Flare stack monitoring involves the observation, measurement, and analysis of flare systems. It ensures that gases routed to the flare are being completely combusted, minimizing the release of unburned gas into the atmosphere. 

Flare stack monitoring is increasingly driven by strict environmental and regulatory standards, and many governments have specifically targeted regulations on flaring and methane leakage as part of broader efforts to reduce emissions.

That said, monitoring should not be viewed solely as a regulatory obligation. Done well, flare stack monitoring also performs an important safety and operational function. 

Unfortunately, many of the existing approaches to flare stack monitoring have not kept up with today’s requirements. As regulations become more stringent and operations more complex, industrial facilities need a new approach that provides greater visibility and real-time data from the entire flare stack. 

Continuous Flare Stack Monitoring solutions leverage advanced thermal and visual cameras to provide 24/7 coverage of the entire flare system. 

Compared to traditional tools, Continuous Flare Stack Monitoring makes it possible to track flame presence, flare integrity, combustion efficiency, and emissions data from multiple flares using a single, remote sensor. 

The explosion-proof, HazLoc-certified cameras are designed and built for industrial environments. Thermal sensors offer high detection accuracy during day or night and can see through fog, smoke, or steam. 

Advanced visualization software automatically detects black smoke and determines the opacity of the smoke using the Ringelmann Opacity Score. Automated alerts then notify Operators of smoke or abnormal flare conditions, while instant alarms are triggered for loss of flame or other severe events. 

Verifiable thermal and visual data is recorded for future analysis and compliance documentation, simplifying compliance, troubleshooting, and process improvement.

Continuous Flare Stack Monitoring solutions deliver substantial benefits across three critical areas of industrial operations.

First, the sensors enhance workplace safety by ensuring the flare and pilot flame are always lit and functioning properly during gas releases. The system automatically detects unsafe conditions that can lead to over-pressurization, uncontrolled venting, fire, or explosions, and can even trigger safety shutdowns before catastrophic failure occurs.

Second, Continuous Flare Stack Monitoring reduces compliance risk by allowing Operators to immediately detect anomalies and respond the moment flare performance deteriorates. Facilities can minimize the duration and severity of any release, mitigating the risk of permit violations and costly enforcement actions. 

Finally, Continuous Flare Stack Monitoring solutions can also be used for process optimization throughout the entirety of the flare system. For example, persistent fluctuations in flame stability or temperature can indicate upstream process imbalances such as uneven gas flow or inefficient gas routing. 

While existing flare stack monitoring tools are useful for specific functions, they do not provide the level of insights needed in today’s environments. 

Continuous Flare Stack Monitoring solutions provide 24/7 coverage of the entire flare system, allowing Operators to monitor multiple flares from a single, remote location. Instead of sending someone out to a remote site to observe it, Operators can simply check the flame right from the control room.

With greater visibility and real-time data on flare characteristics, including shape, color, temperature, and smoke, Operators can detect abnormal conditions, immediately adjust inputs, or take emergency action to prevent failure. As a result, Continuous Flare Stack Monitoring solutions reduce compliance risk, enhance workplace safety, and enable ongoing optimization of upstream processes.