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Case Study

Safely Monitoring & Optimizing Flare Gas Systems with Aegex™ Intrinsically Safe Tablet + FlareMaster

Overview

Industry

Oil & Gas / Refining / Petrochemical / Offshore & Onshore Processing

Challenge

Flare gas systems are critical safety and environmental compliance components in oil and gas operations. The customer faced persistent challenges in:

  • High uncertainty in flare gas flow measurement during process upsets
  • Over-reporting of greenhouse gas emissions impacting regulatory compliance (Tier 3)
  • Limited visibility of real-time process data in hazardous (ATEX Zone 1 / Class I Div 1) areas
  • Inability to service or calibrate meters without interrupting operations
  • Difficulty monitoring multiple flare systems from a single interface

Accurate, reliable, and safe access to flare gas data was essential to protect personnel, assets, and the environment while maintaining compliance and operational efficiency.

Solution

  • The customer deployed the Aegex™ Intrinsically Safe Tablet (ATEX Zone 1 / Class I Div 1) as a hazardous-area-approved interface integrated with the FlareMaster Software and Enhanced Density Module (EDM).

    This solution enabled real-time, high-accuracy monitoring and optimization of ultrasonic flare gas meters across multiple flare systems without requiring plant shutdowns.

    Key Components:

    • Aegex™ Intrinsically Safe Windows Tablet (Hazardous Area Certified)
    • FlareMaster DataFlow Application
    • FlareMaster Enhanced Density Module (EDM)
    • Existing Ultrasonic Flare Gas Meters (Meter-Agnostic Integration)

Implementation

  • The FlareMaster DataFlow application was installed on the Aegex tablet for on-site visualization and control in hazardous areas.
  • EDM modules were connected to provide full, dynamic gas density inputs to the flare gas meters.
  • Multiple flare systems were networked for parallel monitoring and remote interrogation.
  • Custom dashboards and alarm thresholds were configured for key process parameters.

The system was commissioned without interrupting live process operations, ensuring continuous measurement and safety compliance.

Features & Capabilities

    • Real-Time Process Visibility
      • Mass and standard volume flow
      • Totalized flow
      • Flow velocity
      • Process temperature and pressure
      • Historical and calculated data records

     

    • Operational Advantages
      • Reliable and repeatable measurement during severe process upsets
      • Dual redundancy of measurement
      • Remote alarm configuration
      • Customizable trend graphs
      • Live installation without shutdown
      • Primary meter servicing without loss of measurement
      • Flow calibration curve and linearization functions

     

    • Technical Range
      • Meter Compatibility: Any ultrasonic flare gas meter
      • Pipe Sizes: 2" to 82"
      • Operating Temperature: -100°C to 350°C

Results

    • 5% Improvement in Measurement Accuracy
      Significantly reduced uncertainty in flare gas flow measurement, improving the quality of reported emissions data.
    • Regulatory Compliance (Tier 3 Support)
      Prevented over-reporting of greenhouse gas emissions, ensuring alignment with environmental reporting standards.
    • Enhanced Safety in Hazardous Areas
      Operators safely accessed real-time flare data directly in ATEX Zone 1 / Class I Div 1 environments using the intrinsically safe tablet.
    • Operational Efficiency
      Enabled continuous monitoring, remote diagnostics, and servicing without process shutdowns, minimizing downtime.
    • Multi-System Visibility
      Parallel monitoring of multiple flare systems improved plant-wide situational awareness and faster response to anomalies.

Customer Impact

By combining the Aegex™ Intrinsically Safe Tablet with the FlareMaster platform, the customer transformed flare gas monitoring into a high-accuracy, compliance-driven, and safety-first operation. The solution delivered improved emissions reporting, enhanced process control during upsets, and real-time visibility in hazardous areas—strengthening both environmental stewardship and operational reliability.

 

Intrinsically safe mobility meets intelligent flare gas measurement for safer, smarter, and more compliant operations.

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