Synectics Industrial Systems

Specifically designed for adverse environments, high performance, COEX™ thermal camera stations have been designed to monitor the safety flares and associated pilot lights, whilst providing day/night visual verification should the main sensors fail.  Thermocouples are never 100% reliable so the thermal cameras are also working as a back up, removing the need to shut down the plant should the main sensors fail, or need to be replaced.

In addition to providing substantial cost savings by reducing downtime, the thermal camera stations also provide constant visual feedback through the smoke, as well as at night and during adverse weather conditions, such as fog and mist, with specific colour coded temperature readings.

Full Integration

The pilot lights ensure safe combustion of any gases entering the flare system, so the cameras are also acting as a pre-warning on likely events, as well as recording and storing video footage for reviews of any unplanned incidents or emergencies – such as “slugs”. The cameras are also equipped with digital alarms and analogue outputs, plus built-in fibre optic converters for full integration with the plant’s Distributed Control System (DCS).

Being fully networked into the plant’s process and general surveillance camera systems – monitoring any unusual or dangerous activities in other areas of the site – means that the flare cameras can be fixed and therefore do not require any operator intervention.

Environmental Benefits

There are also major benefits associated with the environment. The aim is to keep the flares burning to a minimum level, using nitrogen purging instead of flammable gases in order to meet or improve on the DECC’s site consent targets. Utilising COEX™ Flare Cameras, the methods of recording these figures have been greatly improved.

Normally flare temperatures range between 200-600°C but in emergencies, unplanned events or during depressurisation under maintenance, these temperatures can reach several 1000°C.

Typically, thermal cameras display imaging in B/W, or rather shades of grey, although some manufacturers use false colourisation. At Synectics, we have programmed our flare cameras to recognise specific and expected temperature readings (illus. left), making it much easier for operators to visually recognise changes in the flare characteristics.

The temperature is displayed on-screen, together with alarm outputs linked to under and over normal temperatures, “offering obvious benefits over normal thermal sensors, which do not provide visual feedback”.