Marine & Offshore

Flare & Combustion Systems for Marine and Offshore Facilities

FPSOs, offshore platforms, marine terminals, and LNG/LPG loading facilities require combustion equipment engineered for wind effects on flame stability, salt spray corrosion, weight and footprint constraints, and offshore safety code requirements. HPS designs for the environment the equipment will actually see, not a land-based default.

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API RP 14C / 14E Offshore MARPOL Compliance 316L / Duplex SS Alloys Wind-Resistant Tip Designs Kellyville OK Since 2012
Offshore Safety Code API RP 14C and API RP 14E govern the design of flare and relief systems on offshore platforms. Discuss Your Project →
Engineering Challenges

Offshore and Marine Combustion Engineering Challenges

Each offshore application involves simultaneous wind, corrosion, ATEX zoning, weight, and classification society requirements that must be engineered together.

Wind Effects on Flame Stability

Offshore platforms experience sustained winds and gusts that can deflect, extinguish, or cause instability in conventional elevated flare tips.

HPS Solution: Wind-resistant tip designs with optional windshield shrouds rated for the site-specific maximum sustained wind speed. Pilot burner positions selected for crosswind resilience.

Salt Spray Corrosion of Flare Tip and Stack

Marine environments expose flare tips, stacks, and pilot assemblies to continuous salt spray and chloride-bearing atmospheric conditions.

HPS Solution: 316L stainless steel as standard for all wetted tip components in marine service. Duplex 2205 for high-chloride or submerged service. Hastelloy C-276 for combined salt and acid gas (H2S) service.

Topsides Weight and Footprint Constraints

Offshore platform topsides and FPSO deck space is allocated by structural capacity. Combustion equipment for offshore applications must meet a weight envelope and footprint budget that does not exist for land-based installations.

HPS Solution: Dimensional and weight certificates issued with every offshore equipment package. Weight report with center of gravity coordinates for structural review. Compact designs for weight-constrained topsides.

Explosive Atmosphere (ATEX / NEC Zone) Classification

Offshore platforms and FPSOs have classified electrical area zones adjacent to flare headers, pilot burner assemblies, and gas scrubbers.

HPS Solution: ATEX / IECEx certified ignition panels and electrical components standard on all offshore flare packages. Zone 1 rated components selected by default unless the installation location is classified as Zone 2.

Low Flow Pilot Stability During Shutdown Periods

Offshore platforms experience periods of low or zero flare gas flow during normal operation or scheduled shutdowns.

HPS Solution: High-energy electronic ignition with pilot monitoring and automatic re-ignition. Pilot burner enclosures with windshield and moisture exclusion for offshore service. Purge gas injection to prevent salt accumulation in pilot lines during shutdown periods.

MARPOL Venting and Incineration Requirements

Vessels operating under MARPOL Annex VI are subject to restrictions on venting of ozone-depleting substances and controlled emissions from cargo operations.

HPS Solution: Marine-class vapor combustors meeting MARPOL Annex VI combustion efficiency criteria. Documentation package suitable for inclusion in the vessel technical file and port state control inspection records.

Get Your System Specified

Not sure which offshore combustion system fits your platform or vessel?

Tell us your gas composition, flow rate, and site requirements — we confirm the right equipment and lead time within 48 hours.

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Product Lineup

Combustion Systems for Marine and Offshore Service

Wind-resistant designs, marine-grade alloys, ATEX-certified electricals, and offshore documentation packages included as standard.

HPS Sonic Flare offshore platform wind-resistant design for FPSO and platform applications
FPSO / Offshore Platform Primary Flare

Offshore Sonic and Elevated Flares

Elevated flare tips for offshore platform and FPSO primary flare systems. Wind-resistant shroud designs for high-crosswind offshore locations. 316L SS tip and pilot assemblies as standard. API RP 537 and API RP 521 designed for the offshore relief load case. ATEX Zone 1 rated pilot ignition and flame detection included.

CE>98%
Material316L SS std; Duplex avail.
Wind RatingShroud to 60 mph
IgnitionATEX Zone 1 certified
Design StdAPI RP 521 / 537 / 14C
Lead Time6 to 10 weeks
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HPS Air-Assist Flare marine LNG terminal loading dock vapor combustion system
Marine Terminals / LNG Loading

Marine Terminal Air-Assist Flares

Air-assist elevated flares for marine terminals, LNG/LPG loading facilities, and ship-shore vapor balance installations. Designed for corrosive marine coastal environments with 316L SS or duplex SS construction.

