LSTK execution of three enclosed ground flares for ONGC

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.

CRA executed the engineering, supply, and system-level integration of a Retrofit Low Purge Pressure (LPP) flare tip for the flare system at IOCL’s Paradip Refinery, engineered to deliver safe, stable, and efficient flaring under low-flow, intermittent, and purge-only operating conditions. The solution minimizes continuous purge gas consumption while effectively preventing air ingress into the flare stack, ensuring combustion stability and operational safety. The system demonstrates CRA’s advanced flare combustion engineering capability for large-scale refinery environments, where consistent performance, safety, and operability must be maintained across wide turndown ratios.

Combustion Research Associates (CRA) executed the engineering, supply, and installa-tion of a biogas flare system for a GIDC industrial facility in Gujarat, supporting Toshiba Water Solutions Pvt. Ltd. The system was designed to safely dispose of excess and emer-gency biogas generated during wastewater treatment operations. Engineered for methane-rich biogas containing trace hydrogen sulphide, the flare system delivers high combustion efficiency, operational safety, and compliance with international flaring standards under both normal and upset conditions.

CRA executed the engineering, manufacturing, and supply of bi-directional biogas flame arrestors for Saudi Aramco–linked wastewater and biogas infrastructure projects, executed through VA Tech Wabag. The flame arrestors were designed to provide absolute flame propagation protection for biogas handling systems operating under variable compositions and low-pressure conditions. The solution ensured full compliance with international safety standards while maintaining long-term operational reliability in critical oil & gas–linked utility installations.

CRA delivered a fully integrated Remote Ignition System for Oil India Limited to ensure safe, reliable, and automatic ignition of flare pilots across oil & gas installations. The system was engineered to enable unattended operation, rapid flame establishment, and dependable re-ignition during adverse weather and low-pressure conditions. Designed for seamless integration with existing plant control architectures, the solution enhances operational safety while ensuring continuous flare readiness under normal, upset, and emergency scenarios.

CRA designed, engineered, manufactured, and supplied a comprehensive Burner Management System (BMS) for Oil India Limited to ensure safe, reliable, and compliant operation of flare pilots and process burners. The system provides fully automated sequencing, continuous flame monitoring, and fail-safe shutdown under normal, upset, and emergency conditions, eliminating manual intervention while enhancing operational reliability, personnel safety, and compliance with oil and gas safety standards.

CRA delivered a fully engineered Waste Gas Burner System for UES Holdings Pte. Ltd., covering design, manufacturing, FAT, installation, and commissioning for the safe disposal of excess biogas at a wastewater treatment facility in Singapore. Designed to API 537, the system enables stable combustion with automated sequencing, continuous flame supervision, and fail-safe shutdown across all operating conditions, ensuring high destruction efficiency, enhanced personnel safety, and compliant waste gas management.

CRA executed the design, engineering, manufacturing, supply, and commissioning support of a Biological Gas Scrubber System for the treatment of biogas generated at a municipal wastewater treatment facility operated by Brihanmumbai Municipal Corporation (BMC). The system was engineered to achieve effective removal of hydrogen sulfide (H₂S), odorous compounds, and corrosive contaminants under normal, upset, and peak operating conditions, while complying with applicable environmental and safety regulations. The fully automated scrubber ensures stable outlet gas quality, minimizes odor emissions, and protects downstream equipment from corrosion, supporting reliable and sustainable wastewater treatment operations.

CRA executed the design, engineering, manufacturing, and supply of a Biological Gas Scrubber System integrated with a Digester Gas Mixing System for H. L. Handa & Company’s wastewater treatment facility. The solution was engineered to enable effective hydrogen Sulphide (H₂S) and odor removal from biogas while ensuring homogeneous gas distribution within anaerobic digesters. The integrated system supports stable biological treatment performance, improved digester reliability, and safe biogas handling under continuous municipal operating conditions.

CRA successfully executed the design, engineering, manufacturing, and supply of an automatic moisture trap system for the Tuas Water Reclamation Plant (WRP) project in Singapore. The system was engineered to ensure safe and reliable removal of condensate and entrained moisture from biogas pipelines, protecting downstream process equipment and maintaining gas line integrity. Designed for continuous operation under low-pressure conditions, the moisture trap plays a critical role in biogas conditioning and overall plant reliability.

