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Ronsor Bulletin

In this bulletin, we will discuss about the flare stack monitoring application with the use of thermal imaging cameras as well as product highlights of the Heavy Product Sampling System from SENSOR, BS&B Torque Resistant Safety Head and the FS10i flow monitor from Fluid Components International.

Flare stack monitoring using thermal imaging cameras

Why monitor flare stacks

A flare stack has to be monitored to ensure that it is continuously operating. If the combustion is lost, the plant operator needs to be informed of it and have the flame reignited to prevent a shutdown. For safety and regulations.

Monitoring methods

There are currently 4 main methods used to monitor the pilot light and flare stack. This is by the use of:

  • Thermocouples
  • UV Sensors
  • CCTV
  • Infrared Thermal Imagers

Unlike the other types of monitoring methods, thermal images have no consumables required and require low maintenance, are able to visualise non-visible flames and are unaffected by UV reflections.

High resolution thermal imaging allows flames to be monitored from a safe distance, ensuring that the camera is not damaged by hazardous conditions on the flare stack.

ARC provides a wide detection range from 100 deg C to 1000 deg C (212 deg F to 1832 deg F), so, if the gas composition changes and affects the temperature of the flame, the ARC continues to supply an accurate measurement. The range is high enough to ensure that background heat is ignored. It also operates in ambient temperatures from -20 deg C to 60 deg C (-4 deg F to 140 deg F), making it suitable for installation in almost any location. The pilot light emits more IR radiation than UV, so IR cameras are also very well suited to this application, particularly given their ability to provide continuous, remote monitoring and a fast-response alarm.

Waste gas components burn at different temperatures. Ensuring the flare stack does not drop below an effective temperature is critical to delivering complete combustion of the gas.

AMETEK Arc System

*The above is an extract from Ametek LAND's flare stack monitoring application note.

Heavy product sampling system

The SENSOR Heavy Products Sample System (HPSS) is designed to collect samples of hot, heavy products (such as resid, asphalt, hot tar, gas oil, resins, slurries, surfactants and emulsions) while maintaining personnel safety.

Heavy Products Sampling System

Sample Heavy Products with Minimal Downtime

The HPSS comes with 3 standard features unique to SENSOR which include a removable cartridge valve, condensate-free steam flush assembly and twist lock purge adapter.

Removable Cartridge Valve. Allows for separating the valve's critical components from the sample line without removing the valve body and pipe spool from the process line in the event of required maintenance. The cartridge can simply be removed from the sample valve base and repaired or replaced with a new one, greatly reducing downtime.

Twist Lock Purge Adapter. Without the need for tools, an operator can easily install the twist lock purge adapter onto the dispense tube and utilize steam to completely flush out the sample pathway to the drain of the enclosure. The steam flush is directed in a controlled manner without creating a mess on the inside of the enclosure or window from splatter.

Condensate-free Steam Flush Assembly. This assembly utilizes a unique 3-way valve and steam trap to ensure that condensate-free steam is consistently available for purge operations. The steam purge clears any potential blockage from the sample path without disrupting the process flowing in the sample line.

*Taken from SENSOR HPSS Brochure.

Product Spotlight BS&B Torque Resistant Safety Heads

Type TR™

TR Safety Head

For applications where safety head installation between companion flanges will use high energy sealing systems such as spiral wound gaskets, the Torque Resistant safety head option is recommended. All of the Sta-Saf pretorqued safety heads can be provided in the TR™ option which provides an enlarged internal seating surface to distribute higher companion flange loads to seat the rupture disk correctly.

*Taken from BS&B Sta-Saf Catalog.

Product Spotlight FS10

Thermal Dispersion Flow Switch/Monitor

The FS10 series is a unique flow switch that comes standard with both a 1A relay output for alarm/trip point setting and a 4-20 mA analog output for trending and monitoring.

With the FS10, we are able to set a zero and span (4 - 20 mA) based on what the flow monitor picks up in the field. This output is complemented by a 10 LED array indicating percentage of current flow rate based on the previously set zero and span.

The FS10 is an instrument with a trending analogue output at the price of a flow switch.

More information on FCI FS10.

More Information


AMETEK LAND Flare Stack Monitoring Application Note

FS10 Flow Switch Dual Function

BS&B Sta-Saf Catalog