Flare & Combustion Systems for Upstream Oil & Gas
EPA-compliant combustion equipment for wellhead, flowback, tank battery, and dehydrator applications. OOOOa/b/c certified. Ships in weeks.
What Makes Upstream E&P Combustion Different
Each upstream emission source (wellhead gas, tank battery vapors, dehydrator vents, emergency relief) has its own flow profile, gas composition, and permit requirement.
Highly Variable Flowback Rates
New well flowback swings from near-zero to thousands of Mcfd within hours, with gas composition shifting from N₂-rich early flowback to high-BTU wellhead gas.
Tank Battery VOC & OOOOb Compliance
Crude oil storage tanks are the primary VOC source at upstream sites. An enclosed VCU certified to 95% VOC reduction is the standard OOOOb compliance path.
Glycol Dehydrator BTEX Emissions
TEG dehydrator still column vents are typically the highest HAP emission point at a wellsite. EPA OOOOa/b requires a 95% BTEX control device above threshold throughput.
Remote Locations: No Utilities
Exploration pads often lack pipeline connections, instrument air, and grid power. Combustion systems must run on propane pilots and solar ignition from day one.
Sour Gas (H2S) Service
Permian, Gulf Coast, and Rockies formations often carry H2S requiring NACE MR0175 materials. Flameout events generate SO2 odor and downwind H2S hazards.
Emergency Pressure Relief
Valve failures, blocked outlets, and process upsets generate unplanned high-rate releases. Emergency flares sized per API RP 521 provide the code-compliant disposal path.
Combustion Systems for Production & Exploration
Purpose-built for upstream oil and gas, from exploration drill sites and flowback to permanent production pads.
Utility & Emergency Elevated Flares
Elevated flare stacks for wellhead gas disposal, flowback flaring, and emergency pressure relief. High-turndown tips handle wide flow ranges: fixed or trailer-mounted.
Enclosed Vapor Combustors (VCU)
OOOOb-certified tank battery VCUs with auto-ignition and continuous flame monitoring. No visible flame. Sized from single-tank thief hatch to full battery vapor manifolds.
Portable Flares for Well Testing
Trailer-mounted flares for exploration well testing and initial production flowback. Propane pilot, solar ignition, onboard controls. Sets up in under 4 hours. Rent or buy.
BTEX Condenser & Combustor Systems
Self-contained skid packages for TEG dehydrator still column vent gas. Condenser recovers liquid BTEX; combustor destroys remaining VOC and HAP to meet OOOOa/b and Subpart HH.
Key Standards for Upstream E&P Combustion Equipment
| Standard | Applicability | Key Requirement | HPS Products | Status |
|---|---|---|---|---|
| EPA 40 CFR Part 60, Subpart OOOOb NSPS: Wellsite (after Dec 6, 2022) |
New, modified, and reconstructed wellsite combustion devices at onshore natural gas production facilities. | 95% VOC reduction; auto-ignition and continuous flame monitoring; performance test or design calculation within 60 days of startup. | Enclosed VCUs, utility flares, BTEX systems | COMPLIANT |
| EPA 40 CFR Part 60, Subpart OOOOa NSPS: 2016 Rule (Storage Vessels, Dehy) |
Storage vessels with VOC potential above 6 tons/year and TEG dehydrators above throughput thresholds, after Sept 18, 2015. | 95% VOC reduction from storage vessels; 95% BTEX reduction from dehydrator still column vents; closed-vent system monitoring. | Enclosed VCUs, BTEX condenser systems | COMPLIANT |
| EPA 40 CFR 60.18 General Flare Performance Standards |
Flares used as compliance devices for NSPS or NESHAP regulated streams at upstream sites. | Net heating value ≥300 BTU/scf; pilot flame present at all times; combustion efficiency ≥98%; exit velocity within limits. | All elevated utility and emergency flares | MEETS |
| EPA 40 CFR Part 63, Subpart HH / HHH NESHAP: Oil & Gas Production & Storage |
Major and area HAP sources with TEG dehydrators above threshold process water content. | Benzene from large dehydrators limited to 0.90 Mg/yr; 95% BTEX reduction; monitoring and recordkeeping per Subpart HH. | BTEX condenser systems, enclosed combustors | DESIGNED TO |
| API RP 521 / API Std 537 Flare System Design & Tip Selection |
Industry standard for pressure relief and emergency flare system design at oil and gas facilities. | Tip sized for design vapor rate and pressure; exit velocity within smokeless limits; radiation calculations for personnel protection. | All elevated utility and emergency flares | DESIGNED TO |
Upstream Operations We Engineer For
Horizontal Well Flowback & Initial Production
Peak flowback rates can exceed 10 MMcfd and gas composition shifts rapidly from N₂-rich early flowback to full-BTU wellhead gas. HPS portable and utility flares cover the full flowback event through pipeline tie-in.