CE>98%
Tip Sizes2″ to 30″
Material316L or Duplex 2205
Air SourceBlower-assist; ATEX rated
ServiceLNG, LPG, crude loading
Lead Time5 to 9 weeks
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HPS Marine-Grade Vapor Combustor for vessel and offshore platform vent stream combustion
Vessel / Platform Vapor Streams

Marine-Grade Enclosed Combustors

Enclosed vapor combustors for offshore platform and vessel vapor streams where a visible flame is not acceptable or where MARPOL incineration documentation is required. All-316L SS construction with marine coating system.

DRE>99.5% (MARPOL)
Flame VisibleNo
Material316L SS all-wetted
CoatingMarine offshore grade
MARPOLAnnex VI docs available
Lead Time5 to 10 weeks
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HPS Thermal Oxidizer for offshore and marine high-DRE vapor destruction requiring MARPOL documentation
High DRE / MARPOL Incineration

Marine Thermal Oxidizers

Direct-fired thermal oxidizers for offshore and marine applications requiring DRE above 99.9% and continuous temperature monitoring for permit or classification society documentation.

DRE>99.9%
Combustion Temp1,000 to 1,200 C
MonitoringContinuous temp + O2
ClassificationABS / DNV docs avail.
MARPOL Annex VICompliant design
Lead Time10 to 16 weeks
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Regulatory Compliance

Key Standards for Marine and Offshore Combustion Equipment

Standard / RegulationApplicabilityRequirementHPS ProductsStatus
API RP 14C
Offshore Surface Safety Systems		All offshore oil and gas production platforms on the Outer Continental Shelf; applies to flare and vent system design, pilot monitoring, and emergency shutdown integrationFlare system must be part of the surface safety system design; pilot monitoring with SCSSV integration; fire and gas detection wiring to safety systemAll offshore flare packagesDESIGNED TO
API RP 521 / 537
Pressure-Relieving Systems / Flare Details		Flare and relief system design for all oil and gas facilities including offshore platforms; applies to relief load sizing, flare tip selection, and thermal radiationRelief load sizing per Sections 4 and 5; flare tip selection and sizing per API RP 537; thermal radiation limits per Section 5.15; smokeless combustion requirementsAll HPS flare productsDESIGNED TO
MARPOL Annex VI
Prevention of Air Pollution from Ships		Vessels operating internationally under IMO jurisdiction; applies to incineration of cargo residues, sludge, and controlled substances; ozone-depleting substance venting restrictionsShipboard incinerators must meet IMO Resolution MEPC.76(40); combustion chamber temperature at or above 850 C; continuous monitoring; MARPOL survey documentationMarine Thermal Oxidizers, Enclosed CombustorsMEETS IMO MEPC.76
ATEX / IECEx Zone 1
Explosive Atmosphere Electrical Certification		All electrical equipment installed in Zone 1 or Zone 2 hazardous areas on offshore platforms, FPSOs, and marine terminals; includes pilot ignition panels, flame detection, and instrumentationEquipment must carry ATEX or IECEx certification for the applicable zone and gas group; Ex d, Ex e, or Ex ib protection concepts most common for flare system componentsAll offshore flare electrical packagesCERTIFIED
NACE MR0175 / ISO 15156
Sour Service Material Requirements		Offshore facilities producing or processing H2S-containing streams; applies to wetted components in flare systems handling sour gas or acid gas vent streamsWetted material selection per NACE MR0175 tables for H2S partial pressure and temperature; hardness limits on carbon steel components in H2S serviceSour-service alloy packagesMEETS
Applications

Marine and Offshore Facilities We Engineer For

Offshore Oil and Gas Platforms

Fixed platforms, jack-ups, and semi-submersibles on the Outer Continental Shelf and international offshore blocks. Primary production flare for emergency relief and continuous pilot gas. API RP 14C safety system integration.

Floating Production Storage and Offloading (FPSO) Vessels

FPSO topsides flare systems for production processing train relief and emergency shutdown blowdown. Weight-constrained topsides packages with dimensional and center of gravity certification.

LNG and LPG Loading Terminals

Cryogenic loading arm vapor balance and vent combustion at LNG export terminals and LPG marine loading facilities. Air-assist flares are the standard combustion device for marine terminal loading vapor service. Vapor displaced from vessel tanks during loading must be captured and either returned to shore vapor recovery or routed to a combustion device.

Jackup Drilling Rigs and Drillships

Flare and pit systems for offshore drilling operations including well testing flares, drill cuttings combustors, and mud pit vapor combustion. Modular skid-mounted designs for rig mobilization and move.

Multi-Market Expertise The same engineering serves Upstream Production, Gas Processing, and Pipelines & Terminals markets.
Engineer FAQ

Technical Questions on Marine and Offshore Flare Systems

What wind speed should we design the offshore flare tip for?

