Refineries
Flare ignition panels ensure safe and reliable ignition of flare stacks used to burn off excess hydrocarbons during process upsets and maintenance activities, preventing unsafe pressure buildup.
Trusted Industrial Flare Ignition System in Chennai
Preipolar Engineering develops high-reliability Flare Ignition Package systems to ensure prompt, fail-safe ignition of flare stacks used in industrial process safety and emissions control. Our flare ignition packages include a control panel, high-energy spark module, flame detection circuit, automatic re-ignition logic, and pilot burner interface. They reliably initiate combustion during poor conditions, emergency explosions or routine operation, preventing the release of unburned gas. The ignition packages support both manual and automatic modes, and integrate seamlessly with plant safety and flare management systems. With expert design, our packages maintain alignment with Hazardous Areas safety, and process automation standards.
At Preipolar, we use our calibrated experience in automation to build flare ignition solutions that are robust, smart, and compliant. Our packages include feedback flame monitoring loops, adjustable duty cycles, and failover logic to ensure continuous readiness. We select explosion-proof or safe-area enclosures per hazardous zone classifications and provide ATEX/IECEx certifications. Integration with DCS, ESD, and SCADA enables remote control and status monitoring of the ignition system. Preipolar ensures each system is engineered to global standards, offering clients peace of mind, operational safety, and environmental compliance in sectors like oil and gas, petrochemicals, and refineries.
- To provide safe, reliable ignition of flare stacks that burn off excess process gases.
- To ensure continuous ignition under all weather and process conditions.
- To prevent unburnt hydrocarbon release to the atmosphere (safety & environmental compliance).
- Purge sequence before ignition attempt.
- Multiple re-try attempts for ignition before alarm.
- Automatic switch-over between HEI and FFG if dual system provided.
- Trip on low pilot gas pressure or low combustion air pressure.
Types & Features Of Industrial Flare Ignition Control Panels
High Energy Ignition (HEI) System
A high-energy spark ignition system uses capacitor-driven spark rods at the flare tip to deliver strong ignition energy, ensuring reliable lighting of pilot burners even with wet or heavy hydrocarbon mixtures.
Panel Functions
- Provides HV pulse generation (2–10 joules per spark).
- Monitors pilot flame status (via thermocouple or flame scanner).
- Remote/local operation for ignition sequence.
- Interlocks for flame failure re-ignition.
Flame Front Generator (FFG) System
A Flame Front Generator (FFG) system ignites a small gas-air mixture at the base of the flare, sending a traveling flame through a dedicated pipe up to the flare tip. This moving “flame front” reliably lights the pilot, making it ideal for tall or remote flare stacks where direct spark ignition is not feasible.
Panel Functions
- Controls gas-air mixture solenoid valves.
- Triggers spark igniter at the base FFG chamber.
- Monitors pressure & flow in flame front lines.
- Provides safety purge cycles before ignition.
- Includes automatic/manual ignition modes.
Key Features of Flare Ignition System Control Panels
PLC / Relay Logic Control
- Controls ignition sequence, safety interlocks, and monitoring functions.
- Can be PLC-based automation or traditional relay logic depending on project needs.
- Ensures reliable and repeatable ignition performance.
HMI / Annunciator Window
- Provides operator interface for system status and fault indications.
- Displays ignition progress, flame status, and pressure readings.
- Allows quick acknowledgement of alarms and system resets.
Ignition Transformers
- Generates high-voltage energy required for flare pilot ignition.
- Suitable for HEI electrodes or spark plugs in FFG systems.
- Designed for continuous and reliable spark performance.
Solenoid Valve Control
- Actuates pilot gas, flame front gas, and purge air supply lines.
- Supports automatic and manual override for maintenance.
- Ensures safe and controlled gas flow during ignition cycles.
Flame Monitoring System
- Uses UV/IR flame scanners or thermocouples to detect pilot flame presence.
- Provides real-time flame status feedback to the control system.
- Ensures burner and flare safety by confirming stable ignition.
Alarm & Trip System
- Triggers alarms for flame failure, low gas pressure, and ignition fault.
- Initiates shutdown or interlocks to prevent unsafe operating conditions.
- Enhances personnel and equipment safety during flare operations.
Manual & Remote Operation
- Local push-button operation available on the panel.
