Flare System Upgrade

Overview

Overview:

Flare system upgrade carried out at Oil and Natural Gas Corporation (ONGC) Mehsana Asset to enhance overall relief handling capacity, reduce header backpressure, and improve smokeless flaring performance.

The upgrade included revalidation of relief loads, hydraulic assessment of the flare network, flare tip capacity enhancement, and instrumentation improvements to ensure higher operational safety, reliability, and environmental compliance.

Services:  ZEE Engineering Services were as follows:

1. Process Engineering (Main Driver)

• Revalidate relief loads (API 520 / 521)
• Hydraulic analysis of flare header
• KO drum capacity check
• Radiation & dispersion study
• Confirm flare tip capacity

1. Mechanical

• Flare stack structural check
• Flare tip upgrade (capacity / smokeless)
• KO drum modifications
• Seal drum review

1. Piping

• Header resizing or new tie-ins
• Backpressure verification
• Stress analysis

1. Instrumentation & Controls

• Steam/air assist control
• Ignition & flame detection
• ESD logic update
• Flare gas monitoring (CEMS if required)

1. Civil / Structural / Electrical

• Foundation and support verification
• Area classification review
• Power supply for ignition and controls

1. Safety & Compliance

• HAZOP / LOPA update
• Environmental permit review