Course Overview
This 5-day expert-led program equips process engineers, environmental specialists, and operations personnel with advanced knowledge of flare system design, operation, and emission control technologies. Participants will gain hands-on experience with flare efficiency optimization, regulatory compliance, and troubleshooting for both routine and emergency flaring scenarios.
Course Objectives
Upon completion, participants will be able to:
- Design and evaluate flare systems (API 521/537 standards)
- Optimize combustion efficiency (smokeless operation)
- Calculate flare loads for emergency scenarios
- Implement emission reduction strategies (flare gas recovery)
- Troubleshoot common flare system issues (pilot problems, flame instability)
- Ensure regulatory compliance (EPA, EU BREF, ISO 25457)
- Apply advanced monitoring technologies (IR cameras, flow meters)
- Manage flare operations during plant upsets
Who Should Attend
This course is essential for:
- Process & Environmental Engineers
- Flare System Designers
- Operations & Maintenance Supervisors
- HSE & Regulatory Compliance Officers
- Emissions Monitoring Specialists
- Refinery & Petrochemical Plant Staff
- Oil & Gas Production Engineers
Course Modules
Module 1: Flare System Fundamentals
- Purpose and types of flares (elevated, ground, enclosed)
- API 521/537 design standards
- Flare system components (knockout drums, seals, pilots)
- Hydraulic calculations basics
Module 2: Combustion & Emission Control
- Smokeless operation principles
- Steam/air assist optimization
- Destruction removal efficiency (DRE) calculations
- NOx/SOx formation mechanisms
Module 3: Flare System Design
- Sizing flare headers and relief systems
- Radiation and dispersion modeling
- Flare tip selection criteria
- Flare gas recovery system integration
Module 4: Operation & Maintenance
- Pilot monitoring techniques
- Purge gas optimization
- Knockout drum maintenance
- Corrosion prevention strategies
Module 5: Regulatory Compliance
- EPA 40 CFR Part 60 Subpart Ja
- EU Industrial Emissions Directive
- Continuous monitoring requirements
- Recordkeeping and reporting
Module 6: Advanced Monitoring
- Optical gas imaging (OGI) applications
- Flow measurement technologies
- Composition analysis methods
- AI-based flare monitoring
Module 7: Special Applications
- Offshore flare considerations
- Biogas flaring challenges
- Flaring during plant startups
- Future technologies (plasma-assisted flaring)