Graham Duncan explains how 3D fire and gas mapping software is offering a smarter way to protect people and assets
Flame detection systems are a vital part of safety in the oil and gas sector, where the risk of fire is ever present. Whether on offshore platforms, LNG terminals or petrochemical plants, detecting a flame quickly and accurately can make the difference between a controlled incident and a major emergency.
Many operators still rely on traditional flame detectors, which use infrared or ultraviolet sensors. These technologies have their place, but they are often affected by false alarms or misfires entirely if the flames are small, distant or partly hidden. This can lead to shutdowns, lost production and, more importantly, increased risk to people and plant.
REAL-WORLD SCENARIO
On a North Sea facility, the operator was dealing with regular false alarms. Infrared detectors were being triggered by heat from nearby equipment, despite there being no fire. This led to unnecessary disruption and a loss of trust in the detection system.
Micropack was asked to carry out a full review. Using 3D fire and gas mapping software, we modelled the detector coverage across critical areas. The study showed that several key zones were not properly covered and that the existing system was not well suited to the layout of the site. A number of detectors were then replaced with visual flame detectors. These devices use camera-based technology to recognise flame patterns in a similar way to how a person sees fire, only with far greater reliability. They analyse movement, shape and colour to determine whether a real fire is present.
Since the change, the site has had no false alarms in the affected areas. The operations team now has more confidence in the system and can respond more effectively when a fire is detected.
THE CASE FOR MAPPING
Too often, detector layouts are based on experience or inherited designs. While this may have been acceptable in the past, it is no longer enough. Fire and gas mapping allows for a more accurate and risk-based approach. By modelling visibility and fire scenarios, mapping tools help identify gaps and overlaps in coverage. This gives designers the information they need to place detectors where they will actually be effective, rather than where they are simply easy to install.
In one project, a client was preparing to double the number of detectors on an onshore plant. A mapping study showed that by repositioning existing units and adding just a few visual detectors, they could achieve better coverage with fewer devices. This not only improved safety but also reduced costs.
SMARTER TECHNOLOGY, BETTER OUTCOMES
Visual flame detectors offer a range of benefits that make them well suited to complex oil and gas environments. They provide wide-area coverage and are accurate in detecting both small and large flames, even at extended distances.
A key strength is their ability to reject false alarms from common sources such as hot CO2 emissions from exhausts, heated equipment and welding. This makes them more dependable than traditional infrared or ultraviolet detectors, which are often prone to false triggers or gradual desensitisation in such conditions. Visual flame detectors also perform reliably in poor weather and variable lighting. Unlike radiant technologies, they continue to operate consistently over time.
In a recent example, a detector identified a flame during challenging weather and process conditions, where a radiant flame detector may have struggled. The detector also recorded pre- and post-alarm video, allowing the operator to review exactly how the fire started and progressed. This insight helped the site identify the root cause and take steps to prevent similar incidents in the future.
MEETING MODERN NEEDS
As oil and gas installations become more complex, the need for accurate and reliable flame detection has never been greater. Visual detection, backed by fire and gas mapping, offers a smarter and more effective way to protect people and assets. Safety systems should do more than meet standards. They should work in practice, giving teams the tools they need to respond to real fires and avoid being distracted by
false ones.
By combining modern detection technology with performance-based design, operators can improve safety without adding unnecessary complexity. It is a straightforward step that delivers lasting value.
Graham Duncan is managing director at Micropack Engineering.
