LG Chemical Korea Case Study
In 2012, Zeeco successfully installed a Zeeco QFSC Steam Assisted Flare System for LG Chemicals petrochemical plant in South Korea. Zeeco worked closely with the EPC company, LG / Toyo Korea, to ensure the flare’s proper design, full fabrication, field assembly, and erection / start-up for the facility.
In order to successfully complete and meet necessary flaring requirements for the total facility, Zeeco engineers had to perform difficult radiation analysis for multiple locations and heights for the new flaring system to satisfy requirements. The analysis proved to be challenging due to existing flares operating in close proximity to the new flare’s location, as well as the variation in the topography within the flare’s proposed area. Zeeco engineers were required to consider existing flare systems in any radiation analysis, while still meeting all radiation requirements. The QFSC Derrick Flare System was selected due to its proprietary tip design, which will use a number of injection ports to successfully reduce steam injection noise, lowering the radiation level at grade, and its minimize total land required for installation.
Another challenge was to meet equipment fabrication and installation completion deadline within an eight-month timeframe. Zeeco fabricated and supplied the following equipment:
- 120m Flare Stack
- Integral Liquid Seal Drum in Stack Base
- Buoyancy Type Purge Gas Seal Device
- 120m Derrick Support Structure for Flare Stack
- Set of Ladders and Platforms
- Retractable Davit System
- QFSC Flare Tip with 4 Pilots
- Front Flame Generator (FFG) Rack with Control Panel
- Fixed Aircraft Warning Light System with Control Panel
- Utility Piping
- Interconnecting Piping between the Flare Stack and FFG Rack
Although there were several last minute changes made during installation in the field, Zeeco was able to promptly work with installers to make the necessary changes required for proper installation. We were also able to help meet LG Chemicals start-up deadline by assisting with start-up issues due to pilot gas composition. The pilot’s fuel gas composition contained an inordinate amount of hydrogen, causing problems with pilot ignition. Zeeco personnel made the required adjustments and changes in the field to accommodate the varying fuel gas possibilities for the job. This resulted in a combustible gas/air mixture range, solving the pilot’s ignition issue.