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.

Thermocouples

Why >

  • Installed in extreme environments

  • Demand regular maintenance and replacement

  • Installation, maintenance and repair require factory shutdowns

  • Uneconomical

Ionization Spectrometers

& UV Flame Detectors

Why >

  • Inaccurate in conditions of excessive smoke and variable gas composition

  • Single wavelength

  • Very complicated installation, configuration and operation.

Thermal Camera Solutions

Why >

  • Inaccurate when aligned with the sun.

  • Inaccurate in high winds and inclement weather.

  • Poor readings when flare generates low CE.

  • Single Spectrum

Pyrometers

Why  >

  • Difficult to align the device to ensure function in harsh weather

  • Difficult to align the device to the pilot

  • Single wavelength

  • Small relevant region of measurement