Flue Gas Open Elevated Flare System for ENAP | Ecuador
CRA engineered, manufactured, and commissioned an open elevated flare system in Ecuador for ENAP, executed through EPC contractor Santos CMI, to enable the safe and controlled combustion of lean, methane-rich flue gas generated from upstream oil and gas operations. The complete flare package was designed and delivered in-house by CRA, with engineering emphasis on stable combustion, controlled thermal radiation, acoustic compliance, and reliable long-term operation under site-specific environmental and operating conditions.
Engineering a Stable Open Flare for Lean Flue Gas
The project required the design of an open elevated flare capable of reliably combusting low-calorific-value flue gas while operating within tight environmental and safety constraints. Key challenges included:
- Maintaining stable combustion with lean methane-rich gas
- Limiting thermal radiation at grade due to site proximity
- Controlling noise levels generated by open flaring
- Ensuring structural integrity under wind and thermal loads
- Providing reliable ignition and flame retention for continuous operation
The system had to meet international oil and gas safety standards while remaining robust, maintainable, and suited to long-term field operation.
Open Elevated Flare with Integrated Ignition and Controls
CRA delivered a fully engineered open elevated flare system designed specifically for flue gas combustion.
Scope of Supply included:
- Open elevated flare stack designed for continuous operation
- Stainless steel flare tip with internal lining for thermal and corrosion resistance
- Pilot ignition system supported by a Flame Front Generator (FFG)
- Complete ignition, instrumentation, and control panel
- Integrated piping, cabling, and structural support systems
All components were engineered to ensure reliable performance with lean gas while maintaining safe flame geometry and controlled radiation.
Design Analysis and Performance Assurance
CRA carried out comprehensive engineering studies to validate the system design and ensure compliance with safety and environmental limits:
- 3D system modelling for layout verification and constructability
- CFD simulations to analyze combustion behavior and flame stability
- Finite Element Analysis (FEA) to validate structural integrity
- Radiation analysis to limit heat exposure at grade
- Acoustic assessment to control noise emissions
Design limits achieved:
- Radiation at grade limited to 300 Btu/hr/ft²
- Noise levels controlled to ≤85 dBA at flare height
- Radiation restriction threshold maintained at 1,500 Btu/hr·ft², including solar contribution
The system was fabricated, installed, and commissioned under operating conditions
All mechanical and combustion components were fabricated and assembled in-house by CRA. Factory inspections and functional checks were completed prior to dispatch.
On-site activities included:
- Erection and alignment of the flare stack
- Integration of ignition and control systems
- Live ignition and flame stability trials
- Verification of safety interlocks and operating logic
The system was commissioned under operating conditions and validated against all guaranteed performance parameters.
The flare achieved stable operation while meeting all guaranteed performance criteria.
The system demonstrated stable and continuous combustion of flue gas, achieved destruction removal efficiency greater than 98%, maintained radiation and noise within design limits, and operated reliably with lean gas under normal and transient operating conditions.
The project demonstrates CRA’s capability in delivering compliant open flare systems.
This project demonstrates CRA’s capability to design and deliver open elevated flare systems for demanding flue gas applications. Through validated combustion modelling, rigorous structural analysis, and complete in-house execution, CRA provided a technically robust and compliant flaring solution aligned with ENAP’s operational and safety requirements.
Related Case Studies
See how we turn hard problems into high-performance infrastructure.
