Industrial facilities have always been at the forefront of technology. Today’s companies are actively seeking out and investing in new solutions that reduce emissions, remove workers from hazardous locations, and overcome the shortage of skilled personnel across important technical functions.

Continuous Flare Stack Monitoring solutions leverage advanced thermal and visual cameras to provide 24/7 coverage of the entire flare system. With greater visibility, Operators can easily detect abnormal conditions, adjust inputs, or take emergency action to prevent catastrophic failure. 

Once deployed, Continuous Flare Stack Monitoring solutions serve an active role in improving overall performance. And unlike many traditional monitoring tools, such as thermocouples or pyrometers, the versatile sensors can be used for a wide range of applications.

Continuous Flare Stack Monitoring solutions are reliable, non-intrusive, and easy to use. The turnkey solution is pre-programmed to work out of the box. Operators can simply mount the sensors to existing infrastructure and begin using the data to improve flare performance.

The remote sensors are deployed at a safe distance and do not need to be in contact with the flame. This avoids unnecessary downtime and minimizes the operational impact of installing and maintaining the sensors. Moreover, it also reduces the need for personnel to access high-risk zones where they could be exposed to heat, toxic gases, and other hazards. 

When mounting the sensors, it’s important to ensure that the cameras have a clear line of sight. Ideally, sensors should be mounted on the south side of the flare stack to reduce glare and reflection from the sun. In most cases, existing polls or structures will provide a suitable mounting location without the need for any new construction. 

Many companies test the effectiveness of the sensors with an initial pilot project. Start by identifying facilities that have aging equipment or known performance issues where monitoring will have the most immediate impact. As Operators become familiar with the solution, organizations can then expand the deployment to additional locations throughout their network. 

Continuous Flare Stack Monitoring solutions provide comprehensive coverage of the entire flare system, meaning they can be used for a variety of applications. 

For example, thermal and visual sensors can provide remote, non-contact verification that the pilot flame is present and lit. Thermal cameras can automatically detect if the pilot flame disappears or drops below a specified temperature threshold, while visual cameras allow for confirmation of flame presence. 

Similarly, the system can detect anomalies in the main flare that could indicate incomplete combustion. The sensors monitor key parameters such as flame size, temperature, color, smoke, or opacity. To maintain a stable flame, the system can automatically adjust steam, air, or fuel gas injection rates without requiring manual intervention, improving responsiveness to abnormal conditions. 

Finally, Continuous Flare Stack Monitoring will soon do away with the need for on-site visual observation. Initial testing by the EPA has shown that remote monitoring exceeds the accuracy and precision of traditional techniques required by Method 22. Once approved, companies will be able to use remote monitoring to ensure compliance and better understand flare performance. 

Compared to traditional tools, Continuous Flare Stack Monitoring solutions deliver substantial improvements to safety, compliance, and process optimization. 

Work closely with the vendor to identify which facilities could benefit most from improved visibility and greater access to data. From there, begin to expand into additional sites. As more facilities come online, Operators will be able to check flame characteristics, monitor performance, and ensure regulatory compliance all from a single screen in the control room.