Flare Systems Overview
Here is the overview content
Onshore & Offshore Flares
Utility Flares
Utility Flares are employed in applications which do not require smokeless burning or where smokeless flaring can be achieved without the use of an additional assist medium. They do not require auxiliary gas streams such as steam or air, two fluids normally used to improve smokeless capacity. They include a Dynamic Seal in the base of the tip to reduce purge gas cost and prevent flashback. Also, a stainless steel flame retention ring is designed to prevent flame lift off.
Air-Assist Flares
Air-Assist Flares are comprised of two risers (waste gas and air) and a blower system that provides supplemental combustion air. Air is fed by the blower into the air riser, to combine with the process gas, which it passes through its own secondary riser. Upon mixing, the high pressure air flow causes turbulence in the waste gas stream, improving mixing, and ultimately combustion efficiency. These Flares generally dispose of heavier waste gases which have a greater tendency to smoke.
Steam-Assist Flares
Steam assisted flares are flares designed to dispose of heavier hydrocarbon gases which have a tendency to smoke. In order to prevent smoke formation, steam is injected into the waste stream using peripheral steam rings, center stream spargers and /or inner induction tubes. They are used in applications where high pressure steam is available on site. Steam flares are typically found in downstream applications where high efficiency combustion of heavy hydrocarbons is required.
Fixed Orifice Sonic Flares
Mach-1 sonic flares are used in both onshore and offshore applications to dispose of high pressure waste gas streams with high smokeless capacities. By efficiently inducing high volumes of ambient air for more complete, smokeless combustion at sonic velocities, this advance flaring technology allows for reduced levels of radiation and can be placed at lower, less visible elevations, allowing for a more cost-effective flaring solution. Mach-1 sonic flare technology can also be applied in multi-point orientations to accommodate flame length restrictions.
Variable Orifice Sonic Flares
The VariMach sonic flare tip features spring-actuated variable sonic nozzles to allow the exit area to vent with pressure, ensuring constant sonic velocity of the exiting waste gas. This industry proven technology guarantees sufficient inspiration of air to ensure 100% smokeless combustion and infinite turndown. Radiation levels are also minimized throughout the entire range of flow, yielding shorter stack heights and reducing material costs. Additionally, the VariMach has the lowest purge rate of any flare technology on the market, minimizing utility costs while maintaining flashback protection.
Water Injected Sonic Flares
Triton sonic flare technology allows for safe, efficient and smokeless flaring at elevated oil and gas production rates by injecting sea water into the flame envelope. High pressure sea water injection reduces flare emissions, help minimize overall radiation levels from the flame, abates combustion noise, and preserves flame characteristics during high wind events. The Triton sonic flare is best-suited for offshore applications involving high pressure gas streams comprised of relatively heavy hydrocarbons.
Flame Ring Flares
Carbon dioxide is often used in fire extinguishers and snuffing systems with the intention of effectively extinguishing flames. When CO2 gas is a large percentage of a waste gas stream, at times it proves difficult to maintain a lit flare without the use of assist gas or a properly designed flame ring. A circumferential ring of fire at the flare tip provides stable, reliable ignition and prevents potential auto-suppression of the flame in low BTU applications such as those involving large quantities of CO2 gas.
Ground Flares & Liquid Burners
Vapor Combustion Unit (VCU)
For many applications, a device known as a combustor can successfully be used as a safe and economical method of controlling vapors from the handling, storage or loading of volatile liquid hydrocarbons or ethanol when recovery of the vapors is not a viable option. Vapor Combustors can be configured as an open type, where the flame is elevated and visible; or as an enclosed type, in which the flame is generally near grade level and enclosed in an insulated combustion chamber. The equipment provided for both systems is similar, the stack, anti-flash back burners with an ignition system, assist air blowers for smokeless burning, velocity control or staging valve(s), and deflagration arrestors(s).
Multi-Point Ground Flare
If the land is available, multi-point ground flare (MPGF) systems are an economical approach to smokeless combustion of large amounts of process gas. By inducing air to a large array of high-pressure burning points, smokeless combustion can be achieved with high turndown, while concealing all radiation within walls. MPGF systems provide smokeless capacity and assist medium, involve no moving parts, and require low utilities since burners are designed to crosslight, minimizing the number of pilots necessary.
