Confidential
FEED
Detailed design
Modifications
Procurement
Construction support
Commissioning
Confidential, Middle East
Challenge
Achieving a cleaner flame
A major operator in the Middle East required an upgrade to an existing low-pressure flare system at a degassing station to improve environmental performance and meet regulatory standards. The project involved replacing a low-elevated candle flare with an elevated flare stack to achieve a cleaner flame, while maintaining production and minimising shutdowns.
The brownfield site presented significant challenges: congested plant areas, limited space for new infrastructure and constraints on power supply. Conventional solutions - such as elevating pressure control and safety valves and installing air blowers outside the flare zone - were not feasible due to space limitations and the need to avoid prolonged shutdowns.
What is a low-elevated candle flare and why change to elevated flare stacks?
Low-elevated candle flares are generally unsuitable in the Middle East due to environmental regulations, safety concerns and operational inefficiencies. They often produce smoky, incomplete combustion, which fails to meet emissions standards and can pose risks in congested brownfield sites. Elevated flare stacks offer cleaner combustion, better dispersion and improved safety, making them the preferred solution for modern oil and gas operations in the region.
Solution
In 2023, Wood was selected to deliver this flare upgrade project from concept through to commissioning, including FEED, detailed engineering, procurement, vendor support and construction/commissioning support. The team developed a unique design that met all project objectives and code compliance requirements while overcoming brownfield constraints.
Key innovations
- Connecting all existing pressure control and safety valves at grade level to a new independent low pressure flare system with a knockout drum, elevated stack and air blower.
- Locating air blowers at the base of the stack to reduce power demand, housed in a thermally shielded shelter with safe access for maintenance.
- Eliminating the need for elevated platforms and major electrical upgrades, significantly reducing cost and execution risk.
Strategic scheduling and complex procurement
Engineering deliverables were strategically sequenced to support uninterrupted construction progress and avoid production disruption, with additional Wood resources mobilised to meet the aggressive schedule.
To meet this schedule, Wood coordinated complex procurement and post-order vendor support across multiple international locations - including the UAE, China and India . This global sourcing strategy ensured timely delivery of critical materials and equipment, despite logistical challenges and tight timelines.
Result
Project results demonstrate Wood’s ability to deliver full-life cycle complex brownfield solutions in challenging environments through one interface.
- Accelerated timelines: Delivered from concept to start-up in under two years—100% faster than typical brownfield projects.
- Production continuity: Execution strategy enabled construction with minimal disruption to operations, maintaining production throughout.
- Environmental performance: Achieved a clean flame, removing 100% of black smoke and meeting regulatory standards.
- Global coordination: Seamless integration of resources and vendor management across more than 10 countries, including the UAE, China, India, Turkey, The Netherlands, Germany, Romania and Spain.
- Client satisfaction: Positive feedback highlighted Wood’s responsiveness, technical ability and seamless coordination.