Design, Manufacturing, and Supply of Enclosed Ground Flare Systems at Charali GGS-1 and RDS GGS-3 & 4
CRA was entrusted with the design, engineering, manufacturing, and supply of high-capacity Enclosed Ground Flare (EGF) systems for multiple gas gathering stations at ONGC’s Assam Asset—Charali GGS-1 and Rudrasagar GGS-3 & 4. The systems were engineered to provide safe, reliable, and environmentally compliant destruction of hydrocarbon-rich process gases generated during normal, upset, and emergency operating conditions. The enclosed flare systems were specifically designed to achieve high destruction efficiency while maintaining low visible flame, minimal noise, and controlled thermal radiation. This enabled installation within active plant areas subject to stringent safety, environmental, and operational constraints. The project reflects CRA’s capability to engineer robust flaring solutions for large-capacity gas handling under complex gas compositions and fluctuating flow conditions.
Managing High-Volume Hydrocarbon Flaring Within Active Gas Processing Facilities
ONGC required a flaring solution capable of safely handling large volumes of process gas generated across multiple gas gathering stations. The key challenges included:
- Safe disposal of hydrocarbon-rich gas streams during normal, upset, and emergency conditions
- Strict environmental requirements demanding minimal visible flame, smoke, and noise
- Installation within operational plant areas with tight safety and radiation limits
- Variable gas composition and flow rates requiring stable combustion performance
- Long-term reliability under continuous and intermittent flaring duty
The system needed to deliver consistent, high-efficiency combustion while maintaining operational safety and regulatory compliance.
Engineered Enclosed Ground Flare Systems for Safe, High-Efficiency Gas Disposal
CRA engineered and supplied enclosed ground flare systems tailored to the operating conditions at Charali GGS-1 and RDS GGS-3 & 4, enabling safe and environmentally compliant disposal of hydrocarbon-rich process gases. The solution focused on stable combustion across variable flow conditions while ensuring low radiation, minimal noise, and zero visible flame within active plant environments.
The enclosed configuration allows controlled oxidation of flare gas within a refractory-lined combustion chamber, eliminating flame visibility and minimizing heat dispersion. The systems were designed to operate reliably during normal, upset, and emergency flaring scenarios, ensuring continuous safety and compliance with API 521 and API 537 requirements.
Robust Combustion Design Backed by Precision Manufacturing
CRA executed the complete design and manufacturing scope in-house, ensuring full control over combustion performance, mechanical integrity, and quality compliance.
Design Engineering
- Combustion chamber geometry optimized for hydrocarbon-rich gas with variable composition
- Engineered air ingress and mixing arrangement to ensure complete oxidation and flame stability
- Refractory lining designed for sustained high-temperature operation and long service life
- Radiation and noise containment engineered for installation within operating plant areas
- Design compliance aligned with API 521 and API 537 standards
Manufacturing and Quality Control
- In-house fabrication of combustion chambers, structural components, and internals
- Controlled refractory installation and curing processes
- Dimensional inspection and weld quality verification at each fabrication stage
- Pre-dispatch inspection and documentation to ensure readiness for site integration
This integrated design-to-manufacturing approach ensured reliable system performance, repeatable quality, and smooth deployment across multiple gas gathering stations.
Stable, High-Efficiency Enclosed Flaring Across Multiple Stations
Reliable, Environmentally Compliant Flaring Across Multiple Gas Gathering Stations
- Achieved stable, high-efficiency combustion across all operating scenarios
- Eliminated visible flame and significantly reduced noise and radiation levels
- Ensured safe disposal of hydrocarbon-rich gases under variable flow conditions
- Met ONGC’s environmental, safety, and operational performance expectations
- Delivered a robust flaring solution suitable for long-term upstream operations
Reliable Enclosed Flaring, Proven in Operation
This multi-site project demonstrates CRA’s capability to design and supply high-capacity enclosed ground flare systems for demanding upstream oil and gas applications. By combining advanced combustion engineering, robust mechanical design, and strict adherence to international standards, CRA delivered a reliable and environmentally compliant solution for ONGC’s Assam gas gathering facilities.
The successful commissioning at Charali GGS-1 and Rudrasagar GGS-3 & 4 reinforces CRA’s expertise in engineered flaring systems that balance safety, performance, and sustainability—particularly in live plant environments where combustion stability and emission control are critical.
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