CHALLENGES FOR DEPLOYMENT
While regulations have become stricter and compliance far more difficult to achieve, the industry has fallen short of finding a solution that helps flare stack operators accurately and efficiently monitor flare performance due, in great part, to the extreme temperatures and conditions at the flare stacks as well as wind, rain, the position of the sun and other environmental noise. Available solutions have proven either economically inhibitive or simply inaccurate and ineffective.
Monitoring solutions such as thermocouples, while accurate, are installed within the extreme environment of the flare. The extreme temperatures within the flare combined with the build-up of soot and other solid wastes means that these solutions require regular maintenance and repair demanding complete factory shutdowns until required work has been completed. The cost of these systems coupled with the losses generated in maintaining these systems as a result of factory shutdowns makes them simply uneconomical.
Spectral sensors such as pyrometers, ionization spectrometers, UV flame detectors and thermal camera solutions encounter problems with alignment as well as accuracy when faced with inclement wind and weather, excessive smoke and when the sensor is in line with the sun.
Excessive downtimes and inherently inaccurate and inefficient monitoring leaves current solutions wanting, and factory management exposed to threat of sanction.