(para 1)

1 Sections of flarelines at refineries have been partially or fully displaced from their mountings,
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