Industrial facilities that handle hydrocarbons and volatile gases face a critical challenge: safely disposing of excess or waste gases without endangering workers, equipment, or the surrounding environment. The flare system provides the answer. By burning off these gases in a controlled manner, flares prevent dangerous pressure build-up, protect process integrity, and reduce the risk of catastrophic failure. They also mitigate environmental impact by converting harmful compounds into less hazardous byproducts.
A flare consists of a stack where gases vent and ignite, a pilot flame that ensures continuous combustion, and a piping network that routes excess gas from compressors, process units, or pressure relief devices. These systems operate under demanding conditions—rapid surges during process upsets, wide variations in flow rates, and constantly changing gas compositions. Reliable measurement of flare gas volumes becomes essential not only for maintaining operational safety but also for satisfying environmental compliance requirements that demand accurate emissions data.
Ultrasonic Flare Measurement Technology
Panametrics addresses this challenge with advanced ultrasonic flare flow measurement solutions. Unlike intrusive mechanical devices, ultrasonic sensors mount externally, which eliminates pressure losses and minimizes the maintenance demands associated with moving parts. By transmitting and receiving sound waves across the flare line, these sensors measure the velocity of the gas and provide accurate volumetric and mass flow calculations.
The technology delivers reliable performance across a vast turndown ratio. Operators can capture precise measurements during low-level purge conditions and still respond to high-velocity flows caused by emergency venting events. Ultrasonic systems also maintain accuracy when gas composition changes from hydrogen-rich mixtures to methane and heavier hydrocarbons. This adaptability removes the need for frequent recalibration and ensures continuous compliance with environmental standards such as the U.S. EPA’s Greenhouse Gas Reporting Program.
Panametrics flare.IQ for Efficiency and Compliance
While accurate measurement is critical, proper flare optimization goes beyond flow monitoring alone. Panametrics developed the flare.IQ system to improve flare combustion efficiency and provide operators with actionable intelligence. Flare efficiency depends on several variables, including steam or air assist rates, hydrocarbon composition, and real-time mixing conditions. Without proper control, facilities risk incomplete combustion, which increases emissions of unburned hydrocarbons and black smoke.
The flare.IQ system integrates with ultrasonic flow meters and advanced analytics to deliver continuous visibility into flare combustion performance. It calculates real-time combustion efficiency and destruction removal efficiency (DRE), two key parameters required for both environmental reporting and operational decision-making, by identifying when steam or air injection becomes excessive, resulting in a flare.IQ allows operators to fine-tune assist rates, preventing oversteaming and reducing unnecessary operating costs. Conversely, it also alerts operators when combustion efficiency begins to decline, ensuring corrective action is taken before emissions exceed regulatory limits.
In addition to improving environmental compliance, flare.IQ supports flare gas recovery initiatives. By providing precise flow and combustion data, the system allows facilities to recover hydrocarbons more effectively, reducing both flaring volumes and lost product. This not only lowers emissions but also improves overall plant economics.
Engineering Confidence with Local Expertise
The combination of Panametrics ultrasonic flow technology and the flare.IQ system provides engineers with a comprehensive toolset for tackling one of the most challenging measurement applications in the process industries. Facilities benefit from accurate data across all operating conditions, better control of combustion efficiency, and a reliable foundation for regulatory compliance and sustainability goals.
For plant operators in Florida, Puerto Rico, and most of the Caribbean and Central America, Classic Controls of Lakeland, FL, represents Panametrics and provides the local expertise needed to apply these technologies effectively. With decades of experience in process measurement and control, Classic Controls helps industrial customers design, implement, and maintain flare flow solutions that meet the highest standards of accuracy, safety, and environmental performance.
