A major operator in the Middle East sought to modernize an ageing low‑pressure flare system at a degassing station, aiming to improve environmental performance and comply with updated emissions regulations. The existing low‑elevated candle flare produced incomplete combustion, or visible black smoke, which posed compliance risks, safety concerns, and operational inefficiencies common across congested brownfield facilities in the region. Conventional upgrade strategies requiring elevated valve platforms, expanded electrical infrastructure, or large construction zones were not feasible due to limited space and the operator’s requirement to maintain production with minimal shutdowns. 

Low‑elevated candle flares are particularly unsuitable for Middle Eastern operating environments, where stringent environmental regulations and dense plant layouts increase the need for efficient, clean‑burning combustion systems. Transitioning to an elevated flare stack offered a pathway to significantly cleaner combustion, better dispersion, and a safer operating envelope. 

Performing full‑lifecycle engineering and integration 

In 2023, the operator selected Wood to deliver a comprehensive flare system upgrade covering the full project lifecycle from concept development, FEED, detailed engineering, procurement, construction support, and commissioning. The goal was to replace the outdated flare with a modern elevated flare system that would eliminate black smoke emissions, align with regulatory requirements, and ensure uninterrupted production. Despite brownfield constraints, the project required rapid execution with a complete overhaul of the flare system delivered in just two years, which was an execution timeline 100% faster than the traditional three-to-four-and-a-half-year industry norm. 

Wood led the project across all engineering phases - FEED, detailed design, modifications, procurement, and commissioning - ensuring full compliance with safety codes and environmental standards. Their approach focused on enabling construction without disrupting production, sequencing engineering deliverables to support continuous site progress. 

Overcoming brownfield constraints

The congested plant footprint, limited power availability, and operational continuity requirements required highly innovative design responses. Wood’s multi‑disciplinary team developed a tailored flare upgrade solution that circumvented the need for traditional infrastructure expansions or major shutdown windows, all while navigating complex logistics spanning more than 10 countries in the supply chain. 

All existing pressure control and safety valves were connected at grade level to a new independent low‑pressure flare system incorporating a knockout drum, an elevated flare stack and a dedicated air blower system. This removed the need for elevated platforms and reduced structural complexity. 

Rather than installing blowers outside the flare zone, which would require major electrical upgrades, Wood located the air blowers at the base of the new flare stack. This resulted in reduced power demand, safer maintenance access, and improved thermal protection via a specially designed shielded enclosure.

By eliminating major platform installations and avoiding electrical system expansions, Wood significantly reduced project cost, execution risk, and construction duration, which were key differentiators in a high‑constraint brownfield environment. 

Engineering deliverables were sequenced to maintain uninterrupted construction, supported by additional Wood resources mobilized to meet the accelerated schedule. This ensured flawless continuity and zero production disruption throughout the two‑year execution period. 

The upgraded flare system achieved a 100% elimination of black smoke, substantially improving environmental performance and ensuring regulatory compliance. The project delivered a modern, efficient, clean‑combustion flare system designed for long‑term sustainability and safer operations, while maintaining continuous production at a highly constrained brownfield site. The ability to complete the upgrade in two years, which was half the typical industry timeline, highlights the effectiveness of Wood’s integrated engineering approach and their ability to unlock rapid, safe, and high‑impact improvements for critical energy infrastructure.