Tank Battery VOC & Working Loss Emissions
Crude storage tanks are the largest VOC source at a typical wellsite. An enclosed VCU on the vapor manifold meets OOOOb 95% VOC reduction with no visible flame or odor.
Wellhead & Separator Gas Disposal
Wellhead gas not sold due to pipeline constraints, H2S content, or economics requires flaring under regulatory authorization. HPS utility flares are sized for the specific gas composition and flow rate.
Glycol Dehydrator BTEX & HAP Emissions
TEG dehydrator still column vents emit listed HAPs under the Clean Air Act. Sites above HAP source thresholds must route vent gas to a BTEX control device achieving 95% reduction per Subpart HH/HHH.
Remote Exploration & Appraisal Well Locations
New play exploration wells lack gathering infrastructure and grid power. HPS trailer packages run on propane pilot and solar ignition with satellite telemetry. Drive to location, set up in hours, leave unattended.
Production Facility Emergency Blowdown
Control valve failures, blocked outlets, and process upsets require a code-compliant disposal path. HPS emergency flares are sized per API RP 521 with auto-ignition that activates on the pressure relief signal.
Technical Questions on Upstream E&P Combustion Systems
What combustion device is required for EPA OOOOb compliance at a tank battery?
Can one VCU handle multiple tanks in a battery?
How do I know what size flare to order for a new well?
What is required to document OOOOb compliance at a new wellsite?
Does HPS build flares for sour gas (H2S) service at Permian Basin locations?
How quickly can HPS deliver a portable flare for an active flowback operation?
Upstream is our home market. Operators need compliant equipment that deploys fast, runs reliably without constant attention, and ships with the documentation EPA and state agencies require. Our OOOOb-certified VCUs and in-stock portable flares are built for that reality.
Craig Rosencutter, President, Hero Process SolutionsTechnical Reference for Upstream E&P Applications
Flare & Combustor Spec Sheets
Dimensional and performance data for HPS utility flares, enclosed VCUs, portable flares, and BTEX control systems.
↓ View All DatasheetsUtility & Emergency Elevated Flares
High-turndown flare tips for wellhead disposal, flowback flaring, and emergency pressure relief. API RP 521 designed.
→ View ProductsEnclosed Vapor Combustors (VCU)
OOOOb-certified tank battery VCUs with auto-ignition, continuous flame monitoring, and compliance documentation.
→ View ProductPortable Flares for Flowback & Well Testing
Trailer-mounted portable flares for purchase or rental. In-stock units for rapid deployment.
→ View ProductEPA OOOOb/c Compliance for Upstream Operators
OOOOb requirements for wellsite combustion devices, storage vessel control, and dehydrator emissions.
→ Read GuideTalk to an HPS Engineer
Send us your gas composition, flow rate, and permit conditions. We confirm equipment type and lead time within 24 hours.
→ Contact UsUpstream E&P Combustion System Quote
Send us your gas composition, flow rate, and permit conditions. We confirm equipment type and lead time within 24 hours.
- ✓ OOOOb-certified VCUs with compliance documentation
- ✓ In-stock portable flares for same-week flowback deployment
- ✓ BTEX condenser systems for glycol dehydrator HAP control
- ✓ Sour gas (H2S) service, NACE MR0175 material compliance
- ✓ Remote-site packages: propane pilot and solar ignition
Need datasheets first?
↓ View All HPS Datasheets →Ready to Specify Your Upstream Combustion System?
Send us your gas composition, flow rate, and permit conditions. We confirm equipment type and lead time within 24 hours.
Hero Process Solutions, 14842 Maple Dr, Kellyville, OK 74039