Chimera Liquid Burner
The Chimera was developed to flare liquid hydrocarbons without liquid fallout or soot formation (smoke). These burners provide excellent service for various onshore applications that require high destruction efficiency of liquid hydrocarbons. When oil is flared, a high pressure media such as an air, gas or steam is required to mechanically atomize the heavy hydrocarbons for proper and stable combustion.
Peacock Liquid Burner
The Peacock burner was developed to flare liquid hydrocarbons without liquid fallout or soot formation (smoke). These burners provide excellent service for well testing operations and have been used in applications in The Gulf of Mexico and Arabian Gulf. When only oil is flared, a high pressure air or gas source is required to provide mechanical atomization which ensures the mixture is a fine mist as it exits the burner nozzle. This particular burner nozzle is designed to accept separate high pressure oil and air/gas streams for maximum efficiency.
Pit Flares
Pit flares are generally selected and designed in order to combust a mixture of vapor and liquid from a single source. A pit flare is usually constructed of an excavation lined with a non-combustible lining of rock or refractory material. Often coupled with a pit liner, pit flares can be a cost effective combustion option for an environmentally conscious user.
Ignition Systems & Pilots
Continuum Electronic Ignitor
Model 100 Continuum Ignitor: utilizes a high voltage electric arc to ignite a combustible air/gas mixture. This arc occurs every 20 seconds for a two second duration (timing is adjustable). The Continuum provides a spark inside a "slipstream" chamber that diverts a portion of the waste gas to create a combustible air/gas mixture. This allows the Continuum ignitor to function without pilot gas. The ignitor can be mounted on vertical and horizontal flares and is used in onshore applications.
Electronic and Retractable Pilots
Model 250 Energex Pilot: a high alloy, stainless steel pilot which combines a high voltage electronic excitor and a high energy spark rod to provide rapid, reliable ignition. This model provides instantaneous re-ignition if the pilot should ever lose its flame.
Model 255 Geminex Pilot: can be ignited using a flame front generator and/or the high-energy excitor ( electronic sparking device). This pilot inherently provides redundancy in the event that one ignition system should fail to ignite the pilot for any reason.
Model 270 Retrax Pilot: a high-tech, retractable, electronic pilot. Its advanced design allows the plant operators to lower the Retrax pilots individually or all at once for ease of maintenance. Since the Retrax can be lowered from grade, operators do not need to wait for a plant shut down to service the pilots.
Model 275 Pilot: a high-tech, retractable pilot that has been adapted to operate on both high-energy electronic ignition and flame front ignition. The Model 275 pilot is a combination of the Model 270 Retrax pilot and the Model 255 Geminex FFG pilot, allowing for redundant ignition technology and retractability.
Model 850 Flamex Pilot: a time-proven product that combines electric spark ignition with continuous spark monitoring, thermocouple monitoring and retractability. This electric pilot provides a rapid, direct spark every 10 to 20 seconds, ensuring reliable ignition. This model features an inspirator that induces air into the fuel gas line, creating a combustible mixture for the pilot to ignite.
Combustion Equipment Accessories
Purge Seals
The Dynamic (velocity) Seal is a simple device which ensures significant cost savings over time. The reverse conical baffle design reduces flow area in the flare tip while simultaneously increasing purge gas velocity. In combination with the Dynamic Seal, a constant flow of purge gas will maintain a seal in flare system, ensuring that air infiltration does not occur.
Vessels
Specially designed vessels should be integrated to remove condensation and stop flame propagation. Two such Vessels are: Knockout Drums and Liquid Seals.
Sentinel Ultraviolet Flame Monitor
This monitor reliably provides remote flame detection up 550 feet away. It excels in durability, ease of maintenance and rapid response time. If the monitor detects the absence of a flame for an adjustable amount of time, a set of dry form C contacts are activated and the pilot re-ignition system is set into motion.
CEMs Continuous Emission Monitors
Our emission monitors are compliant with the US EPA 40 CFR 63, Subpart BBBBBB Gasoline Distribution Area Source Rule (GDACT) and meet all egulatory requirements. They incude a programmable logic controller (PLC) capable of performing all required local and federal emission calculations and reports as well as daily, two point auto calibration checks. Our systems permit driven customization, are all stainless steel sample handling system and feature explosion proof enclosure models. Our monitors are compatible with many custom gas configurations and can be used for process control. We offer installation services and will certify your system using qualified, licensed personnel.