Design, Manufacturing, FAT, Installation, and Commissioning of Waste Gas Burner System

The wastewater treatment facility required a combustion system capable of safely handling excess biogas with fluctuating flow rates and composition. The primary challenges included:

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• Reliable ignition and flame stability for medium-calorific biogas
• Fully automated operation without manual intervention
• Prevention of unburnt gas accumulation during abnormal conditions
• Compliance with international combustion and safety standards
• High operational reliability in a continuously operating treatment plant

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The system needed to operate seamlessly during startup, normal operation, and emergency scenarios while maintaining maximum safety and combustion efficiency.

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CRA engineered and supplied a complete Waste Gas Burner System integrated with an advanced Burner Management System (BMS) to deliver safe, reliable, and automated combustion.

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Core System Delivered

• Vertical waste gas burner with optimized combustion geometry
• Burner Management System for automated sequencing and control
• Pilot ignition and flame supervision system
• Redundant safety instrumentation and interlocks
• Modular mechanical and control architecture

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The system enables controlled startup, ignition, flame monitoring, and shutdown while preventing unsafe operating conditions.

CRA executed a tightly integrated engineering and manufacturing approach to deliver an API 537–compliant Waste Gas Burner System with built-in safety, reliability, and automation.

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• Combustion and control design optimized for biogas composition and flow conditions
• Automated burner sequencing, flame supervision, and fail-safe shutdown logic
• Precision fabrication using certified materials and controlled processes
• In-house assembly and Factory Acceptance Testing (FAT) of ignition and safety interlocks
• QA/QC aligned with applicable standards and project-specific requirements

CRA executed on-site installation and commissioning to seamlessly integrate the Waste Gas Burner System with plant utilities, ensuring safe startup and verified performance under live operating conditions.

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• Mechanical installation, alignment, and integration with existing gas headers
• Electrical and instrumentation hook-up with plant control and safety systems
• Cold and hot commissioning of ignition, flame detection, and shutdown logic
• Functional testing across normal, upset, and emergency scenarios
• Performance validation against design and safety criteria
• Operator familiarization and system handover

The Waste Gas Burner System delivered stable, fully automated combustion of excess biogas, ensuring safe operation and regulatory-compliant destruction efficiency under all operating conditions.

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• Achieved high destruction efficiency with stable flame performance
• Fully automated operation with continuous flame monitoring and fail-safe shutdown
• Safe and reliable performance during normal, upset, and emergency scenarios
• Reduced operator intervention while enhancing overall plant safety

This project demonstrates CRA’s capability to deliver fully integrated waste gas combustion systems for biogas applications by combining robust burner design, API 537–compliant automation, and disciplined execution across engineering, manufacturing, and commissioning. The Waste Gas Burner System provides UES Holdings with a safe, reliable, and fully automated solution for compliant biogas disposal, reinforcing CRA’s expertise in high-integrity combustion systems for wastewater and waste-to-energy facilities.