COURSE OVERVIEW:

Flare systems and overpressure protection are the final layers of defense in process plants, designed to safely manage the release of hydrocarbons during emergencies and process upsets. This course provides a comprehensive examination of the engineering principles used to design, size, and maintain relief systems and flare headers. Participants will explore the regulatory requirements and international standards, such as API 520, 521, and 537, that govern the protection of pressure vessels and the safe disposal of waste gases.

The scope of this training involves a detailed analysis of relief scenarios, ranging from blocked outlets and fire exposure to power failures and heat exchanger tube ruptures. Attendees will learn the technical mechanics of Pressure Relief Valves (PRVs), Rupture Disks, and Depressurization Systems (Blowdown), focusing on their selection and sizing based on the "worst-case" relief load. The course emphasizes the hydraulic design of the flare network, including the analysis of back-pressure, Mach number limits, and the prevention of acoustic-induced vibration in large-diameter piping.

Coverage includes the operational and environmental aspects of flare management, such as smokeless operation, radiation shielding, and the minimization of greenhouse gas emissions. Participants will examine the design of flare tips, knockout drums, and liquid seals, as well as the implementation of Flare Gas Recovery Systems (FGRS) to reduce flaring during normal operations. By integrating rigorous engineering calculations with safety best practices, this course equips professionals to manage the integrity of overpressure protection systems and ensure compliant, safe plant operations.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Identify the legal and regulatory requirements for overpressure protection systems.

2.  Classify different types of relief devices including PRVs, pilot-operated valves, and rupture disks.

3.  Determine the controlling relief scenario for various pieces of process equipment.

4.  Size Pressure Relief Valves according to API 520 standards for vapor and liquid service.

5.  Evaluate the impact of fire exposure and thermal expansion on relief requirements.

6.  Design and size flare knockout drums for effective liquid-vapor separation.

7.  Perform hydraulic calculations for flare headers considering back-pressure and sonic flow.

8.  Assess the risks of Acoustic Induced Vibration (AIV) and Flow Induced Vibration (FIV).

9.  Define the requirements for smokeless flaring and steam/air injection.

10.  Calculate flare radiation levels and determine safe sterilization distances.

11.  Implement Flare Gas Recovery Systems (FGRS) to minimize environmental impact.

12.  Conduct a Flare System Header Study using specialized simulation software.

13.  Formulate a maintenance and proof-testing schedule for relief devices.

TARGET AUDIENCE:

Process Engineers, Safety Engineers, Piping Designers, Operations Managers, and Maintenance Personnel responsible for relief system integrity.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.