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Flare System Design & Radiation
Published 9/2026
Created by ProjectEngPro Engineering and Project Management
MP4 | Video: h264, 1920x1080 | Audio: AAC, 44.1 KHz, 2 Ch
Level: Intermediate | Genre: eLearning | Language: English | Duration: 20 Lectures ( 3h 58m ) | Size: 2.2 GB
Flare load and tip sizing, radiation and stack height, smokeless operation, purge, seals and diagnosis
What you'll learn
Establish a design flare load from individual relief and global scenarios, and defend the simultaneous case Size a flare tip from exit velocity and Mach number criteria, at maximum load and at turndown Work a radiation calculation through to a stack height, including the iteration that makes it circular Apply radiation criteria for personnel, equipment and boundaries, and set the sterile area from them Account for wind tilt and downwind radiation increase when assessing radiation at grade Recognise when unignited dispersion rather than radiation governs the stack height Specify smokeless operation and assist ratio, and know why smokeless capacity is not total capacity Calculate purge requirement and explain how molecular and velocity seals prevent flashback Select flare type and structure on load, plot space, radiation and emissions grounds Diagnose smoking, pilot loss, flame lift-off and liquid carryover, and assess a flare against a new loadRequirements
No prior flare design experience is required - load, velocity, radiated fraction and flame geometry are built up from the start Any engineering, technical or operations background is enough to follow the course Comfortable with basic algebra - the radiation and sizing calculations are worked step by step, in full Helpful but not essential: access to a relief load summary or a flare datasheet from your own plant No software or purchases needed - no flare or dispersion package and no standard needs to be boughtDescription
This course contains the use of artificial intelligence.
▸ The flare is sized once, and the plant lives inside that decision for thirty years.
Every relief device on the plant discharges into the same place. The header collects it, the stack carries it up, and the tip burns it - and the height of that stack was fixed by a radiation calculation done years before anyone thought about the expansion project that is now on the table. When a flare becomes the constraint, it is rarely because the tip is too small. It is because the radiation at grade, the sterile area or the back pressure at the relief valves will not allow any more load through it.
The consequences are specific and expensive. A stack that puts too much radiant heat on an access way, so the plot plan loses an escape route. A tip that smokes on every significant relief because the steam assist was sized for a load nobody has since revisited. A pilot that will not relight when it is needed. Purge gas burning continuously at a rate that nobody has audited since commissioning. Liquid arriving at the tip and falling as burning rain.
This course teaches the flare as an engineering system: how the design load is established, how the tip is sized against velocity and Mach limits, how radiation sets the stack height by iteration, how wind tilts the flame and moves the radiation to grade, when unignited dispersion governs instead, and how seals and purge keep air out of a system that must never contain a flammable mixture.
▸ The calculation chain, not the equipment catalogue
Everything in this course is taught in the order a real design has to happen. The relief loads are collected and the simultaneous case is argued before anything is sized. The tip diameter comes from exit velocity, not from a vendor's table. The stack height falls out of a radiation calculation that has to be repeated because height and tip diameter both change the answer. Only then do structure, materials and emissions enter the picture.
The judgement is separated from the rules throughout. Permissible radiation levels, exposure durations and sterile area definitions vary between jurisdictions and owner specifications, and the course says which is which rather than presenting one number as universal. The same applies to the fraction of heat radiated, where the assumption made at the start quietly controls the height that comes out at the end.
Five focused sections, worked through in an afternoon.
▸ What you will master
• Establish the design flare load - individual relief against global scenarios such as power failure, cooling water failure and fire - and defend the simultaneous case you chose
• Select between elevated, ground and enclosed flares, and between derrick, guyed and self-supporting structures, on load, plot space, radiation and emissions grounds
• Size a flare tip from exit velocity and Mach number criteria, and check it at turndown as well as at maximum load
• Work the radiation calculation through to a stack height, including the iteration between height, tip diameter and flame length that makes it circular
• Apply radiation criteria properly - personnel, equipment and boundary limits, escape time, and the sterile area that comes out of them
• Account for wind tilt and downwind radiation increase, and combine wind cases with relief cases sensibly instead of stacking worst cases
• Recognise when unignited dispersion, not radiation, is the constraint that sets the height
• Specify smokeless operation - steam, air and pressure assist, assist ratio control, and the gap between smokeless capacity and total capacity
• Calculate purge gas requirement, understand molecular and velocity seals, and explain the flashback mechanism that both exist to prevent
• Diagnose a flare that is misbehaving - smoking, pilot loss, flame lift-off, excessive purge, liquid carryover - and assess an existing flare against an increased relief load
▸
Who this course is for
Process and process safety engineers sizing relief and disposal systems Mechanical and equipment engineers specifying flare stacks, tips and structures Project and design engineers working plot plans constrained by radiation contours Operations and technical support engineers running flares that smoke, trip or lose pilots Loss prevention and HSE engineers assessing radiation exposure and sterile areas Graduate engineers moving into relief systems, process safety or design rolesHomepage
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