High-energy flare ignition system
High-energy system and components for lighting ground, elevated and offshore flares remotely, in automatic or manual mode
TESI · XEC03H · TG40 · CAR 2/560 …
- 18 J · 2 Hz (XEC03H)
- ≤ 500 m power supply cable
- Automatic re-ignition
TESI's high-energy flare ignition system is built to light ground, elevated and offshore flares on demand, the flares that burn off process gas at refineries and petrochemical sites. It is made up of an automatic re-ignition control box, XEC03H ignition modules, armoured ignition cables, high-energy ignition rods and tips, and a pilot torch with an FFG (flame front generator) outlet, and it works in automatic or manual mode.
The control box sits in a safer area away from the flare stack and runs ignition remotely in automatic or manual mode. On an ignition command it starts the spark cycle at once, watches the flame at the stack outlet through feedback signals and re-ignites when the flame is missing; if the automation fails, operation can be switched to manual. It does not handle the flaring time or the fuel control valves. The standard duty cycle is 33 % (20 s of sparking, 40 s of pause, up to 3 times in a row) and the standard cooling cycle is 20 minutes; both can be adjusted.
The XEC03H ignition module is designed to give a strong spark even with a power supply cable of up to 500 m, and its resin-filled housing keeps water out. The ignition cables withstand high temperatures and harsh surroundings, and cable and electrode connect quickly without special tools, which makes servicing easy and safe. The high-energy electrode, built for high temperatures and fully waterproof, keeps the spark performance up.
High-energy flare ignition system
- High-energy ignition for ground, elevated and offshore flares
- Strong spark over long distances, with power supply cables of up to 500 m
- Automatic re-ignition based on flame feedback, with a manual mode if the automation fails
- Adjustable duty and cooling cycles
- Resin-filled, 100 % waterproof ignition circuit housing
- Cable and electrode connect quickly without tools for easy, safe servicing
- Armoured ignition cables built for high temperatures and harsh conditions
High-energy flare ignition system
Automatic re-ignition control box
Inputs: panel supply, supply to the high-energy exciter and flame detector signal; output: supply to the high-energy exciter. The cover can carry flame-off (red), flame-on (green), voltage-present and ready-to-spark (white) lamps, main-supply and spark-supply switches, an automatic/manual selector, and manual-ignition and lamp-test push buttons. The figures refer to an example layout and are adapted to the layout and construction of the flare stack.
XEC03H ignition module
Panel-mounted module fed with 115–230 V AC, 50/60 Hz (12/24 V DC on request); it draws 110 W and produces 18 J (±10 %) per spark at 2 sparks per second from a 1000 V DC output. Duty cycle 33 %, sparking for up to 1 minute. Powder-coated steel housing, IP65, 170 × 140 × 85 mm, 5 kg.
High-energy ignition rods
Standard diameters of 12, 14 and 17 mm, with length and diameter adapted to the customer. A safe-area rod with a rapid fitting is available. Screwed tips are easy to exchange; on the 12 mm igniter the tip is welded and cannot be removed. The strong spark cleans the tip at every ignition. Special solutions include side or coaxial pneumatic retraction devices, flexible rods for tilting burners and guide pipes.
High-energy pilot torch with FFG outlet (TG40)
42.2 mm (1 1/4") tube with a straight or angled pilot outlet; FFG connection threaded or flanged to the customer's specification, G 3/8 gas connection with other sizes on request. Venturi (induced-draft) air, a high-energy igniter of up to Ø17 mm and redundant thermocouples for the automatic re-ignition cycle. Tube length is set when ordering; the FFG can be retrofitted or upgraded.
Key specifications
| Specification | RE-IGNITION |
|---|---|
| Supply voltage | 115–230 V AC, 50/60 Hz |
| Output voltage | 115–230 V AC (supply to the HE exciter) |
| Duty cycle | 33 % — 20 s sparking / 40 s pause, ≤ 3 cycles in a row |
| Cooling cycle | 20 min pause |
| Degree of protection | IP66 |
| Dimensions | 545 × 373 × 320 mm |
| Specification | CAR 2/560 | HNOK 6000 | RV 2.5 mmq + ARMOUR |
|---|---|---|---|
| Outer diameter | 15.00 ± 0.5 mm | 10.9 ± 0.1 mm | 4.40 ± 0.10 mm |
| Voltage rating | 4500 V DC / 3200 V AC | 6000 V DC | 600 V AC / 1000 V DC |
| Operating temperature | -50 … +180 °C (≤ +200 °C short-term) | -40 … +80 °C | -60 … +400 °C (continuous) · +750 °C (intermittent) · +1565 °C (peak) |
| Conductors | 2 × 2.5 mm² | 1 × 1.5 mm² | 1 × 2.5 mm² |
Accessories
- HERC17 high-energy tips (17 mm): HERC17 and the more durable HD at 760 °C (max. 1000 °C); HT and HD HT for high temperatures at 1000 °C
- HEM17 (17 mm stepped down to 12 mm) and HEM14 (14 mm stepped down to 12 mm) tips: standard at 760 °C (max. 1000 °C), HT version at 1000 °C
- CAR 2/560 armoured high-energy cable: two cores, AISI 304 stainless braid, silicone rubber jacket; non-combustible, oil-resistant, halogen-free, very flexible
- HNOK 6000 armoured high-energy cable: single core, galvanised steel braid, PVC jacket; oil-resistant, halogen-free, very flexible
- RV 2.5 mmq + ARMOUR high-temperature cable: nickel-plated copper, mica and glass-braided PTFE insulation, stainless steel armour; non-combustible, oil-resistant
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