Flare Pilot Systems

FLARE Pilot Systems

Ignition System / Flame Front Generator

OUR EXPERTISE

Best-in-class combustion engineering.

Backed by industry leading advances gained from over 35 years of pilot supply and exposure, Prism has the knowhow to keep your flare system burning. The original “Premier Pilot” guarantees a long and dependable life, designed, and manufactured to endure the harshest environments. With decades of experience as a successful workhorse, the quality behind the Premier Pilot speaks for itself. Your best option for a new installation, we have installed hundreds of Premier Pilots as upgrades on competitors existing flare stacks as well.

The Premier Pilot couples with most flare stack’s, such as:

Utility

Gas Assisted

Pressure Assist

Smokeless Flare System

Air Assisted Smokeless

Steam Assisted Smokeless

Why Flare Ignition Systems?

The flare pilot device, otherwise known as a “flame front generator”, is an essential part of sustaining safe facility operations within the industry. By mixing fuel and air through a fuel orifice, the mixture is metered, ignited, stabilized, and finally directed to the source waste gas. A flare pilot must be able to reliably ignite the flare at wind speeds up to 85 mph with a combined 2 inches of rainfall per hour. A failed pilot will result in the release of toxic gases being released into the atmosphere, create the potential for a vapour cloud explosion, and produce odours and other adverse health effects. Although some cases allow the use of direct spark flare ignitors, they are not recommended as without an independent fuel supply it is impossible to ensure a flammable mixture will always exist. The safest route is to always use automatic continuous spark igniters to ensure a stable operation and ignition of the flare gas.

The number of pilots required also depends on the diameter of the flare tip. As the flare tip diameter increases, the number of pilots required to reliably light the flare increases, as shown below.

Min. Number of Pilots Recommended	Flare burner Diameter (mm)	Flare burner Diameter (in.)
1	Up to 200	Up to 8
2	Up to 600	Up to 24
3	Up to 1050	Up to 42
4	Up to 1500	Up to 60

Prism Flare Ignition Systems

Backed by the best in the industry.

Unlike other industrial burner manufacturers, Prism has worked hard to tackle the numerous issues that have plagued competitor models, overcoming the ordinary, and offering you incomparable combustion engineering (or “combustion tech”). With a rugged 304 and 310SS design built for extreme environments, the Premier Pilot is fully welded and does not feature any threaded thin wall components. Straight and 45-degree models are available based on the application, both featuring an SS thermowell coupled with strategic thermocouple placements that extend the products life and aid in the precision of real time pilot temperatures.

The Pilot’s design has accounted for: zero freeze up issues due to extreme temperature swings, the capability for either a natural gas or propane fuel source, and the use of a true stoichiometric air mixture of fuel gas, consistently delivering the most efficient BTU burn rating.

With adjustable tracking mounts, the Premier Pilot works to accommodate any approach to the flare tower’s tip. Our retractable pilots come standard on all models and are sealed with worm gear and a drill adaptor for added ease when raising pilots for maintenance or manual flare ignition.

All products are fully burn tested and calibrated before shipping

12-24VDC and 120VAC input power

SPE-1000 inspected sparker panel

Fully stocked, ready-to-ship pilot tip replacements available

Premier Pilot Feature Selections:

SS woven high-temperature fuel gas hoses for problematic draw down of your flare

Mica/Glass multi-layered high-temperature cabling

ICE BOX pilot cooling enclosure for extreme protection

Pre-assembled and ready to install fuel gas harness package

Sour fuel gas package enabling

Silicon Nitride pilot tip

Self-sustained solar packages for remote operation

OUR PRODUCTS

Available Options

We specialize in :

B149.3 Fuel Gas Train

C1D2 Premier Control Panel

Electri-Lite

Premier 45 with 310SS

Premier Straight with 304SS Nozzle

B149.3 Fuel Gas Train

C1D2 Premier Control Panel

Electri-Lite

Premier 45 with 310SS

Premier Straight with 304SS Nozzle

B149.3 Fuel Gas Train

C1D2 Premier Control Panel

Electri-Lite

Premier 45 with 310SS

Premier Straight with 304SS Nozzle

Controls

The Premier Pilot’s control panel has been designed around Prism’s many years of combustion solutions experience and four decades of customer feedback. Keeping your flare stack reliably lit, the controls are temperature rated down to -40 degrees and built for any classification of environment. Large displays provide real time feedback of individual pilot temperatures and alarm status, with the capability for remote programmability, alarm status output, and live pilot rod status information.

The robust circuit board baked into the burner management system are built to withstand six times the current load required and will defend against the breakdown of condensation from many years of temperature swing cycles. Locking spring lever wire connections ensure a solid connection to field wiring, while the side mounted switch allows for manual, automatic, and remote pilot rod ignition.

All controls come fully programmed, calibrated, and run-tested to meet your company’s individual needs with the quality you expect.

Supporting Documentation

Technical data for customers.

Prism is a member of CSA B149.3 Flare Working Group and has the knowledge to ensure the safety and field approval of combustion engineering appliances and equipment in Canada. Whether you are purchasing a new flare system or looking to upgrade your non-compliant equipment, Prism is ready to assist you through the process.