Flare Monitoring System NGSH-10313
Introduction
Parijat Controlware, Inc. (PCI) offers a complete automation solution for monitoring Flare systems, blending with AI-enhanced technologies by integrating Radiometric cameras and a comprehensive suite of pre- and post-combustion gas sensors to identify flare efficiency and gas type accurately.
The solution is primarily software. The solution shall work with any generic Radiometric thermal camera. The mention of sensors is for reference only and integration with them is available as an option.
Target Industries and Applications
• Petrochemical Refineries
• Chemical Manufacturing
• Pharmaceutical Plants
• Oil & Gas Production
• Paints, Coatings, and Adhesives
AI-Driven Features
• Detect Natural gas, methane, propane, ethane, CO2, Nitrogen, Hydrogen, C4 and higher,
ethylene, H2S etc. fuels
• Predictive Emission Control: Forecasts potential non-compliance events and adjusts system
parameters proactively.
• Anomaly Detection: Identifies burner performance deviations, or emissions spikes in real
time, using pattern recognition and sensor fusion.
• Energy Optimization: Recommends burner settings, to minimize fuel and power
consumption.
This architecture showcases the flow from radiometric thermal cameras and gas sensors (pre- and
post-combustion) into a centralized AI & signal processing unit. The system analyzes heat, gas
patterns, and flame behavior in real time, then delivers actionable insights via:
• Smart dashboards
• Mobile access
• Control cabinet integration via Ethernet
It ensures high-efficiency flare monitoring, anomaly detection, and EPA OOOOb/OOOOc compliance
— all in one intelligent edge-enabled platform.
System Components & Sensor Placement
• Radiometric Camera (placed 30–50 meters from flare tip):
• Visual detection of hydrocarbons (CH₄, C₂H₆, C₃H₈ etc.) by sensors.
• Pre-Combustion Sensors: – – –
-QEPAS for hydrocarbons
-NDIR for CO₂
-TCD for N₂
-Electrochemical for H₂
• Post-Combustion Sensors: – – –
-Mid-IR Spectroscopy for CH₄, CO₂, H₂
-NDIR for CO₂
-TCD for N₂
Intelligent Algorithms for Insightful Analysis
• Radiant Heat Output using Stefan–Boltzmann Law
• Combustion Efficiency Calculation using CO₂, CO, CH₄ ratios
• Flame Segmentation using IR Thresholding or AI Models (YOLO/UNet/Mask R-CNN)
• Gas Composition Analysis & Anomaly Detection with Real-time ML-based analytics
EPA OOOOb, OOOOc Flare Compliance Ready
• Meets EPA’s new 95% Destruction Efficiency standard
• Continuous monitoring of pilot flames
• Automated visual confirmation using OGI camera
• Real-time alerts on combustion failure and emission deviations
Client Benefits
• Full EPA OOOOb OOOOc Compliance
• Flare Type Identification
• AI-based real time smart alerts
• Edge-Based Intelligence
• Reduced Inspection Burden
Dashboard & Real-Time Alerts
The dashboard provides a clear snapshot of flare performance
• Combustion Efficiency: Displays real-time efficiency; (96%) meeting EPA OOOOb standards.
• Gas Composition: Shows estimated breakdown of flared gases (e.g., CH₄, C₂H₆, CO₂) using AI enhanced analysis.
• Camera Views: Dual feed — thermal for heat intensity, & visual confirmation.
• Flare Status Graph: Tracks flare behaviour trends to detect anomalies or flame-out events.
Web-based dashboard for live data and visualization.
Smart alerts based on flare color, gas type, and abnormal flame behavior.
AI-powered decisions to reduce false positives.
Options:
• Cameras
• Sensors
• MWIR camera support
• Digital Twin Modules
• Remote Monitoring Access
• Mobile Apps
• Smart Watch or Glass Integration
• RTO (Regenerative Thermal Oxidizer) or VCU (Vapor Combustion Unit) Integration
• CEMS or PEMS Integration
Some of the above activities may require custom development & working with client’s SME