CRA collaborated with Vapor Desal to deliver a UKCA‑compliant thermal oxidizer for NRG Fuels’ plastic pyrolysis facility in Derby, UK. Designed to treat lean, VOC‑laden gas streams with low hydrocarbon content using process‑derived fuel, the system ensures high destruction efficiency, combustion stability, and full regulatory compliance under variable operating conditions.

CRA partnered with Lalbuksh Voltas to design and deliver a high-performance biogas compression skid system for Mazoon Dairy in Oman. The system was engineered to compress and transport biogas across a 4-kilometer pipeline for energy recovery at a remote utilization point—demonstrating CRA’s international execution capability and responsiveness to challenging site environments.

CRA supplied a customized enclosed ground flare for Ion Exchange India Ltd. at the SCG Dayasa project in Indonesia, designed to safely combust excess and off-spec biogas under low-pressure conditions with smokeless performance, minimized emissions, and reliable compliance across variable gas compositions.

CRA successfully delivered a custom-built Biogas compression skid system for Adani Infra (India) to support efficient Biogas recirculation within an anaerobic digester. The system was designed to boost digester performance by injecting Biogas through multiple lances in a controlled, sequential manner. The package combined a reliable compression unit with a modulating rotary sequential valve system, improving biological conversion rates and overall Biogas yield.

As part of ONGC’s drive to modernize its flare infrastructure and eliminate atmospheric venting, CRA was awarded a Lump Sum Turnkey (LSTK) contract to design, engineer, and install new enclosed ground flares across three installations in Assam. These revamps were aimed at improving safety, enhancing environmental compliance, and providing long-term, reliable combustion systems for relief gases under a single integrated contract.

CRA and Lalbuksh Voltas delivered a robust biogas dehumidification system for Mazoon Dairy, Oman—engineered to strip moisture from dairy-derived biogas, combat corrosion, and stabilize combustion. Designed for desert extremes, it ensures clean, reliable gas flow for energy recovery under fluctuating conditions.

CRA collaborated with Schlumberger to deliver an enclosed flaring system for Cairn India’s upstream operations in Barmer, Rajasthan. Designed to safely combust lean, contaminated gas with minimal hydrocarbons, the system ensures stable combustion, environmental compliance, and reliable performance in remote desert conditions. The solution emphasized advanced combustion design and integrated subsystems to manage challenging gas characteristics under continuous operation.

CRA designed and commissioned a chemical biogas scrubber for Shiv Construction at the 50 MLD Berhampur wastewater treatment plant in India. The system eliminates hydrogen sulphide and acidic contaminants from biogas produced during sludge digestion, ensuring stable low‑pressure performance. It safeguards downstream equipment, improves biogas quality, and enables safe, reliable utilization in municipal wastewater infrastructure.

CRA was awarded the contract to indigenize Integrated Weapon Containers for the SPICE missile system. The project encompassed the complete engineering lifecycle—research, prototyping, qualification testing, and serial production—fully managed in-house to meet Indian Air Force standards.

CRA and Veolia Water engineered a turnkey biogas system for Delhi Jal Board, transforming digester gas into clean fuel. Featuring H₂S Scrubber, Dehumidifier, Gas Booster, and Open Flare, the package secures safe gas handling, boosts reliability, and advances Delhi’s renewable energy and emissions‑cutting goals.

Andritz Technologies Pvt Ltd commissioned CRA to deliver a fully enclosed thermal oxidizer with a triple-fuel burner for TNPL – Unit II, engineered to safely combust sour gas and NCG streams with high sulfur content, ensuring emission control, safety, and reliable long-term operation.

CRA delivered a high‑efficiency air‑assisted open flare system for ONGC’s Ankleshwar site, engineered for stable, smokeless combustion under variable gas flows and weather conditions. The turnkey skidded package featured a redundant FFG ignition network, CFD‑validated burner, and comprehensive structural, thermal, and interlock safety design.

CRA was commissioned by BrahMos Aerospace to design, manufacture, and qualify The Corset-an advanced missile handling system engineered to ensure the safe handling, transport, and integration of the BrahMos supersonic cruise missile across multiple deployment platforms.

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.