Flare Tip Retrofits for Refineries
Replacement flare tips, pilots and ignition systems built to fit existing refinery flare stacks.
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New tips, pilots and ignition on the existing stack
CRA designs replacement flare tips, pilots and ignition systems that fit the existing refinery stack and suit the refinery's current smokeless and relief duty.
Scope
Tip, pilots and ignition
Assist
Steam or air
Fit
Existing stack
Installation
Planned shutdown
What does a flare tip retrofit involve?
A flare tip burns relief and purge gas at the top of the stack. When the tip wears or the refinery's duty changes, a new tip designed for today's gases restores smokeless, stable flaring on the existing structure.
How it works
CRA reviews the existing stack and the current relief cases, then designs the tip, pilots and ignition to match them.
Relief loads, gases and smokeless needs are checked against the existing flare.
The new tip and its assist system are designed for that duty.
Pilots and ignition are matched to the new tip.
The tip is fitted to the existing riser during a shutdown.
Key Benefits
The new tip is designed around the existing riser, connections and support.
Steam or air assist is matched to the gases the refinery flares today.
New pilots and ignition keep the flare lit across the flow range.
A purge reduction seal can cut the purge gas the flare needs.
The retrofit is engineered for installation during a scheduled shutdown.
The CRA Edge
CRA has more than 30 years of experience in gas handling and flare engineering.
Design, R&D and manufacturing are carried out under one roof.
ISO 9001 certified through TÜV NORD, with designs aligned with ASME, API and CE.
Designs are customised to the process needs and the regulations that apply at site.
Applications
Frequently Asked Questions
When should a refinery replace a flare tip?
Common reasons are visible damage to the tip, smoking at normal flaring rates, pilots that go out, and relief loads that have changed since the flare was built.
Can CRA retrofit a flare tip supplied by another maker?
Yes. CRA designs the replacement tip around the existing stack and connections.
Does CRA replace pilots and ignition as well?
Yes. CRA supplies pilots and ignition systems with the tip, including high-energy and flame front generator ignition.
What data does CRA need for a flare tip retrofit?
CRA needs the existing stack details, the relief loads and gas compositions, the smokeless requirement, the steam or air available and the site conditions.
Can a retrofit reduce purge gas use?
Yes. A purge reduction seal fitted with the tip can lower the purge gas the flare needs.