Understanding the significance of flaring in offshore, refinery, and petrochemical operations

Flaring has long been an integral part of offshore oil and gas, refinery, and petrochemical operations, serving as a critical safety mechanism to manage excess gas. However, with increasing environmental regulations and economic pressures, operators are scrutinising their flaring practices to minimise emissions and maximise efficiency..

Why are operators concerned about flaring?

Flaring is often necessary, but it presents various challenges related to safety, operational efficiency, and environmental impact. Here’s why offshore, refinery, and petrochemical operators are actively addressing flaring:

1. Safety Measures

• Emergency Relief: In emergency situations, such as equipment malfunctions or sudden pressure build-up, flaring provides a controlled release to prevent hazardous conditions.
• Operational Upsets: Unplanned shutdowns or process disruptions can lead to excess gas production, necessitating flaring to ensure system integrity.

2. Gas Processing Limitations

• Inadequate Infrastructure: Some facilities lack the necessary infrastructure to capture and process excess gas, leading to routine flaring.
• Technological Constraints: Certain technological limitations make it difficult to reinject or repurpose the gas efficiently.

3. Production and Processing Operations

• Routine Operations: Excess gas that cannot be reinjected or transported is often flared as part of standard operations in refineries and petrochemical plants.
• Startup and Shutdown Procedures: During facility startup or shutdown, flaring helps manage transient gas flows safely.

4. Regulatory Compliance

• Gas Composition: When gas contains high levels of contaminants such as hydrogen sulfide (H₂S), it may be unsuitable for transportation and must be flared.
• Regulatory Restrictions: Various jurisdictions impose strict flaring regulations, necessitating compliance to avoid penalties and operational disruptions.

5. Economic Factors

• Market Conditions: Fluctuating gas prices influence the economic viability of gas transportation, sometimes making flaring the only feasible option.
• Investment in Infrastructure: Limited investment in gas recovery and transportation infrastructure contributes to flaring.

Addressing flaring through leak testing of PSVs

One critical approach to reducing unnecessary flaring is ensuring the integrity of Pressure Safety Valves (PSVs) through effective leak testing. Leaking PSVs can contribute to continuous, unnoticed flaring, exacerbating both emissions and resource losses.

Radioactive Tracer Gas: A Reliable Leak Testing Method

Using radioactive tracer gas technology, operators can accurately detect leaks in PSVs and associated flare systems. This method offers several advantages:

• Precision: Identifies even minute leaks that might be overlooked by conventional methods.
• Non-Intrusive Testing: Minimal disruption to ongoing operations.
• Enhanced Safety and Compliance: Early detection of leaks helps prevent unnecessary flaring and ensures adherence to environmental regulations.

Additionally, advancements in scanning technology and pipe scanning allow for more efficient monitoring of flare systems in refineries and petrochemical plants. By utilising specialised pipe scanners, operators can detect and address potential leaks before they contribute to excessive emissions. Implementing a flare gas recovery system can also help capture and repurpose gas that would otherwise be wasted, improving both environmental performance and cost efficiency.

Conclusion

Flaring has historically been an accepted part of offshore, refinery, and petrochemical operations, but with evolving environmental goals and tighter profit margins—particularly in high-tax regions like the North Sea—operators are actively seeking ways to reduce emissions and improve efficiency. Investing in leak detection technologies such as radioactive tracer gas testing for PSVs, along with tracer-based leak testing and pipe scanning, can help mitigate unnecessary flaring, enhance resource utilisation, and ensure regulatory compliance. By prioritising proactive maintenance and innovative solutions, refinery and petrochemical operators can strike a balance between operational safety, environmental responsibility, and economic viability.

Learn more:  Download our case study - Tracerco Diagnostics^TM Flow studies on offshore flare system 
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