Cutting OPEX in Flame Arrester Maintenance: A Proven Innovation from PROTEGO®- Learn More

By Dr. Michael Davies

The conditions that flame arresters are subjected to in numerous industrial operations necessitate regular inspection and maintenance. Regular maintenance can easily become a burden in these situations. In process operation, OPEX (Operational Expenditure) should have a key focus on controlling cost by minimizing downtime and avoiding equipment failure during maintenance.

In harsh environments such as offshore applications, safe and reliable maintenance can be a challenging task. The time required for maintenance increases when a filter disc breaks or becomes bent. Equipment downtime stretches longer than scheduled. In some cases, the damage may not be immediately visible, leading to potential safety concerns down the line. Over time, this translates into avoidable costs and operational inefficiencies. More importantly, protecting people, the environment, and assets is the ultimate goal.

Keeping the above in mind, PROTEGO® engineers have developed a redesigned flame arrester unit as a solution to this issue. The objective was very clear: to make maintenance easier without sacrificing safety, while lowering the possibility of damage during handling. As a result, even for larger flame arrester diameters, the unit is more durable, easier to service, and more accessible.

A distinguishing feature of this new design is the increased distance between the FLAMEFILTER® and the surrounding cage. This subtle but significant change allows operators to remove the flame filter discs more easily. There is no longer a need to apply pressure or use force, both of which previously contributed to potential disc misalignment and breakage if the system is heavily gunked up. In order to prevent distortion during handling, the FLAMEFILTER® has been strengthened with a solid external ring and its internal layers are now stabilized in a special process with stabilizing pins. This prevents any mechanical force applied during maintenance to destroy the FLAMEFILTER®.

Ease of service was a major priority throughout the design process. These changes allow skilled onsite maintenance crews to handle maintenance duties that previously needed specialized assistance from the vendor or PROTEGO® Authorized Repair Centers. Operators can perform filter removal and reassembly with a much lower risk of damage, regardless of whether they are working with smaller or larger models.

The compatibility of this unit with current PROTEGO® installations is another significant feature. Facilities that are already using PROTEGO® flame arresters can upgrade to the new design without modifying any face-to-face dimensions. There is no change in flow volume or regulatory approval. This effectively means that operators can put the new unit into service without modifying the piping system. The retrofit process is straightforward, and operational continuity remains uninterrupted.

Several smaller refinements also contribute to performance and usability. Now, a gasket seal acts as a barrier to prevent contamination between the cage and the FLAMEFILTER®. Over time, this keeps the internal parts cleaner, which lowers the frequency and difficulty of subsequent maintenance. Structural reinforcements ensure the disc maintains its shape even after repeated servicing. These elements, while less visible, add to the unit’s reliability and longevity.

The long-term benefits of this flame arrester are immediately apparent to maintenance crews and plant operators. It decreases downtime by facilitating quicker servicing. It lowers the cost of spare parts by reducing the chance of unintentional damage. Additionally, it reduces the need for outside assistance by empowering internal employees to oversee every aspect of the maintenance procedure. What was once a vulnerable point in the system is now a streamlined part of routine operations. The feedback of operating companies has been amazing so far.

Although the upgraded flame arrester involves a higher initial cost, this investment is recovered within a short service cycle. The savings in time, labor, and replacement components result in a positive return that compounds over time. In maintenance-heavy environments, those savings are quite significant. They are immediate and measurable.

This new flame arrester unit from PROTEGO® is not simply a redesign. It is the product of field experience, operator feedback, and thoughtful engineering. It provides a practical solution to a widespread problem, offering safer and more efficient maintenance in even the most demanding industrial conditions and assures compliance with internationally recognized standards (e.g. NFPA 69,67, ISO 16852).

For teams prioritizing system uptime, safety, and operational efficiency, this flame arrestor represents a meaningful advancement. It removes barriers, solves long- standing issues, and ultimately contributes to more stable and cost-effective plant operations.

Author

Dr. Michael Davies is the Chief Executive Officer of the PROTEGO® Group. He actively contributes to the development of industry safety standards through his service on multiple committees, including:

NFPA 68 – Standard on Explosion Protection by Deflagration Venting
NFPA 69 – Standard on Explosion Prevention Systems
NFPA 67 – Guideline on Explosion Protection for Gaseous Mixtures in Pipe Systems

In addition, Dr. Davies is a member of the American Petroleum Institute’s API 2000 Committee (Venting Atmospheric and Low Pressure Storage Tanks). He is also an active member of the American Institute of Chemical Engineers (AIChE), further underscoring his leadership and expertise in process safety and explosion protection.