Why Flare Stack Monitoring is essential for the O&G / Steel Industry

Flare stacks are used in many industries to burn off unwanted waste gas byproducts, or flammable gases released by pressure relief valves during unplanned over-pressuring of plant equipment. Applications include oil and gas well drilling operations, oil refineries, chemical process plants, gas distribution infrastructure, landfills and blast furnaces in steel plants. Environmental Regulators demand close monitoring of flare stack to prevent toxic gases entering atmosphere. Flare systems are often a last line of defense to prevent dangerous pollutants from entering into the atmosphere. Flaring without the pilot flame releases gas into the air, increasing the risk for explosions and negative environmental impact. Therefore, having a reliable method to monitor and verify that all stacks are operating correctly, within the prescribed operational limits, is critically important. Various technologies have been used to monitor flares but have limited performance when looking through smoke or in case of cloudy/ foggy/ moist environments. Thermal imaging is an ideal non-contact monitoring tool that offers automated remote monitoring of flare stack on a 24/7 basis, in virtually any weather.

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Flare Stack Monitoring, Industry Practices

Thermocouples are the most commonly used tool to monitor flare stacks. But these are contact type sensors, have relatively smaller design life and eventually fail over period of time due to harsh environment condition. Also, not being easily accessible due to their mounting location inside the stack, routine maintenance and quick replacements are difficult. UV Sensors detect a flame through its emitted ultra-violet energy. But they are less effective for flare monitoring as they need to be installed quite close to the stack. Otherwise they may detect UV energy from other sources, such as reflected sunlight and give false alarms. Also they can be blinded by smoke. Visual Cameras are often used as a low-end solution to visualize the flare in control room. But these are not at all suitable for smoky or foggy environment due to poor visibility. Further, the CCTV cameras cannot visualize those flames that are invisible to the naked eye.  Thermal camera recognizes the difference between the heat signature of a flare stack flame and the surrounding background (usually the sky or clouds). Even if the stack flame is invisible to the naked eye (or to a visual camera) because of its composition or low gas flow volume, a thermal camera can monitor whether a flare is burning or not.

Visual Image
Visual Image
Thermal Image revealing invisible flame
Visual Image
Thermal Image revealing invisible flame

VISION WITH FLIR INFRARED:
Thermal Cameras are the best monitoring option for Flare Monitoring. They notify the Plant Manager immediately if flare stack combustion is lost, without any false alarms.

FLIR thermal imaging cameras can

Verify combustion, minimize unburned pollutants & assist in environmental compliances

Instantly report loss of combustion with visual, audible and email/text alarms

Transmit thermal & visual images in real time to a central control room over Ethernet

Provide remote visual monitoring over a TV Screen or PC display

Provide a quantitative readout of flame temperature and size with alarms, for process control

Improve combustion efficiency by assisting control of the assist gas to waste gas ratio

Provide 4 – 20mA analog outputs (or digital o/p) to be integrated to 3rd party control systems

Assist data analysis, archiving and report generation using Hi-Tech’s Flare Monitoring Software

Why would you choose
Hi-Tech’s Flare Monitoring System?

Huge install base with a proven track record

Designed for extreme harsh outdoor environments

Highest thermal resolution (640x480) available in the industry for accurate measurements

Industry’s best thermal range to ensure flame temperatures even above 1500°C can be recorded

Radiometric accuracy ±2 °C

Best distance to spot-size ratio, as high as 5800:1

Wide array of optics: lenses ranging from 6° to 80°

High image frequency of 30 frames/sec to ensure zero event loss

Best in class thermal sensitivity (<25 mK) to capture even the smallest temperature deviation

Rugged industrial enclosure with IP67 protection class, liquid/ air cooling facility, unmatched design to prevent entry of iron dust and moisture (includes explosion proof variants)

Automatic alarm generation with email / text message alerts in case of anomalies

State-of-the-art in-house Software with at-a-glance decision making, analytics, reporting

Multiple communication protocols like RTSP, TCP/IP, GigE, Rest API, FTP, SMTP, and MODBUS

Meeting Industry Needs

Flare stacks are installed in wide range of industrial environments. Different industries, plants, and installations can have very different requirements and constraints. For example, where some sprawling facilities may have several types of flare stacks, others installations may be in remote locations with a single stack and a very small control room. Many chemical plants have certain areas where explosion-proof equipment is necessary, other facilities may instead depend on advanced automation and highly-integrated data management systems. 

To meet the diverse needs of flare stack operations across all industries, Hi-Tech has designed the Flare Monitoring System design with maximum flexibility to meet these diverse needs, as depicted in the System Architecture.

Hi-Tech’s Flare Stack Monitoring Software

Hi-Tech’s Flare Monitoring Software has been developed in-house by our proficient software development team in consultation with industry experts and actual end users. 

  • Hi-Tech’s intelligent software can record temperatures based on region of interests (ROI) defined using on-board box, polygon or free-hand tools.
  • Each reading is compared against customized threshold values set by the user.
  • If a reading exceeds the threshold, alerts are triggered via email /SMS/WhatsApp
  • Has an attractive, user-friendly dashboard with simultaneous thermal and visual streams along with trend charts and alarm list, for at-a-glance decision making.
  • It configures temperature /event data to be sent out via I/O module to 3rd party devices.
  • Integrates the system with User’s SCADA.
  • Generates ser configurable reports and trend analysis based on wide variety of graphic charts.
  • Archives all events (image and video) for future reconciliations.

Our Product Offerings

Axxx Series Cameras
IP67 / Ex enclosures
Flare Monitoring Software

Enhancing the combustion efficiency of a Flare System

Smoke is an indication that hydrocarbons are not being combusted completely. Also, if Vent Gas is being sent to a flare but there is no visible flame, or if only a steam plume is visible, the flare may be operating at low combustion efficiency. The size and brightness of the resulting stack flame, and the amount of smoke generated, depends on how much flammable material is released. Assist gases such as air or steam may be injected into the gas flow to improve combustion and help minimize smoke.  

IR cameras can be integrated with visual cameras to monitor smoke. Thermographic and visual images can be transmitted in real time to a central control room as digitized data. The FLIR thermal cameras can facilitate the plant’s automated assist gas injection control, to minimize smoke. The cameras sense flame temperature and size, key elements in a control scheme. If data falls outside the user’s preset limits, the system transmits alarm signals to the control systems. This can help avoid excessive steam consumption and provide significant cost savings.

Well Operating Flare: High Combustion Efficiency
Over-steamed Flare: Low Combustion Efficiency

Our Valued Clients

When it comes to Flare Monitoring in India, Hi-Tech Systems & Services Ltd. is the go-to company, having implemented most projects so far, across the nation.

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