LSTK Delivery of Ground Flare Systems at ONGC Assam

ONGC required the complete replacement of existingflare infrastructure at three geographically separate installations to meetmodern safety and environmental standards. This large-scale, LSTK projectrequired CRA to:

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• Manage multi-site coordination across remote locations with aggressive commissioning targets.
• Integrate new systems with undocumented legacy piping and infrastructure, necessitating custom tie-in solutions.
• Execute all construction and hot work within live operating plant environments under strict safety and shutdown constraints.

CRA executed a comprehensive Lump Sum Turnkey contract covering all phases, from detailed engineering through finalcommissioning. The project scope included complete system replacement,delivered under a single integrated contract covering civil, structural,mechanical, electrical, and instrumentation works.

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CRA’s Turnkey Scope of Work:

• New Flare Systems: Installation of three high-capacity enclosed ground flares, complete with sub-header integration.
• Vessel Installation: Supply and installation of Catch Pots, Knock-Out Drums, Seal Drums, and associated pumping systems.
• Safety & Utilities: Installation of a pilot ignition network routed from FFG/PLC panel and all utility piping (pilot gas, service water, instrument     air).
• Ancillary Works: PSV/PCV modifications, isolation upgrades for safer maintenance, and complete civil work, including design simulations and in-situ concrete piles.
• Compliance: Full QA/QC, documentation, and compliance with OISD, DGMS, and CPCB.

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Solutions to Key Project Challenges:

• Remote multi-site coordination: Modular execution teams deployed in parallel.
• Integration with undocumented legacy piping: Comprehensive pre-bid surveys and 'as-existing' validation.
• Hot work in live plant: Phased shutdown planning with strict safety permits and controlled tie-ins.
• Infrastructure variability: Customized tie-in and layout solutions engineered for each installation.

Each flare system successfully commissioned haspassed a 72-hour Performance Guarantee Test Run. CRA worked closely with siteteams across the fields, navigating live plant constraints, legacy tie-ins, andaggressive commissioning targets to achieve reliable performance.

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Performance Guarantee Test Run Confirmed:

• Emission Control: Achieved compliance with OISD and CPCB environmental norms.
• Mechanical Integrity: Demonstrated high quality of design and construction.
• Long-term Reliability:Assured stable and reliable combustion systems for relief gases.

CRA’s successful execution of this LSTK contractdemonstrates its capability to manage complex, multi-site revamps within a liveplant environment. The delivery of three high-capacity enclosed ground flaresystems ensures ONGC’s continued operational safety and compliance withstringent national regulations, successfully achieving the goal of eliminatingatmospheric venting and modernizing critical infrastructure.