RETROFIT SOLUTIONS TO RESTORE RELIABILITY, IMPROVE COMBUSTION AND UPGRADE IGNITION AND CONTROL SYSTEMS WITHOUT REPLACING THE ENTIRE SYSTEM
Replacement burners are a retrofit solution for modernising existing flares without replacing the entire system. Upgrading a flare tip involves replacing the burner with a modernised design, tailored to the plant’s actual operating conditions and incorporating improvements in combustion, ignition, reliability and maintenance.
This solution is particularly useful when a site already has an established flare system in place, but new requirements arise: changes in gas composition, ignition or re-ignition problems, visible smoke, obsolete components, or stricter safety and availability requirements.
It is also common to replace a flare tip or burner that has become worn through use. The combustion zone operates under high temperatures, oxidising atmospheres, thermal cycles, corrosion and continuous operation – conditions which, over time, can lead to wear, cracks, deformation or a loss of performance.
At PREMATECNICA, we approach every project with a practical focus: compatibility with the existing system, genuine improvements to the burner and minimal impact on the rest of the installation.
OPERATION AND SCOPE OF THE UPDATE
Replacing the flare tip involves substituting that component with a custom-designed burner, whilst retaining the main structure of the flare and its existing installation as far as possible.
The typical scope of a project includes a technical review of the existing equipment, defining the design basis for the service, redesigning the burner and validating compatibility with the existing system. Where applicable, you can also incorporate improvements to ignition, flame detection and control to reduce the need for operator intervention and enhance system availability.
USEFUL INFORMATION FOR SPECIFYING THE PROJECT
To quickly identify a replacement burner, it is usually helpful to know the type of flare and its current configuration, the normal and emergency flow rate ranges, the composition of the flue gas, and a clear description of the problem to be resolved: ignition, smoke, stability, noise, maintenance or damage caused by operation.
It is also useful to have plans, photographs, the make and model of the existing burner, details of materials and access points, as well as a record of any previous incidents. If there are signs of fatigue, cracks, corrosion or a loss of performance due to prolonged exposure to heat, this information helps to better define the scope of the retrofit.
PREMATECNICA DESIGNS AND IMPLEMENTS YOUR REPLACEMENT BURNER
Every retrofit project requires a specific design basis. At PREMATECNICA, we analyse the gas composition, the flow rate range, the issues to be resolved — such as ignition, smoke, stability, maintenance or wear and tear on the flare tip —, the current configuration of the flare and the installation and operational constraints.
Building on that basis, we help to identify the most suitable solution: redesigning the burner, ensuring compatibility with the existing system, upgrading the ignition and pilot lights, integrating the system with the control unit, and validating that it performs as expected. We also support the customer throughout the installation supervision, commissioning, maintenance, inspections and the supply of spare parts.