API RP 537 and API RP 521 guidance calls for evaluating the flare tip at the maximum sustained wind speed at the flare tip elevation for the specific site. For Gulf of Mexico offshore locations, the 100-year return period sustained wind speed at 10 meters elevation is typically 85 to 95 mph, but actual tip-level wind speeds depend on the height of the flare stack and the metocean data for the specific block.

What material specification should we use for an offshore flare tip?

For offshore and marine service in salt-laden atmospheric environments without H2S, 316L stainless steel is the standard material for flare tip internals, pilot burner components, and ignition lines. For installations where the flare gas contains H2S above 200 ppmv, NACE MR0175 sour service alloys are required: Incoloy 825 for moderate H2S service and Hastelloy C-276 for high-H2S or acid gas streams.

Does the pilot ignition panel need ATEX certification for offshore installation?

Yes. Any electrical equipment installed in a Zone 1 or Zone 2 hazardous area on an offshore platform must carry ATEX (EU) or IECEx (international) certification for the applicable zone and gas group.

What classification society documentation can you provide for an FPSO installation?

HPS can provide a technical documentation package for FPSO installations under ABS, DNV, or Lloyd’s class survey, including: manufacturer’s design calculation package; material certificates (mill certs, heat treatment records); non-destructive testing records (radiographic and dye penetrant test reports for welds); hydrostatic pressure test certificate; dimensional and weight certificate with center of gravity coordinates; and ATEX/IECEx certificates for electrical components. The documentation format follows ABS Steel Vessel Rules or DNV OS-A101 requirements as specified by the vessel owner. Witness inspection by a class surveyor can be accommodated at our Kellyville fabrication facility during the manufacture phase.

How does MARPOL Annex VI affect our vessel’s combustion equipment?

MARPOL Annex VI regulates air pollution from ships, including from shipboard incinerators used to dispose of cargo residues, sludge, and other regulated substances. IMO Resolution MEPC.76(40) sets the performance requirements for type-approved shipboard incinerators: combustion chamber temperature at or above 850 C measured continuously, secondary combustion chamber for solid waste applications, and documentation in the vessel’s garbage management plan.

What lead time should we plan for an offshore flare tip replacement?

Standard offshore flare tips with 316L SS construction and ATEX-certified electrical packages typically ship in 6 to 9 weeks from order. Tips requiring duplex 2205 or Hastelloy alloy material, or those needing classification society documentation packages, run 8 to 12 weeks depending on material availability and inspection scheduling.
316L
SS Standard Marine Build
ATEX
Zone 1 Certified Electricals
API 14C
Offshore Safety Systems
MARPOL
Annex VI Compliant Combustors

Offshore work is a different category. The wind conditions, the alloy requirements, the ATEX certification, the weight certificate for the deck structural review, and the class society documentation all have to be right before the equipment leaves the yard. We build offshore packages with that documentation as part of the standard scope, not an after-the-fact request.

Craig Rosencutter, President — Hero Process Solutions
Resources

Technical Reference for Marine and Offshore Applications

Data Sheets

Flare and Combustor Spec Sheets

Download dimensional data for HPS offshore flare tips, pilot assemblies, and marine-grade enclosed combustors.

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Product Page

Elevated Flares for Offshore Service

Wind-resistant tip designs, 316L SS construction, and ATEX-certified pilot ignition for offshore platform flare systems.

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Reference Guide

API RP 14C and Offshore Flare System Standards

Overview of API RP 14C, 521, and 537 requirements for offshore platform flare and relief systems.

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Technical Article

Wind-Resistant Flare Tip Design for Offshore

How wind speed and crosswind velocity affect flare tip selection and the design approaches for maintaining flame stability offshore.

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Buyer’s Guide

Offshore Flare Equipment Selection Guide

What to specify when ordering an offshore flare tip, pilot assembly, and ignition panel: alloys, certifications, and documentation requirements.

→ Read Guide
Engineering Support

Talk to an HPS Engineer

Send us your site metocean data, gas composition, and installation specifications. We will confirm the appropriate equipment and lead time.

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Get a Quote

Marine & Offshore Flare System Quote

Send us your site metocean data, gas composition, relief load, and installation requirements. We confirm equipment type, alloy selection, certifications, and lead time within 48 hours.

  • ✓ Wind-resistant tip designs rated to site wind speed
  • ✓ 316L SS or Duplex alloy construction standard
  • ✓ ATEX Zone 1 certified pilot ignition package
  • ✓ Weight and CG certificate for structural review
  • ✓ Classification society documentation available

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Ready to Specify Your Marine or Offshore Combustion System?

Send us your site conditions, gas composition, and installation requirements. We confirm alloy selection, ATEX certification level, and lead time within 48 hours.

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Hero Process Solutions — 14842 Maple Dr, Kellyville, OK 74039