- Remote control capability from CCR / DCS / SCADA.
- Allows flexibility during maintenance and normal operation.
Explosion-Proof / Hazardous Area Design
- ATEX / IECEx certified for Zone 1 / Zone 2 hazardous gases.
- Weatherproof and corrosion-resistant enclosures for outdoor flare stacks.
- Designed to ensure safe operation in high-risk petrochemical areas.
Flare Ignition System Key Components In Chennai
| Component | Description |
|---|---|
| Ignition Source Unit | High-energy spark or pilot ignition system designed to provide reliable flare startup under all process and weather conditions. |
| Pilot Burner Assembly | Maintains a stable flame that continuously ignites main flare gas; typically equipped with flame arrestors and gas flow control valves. |
| Flame Detection System | UV/IR or thermocouple-based sensors continuously confirm flame presence and provide feedback to the ignition controller for safe operation. |
| Ignition Control Panel | Houses relays, ignition transformers, timers, and interlocks for automatic and manual control of ignition and re-ignition sequences. |
| Alarm & Safety Interlocks | Integrated audio-visual alarms and interlocks to prevent gas release without ignition confirmation, ensuring personnel and equipment safety. |
| Remote Monitoring Interface | Enables communication with PLC, DCS, or ESD systems for remote supervision, alarm logging, and ignition status monitoring. |
| Power Supply & Ignition Transformer | Provides high-voltage energy for spark ignition and powers control modules and flame monitoring systems reliably. |
| Cabling & Junction Boxes | Explosion-proof wiring assemblies and junction boxes ensure safe signal and power transmission in hazardous zones. |
| Enclosure & Weather Protection | Flameproof, stainless-steel enclosures (ATEX/IECEx certified) protect electronic modules from heat, corrosion, and outdoor exposure in refineries or offshore units. |
Why Choose Preipolar Engineers for Flare Ignition Package
Proven Safety and Reliability Record
Engineered with advanced ignition logic to guarantee continuous flare operation, preventing unburned gas release during emergencies or system upsets
Expertise in Hazardous Area Design
Flare ignition systems are designed to meet ATEX and IECEx standards for safe use in hazardous oil, gas, and offshore zones.
Custom Ignition Solutions for Every Industry
Each ignition package is customized for fuel type, flare stack height, and process pressure to ensure consistent and stable flame performance.
Advanced Ignition and Flame Detection System
Features high-energy igniters, UV/IR flame scanners, and auto re-ignition for instant detection and continuous flame reliability in extreme conditions.
Industrial Applications of Flare Ignition System
Petrochemical Plants
Used to ignite flare systems handling volatile process gases, ensuring continuous flame presence and preventing hazardous gas release into the atmosphere.
LNG Plants
Provides reliable ignition in cryogenic environments where gas composition can vary, ensuring safe disposal of boil-off gas and emergency vent gases.
Gas Processing Facilities
Supports controlled burning of separated or waste gases, maintaining system safety during routine operation, equipment trips, or high-pressure venting situations.
Power Plants
Used in auxiliary flare systems to safely ignite fuel gas vents during turbine startups, shutdowns, and purge operations, ensuring compliance with safety and emission standards.
Get Reliable and Safe Flare Ignition Solutions Today
Ensure safe and continuous flare operation with Preipolar’s proven ignition systems. Contact us today for custom-engineered solutions built to perform in hazardous and demanding environments.
Common Questions About Industrial Flare Ignition Systems
It ignites waste or vented gases from industrial processes safely, excluding emission of unburned gas and providing safe burning under all conditions.
It employs high-energy igniters or pilot flames, with the verification of ignition provided by flame detectors. Automatic re-ignition on flame failure provides continuous operation.
Yes, Preipolar's systems are corrosion-proof and shock-resistant and are well-suited to offshore platforms and FPSOs subjected to harsh conditions.
All ignition packages are constructed according to ATEX, IECEx, and OISD safety standards for hostile industrial and refinery environments compliance.
It consists of the ignition panel, pilot burner, high-energy igniter, flame-detecting sensor, control module, and safe power supply circuit.
Redundant power supply, auto re-ignition logic, and continuous flame monitoring systems ensure ignition even during varying process conditions.
Yes. Our skilled engineers install the system, commission it, train users, and perform Add preventive/corrective maintenance when required.
