Flare Ignition Systems and Flare Pilots
Flare Pilots &
Retractable Systems
The flare ignition system is one of the most critical components on any flare system to ensure the flare gas is ignited under any conditions. HERO offers the best available flare pilot technologies to meet your specific application. With thousands of pilots in service, our Hotspot Ignition Systems utilizes the most reliable ignition probe technology to ensure reliable performance you can count on. The Hotspot pilot can be installed on new or existing flare stacks.
For rare applications, the Flame Front Generator (FFG) pilot may be a more suitable choice. Use our “Pilot Selection Guide” below to determine the best pilot ignition technology for your application. All of the HERO ignition systems can be provided with AC or Solar power and operate with either Natural Gas or Propane.
What Is a Flare Ignition System and How Does It Work?
A flare ignition system is the equipment that keeps a flare ready to burn and lights it on demand. It has three jobs. First, a continuously burning pilot sits at the flare tip so there is always a flame ready to ignite the waste gas the instant it arrives. Second, an igniter lights that pilot, either with a high-energy electric spark at the pilot or with a flame front generator that ignites a fuel-air mixture at grade and sends the flame up a line to the pilot. Third, a monitoring device confirms the pilot is lit and alerts your crew if it goes out.
Because a flare that fails to ignite is both a safety and a compliance problem, reliability is the whole point, which is why Hero builds ignition systems proven across thousands of installations. Tell us your stack height and environment and we will confirm the right setup.
Hotspot Ignition System
Flame Front Generator
Flare Pilots & Retractable Systems
Tired of retraction systems that hang up? Looking for an upgrade to the common Unistrut system that rusts and corrodes? The HERO Retraction System is better in almost every way. Heavy duty bearings and machined subcomponents ensure trouble-free operation. Stainless steel guide cables guarantee smooth travel from the base to the flare tip.
The HERO Retractable System allows pilots to be raised and lowered at grade level by cranking a manual winch. This alleviates the need for any man baskets to access the pilots. Periodic maintenance and inspections can be carried out while the flare is in service.
Our pilot retraction system works!
The HERO retraction pilot system can be retrofitted on an existing flare stack with minimal field work required. Our system is designed to bolt onto the flare stack to alleviate any welding at high elevators.
Hotspot vs Flame Front Generator: Which to Choose
Most sites do not need to think hard about this: the Hotspot Ignition System covers about 99% of applications, ships from stock, and supports a retractable pilot. Choose the Flame Front Generator only for the specific cases it is built for. Either way, the system can be powered by AC or solar and run on natural gas or propane, so it fits both grid-connected and remote sites.
| Factor | Hotspot Ignition System | Flame Front Generator (FFG) |
|---|---|---|
| Best for | About 99% of flare applications | Tall, offshore, or specific existing-FFG flares |
| Stack height | Standard heights | Flares 200 ft or taller |
| Environment | Onshore and most field conditions | Offshore / salt / corrosive environments |
| Retractable pilot | Available | Not available |
| Availability | In stock for immediate shipping | Engineered to the application |
Send us your stack height, location, and utilities and we will confirm Hotspot or FFG for your flare.
Pilot Flame Monitoring
Knowing the pilot is lit is as important as lighting it, because a dark pilot means the flare cannot do its job and your site may fall out of compliance. Hero ignition systems include continuous pilot monitoring that confirms the flame and alerts personnel if it goes out, so you are not relying on a line of sight to a flare tip hundreds of feet up.
Reliable monitoring is also what regulators expect, since the rules require proof that the pilot or auto-igniter is working. Ask us about the monitoring option that fits your stack and control system.
Compliance: Continuous Pilot and Flame Monitoring
Flare ignition is a regulated function, not just good practice. EPA 40 CFR 60.18 and the NSPS OOOO program require a flare to have a continuous pilot flame or an auto-igniter and to show that it is working, and API 537 sets the industry standard for flare pilot and ignition design.
Hero ignition systems are built to keep a reliable pilot lit and monitored so your flare stays ready and your compliance records hold up to an audit. We can help match the ignition and monitoring package to your permit. For more on the new-source rules, see our OOOOb/c overview.
Need a Flare Pilot That Lights Every Time?
Hero Hotspot ignition systems are in stock and ready to ship, with retractable and solar options. Send us your stack height and conditions and we will confirm the right pilot and ignition package.
Related Systems and Resources
Pilots and ignition systems go on every flare and combustor Hero builds. Explore related systems below, or browse all products.
Frequently Asked Questions
For the vast majority of flares, the Hotspot Ignition System is the right choice. It covers about 99% of applications, ships from stock, supports a retractable pilot, and uses proven ignition probe technology with thousands of units in service. The Flame Front Generator is reserved for flares 200 feet or taller, offshore or corrosive environments, or existing flares built around a specific FFG design.
A flare ignition system keeps a flare ready to burn and lights it on demand. A continuously burning pilot stays lit at the tip, an igniter lights that pilot with a high-energy spark or a flame front generator, and a monitoring device confirms the pilot is lit. Together they ensure the flare ignites waste gas reliably under any condition.
Hero offers two core technologies: the Hotspot Ignition System for standard applications and the Flame Front Generator for tall or offshore flares. Both can be powered by AC or solar and run on natural gas or propane. Hero also offers retractable pilot systems that raise and lower pilots at grade with a manual winch, so you can service them while the flare stays in operation.
Yes. EPA 40 CFR 60.18 and the NSPS OOOO program require a flare to keep a continuous pilot flame or an auto-igniter and to prove it is working. Hero ignition systems include continuous pilot monitoring that confirms the flame and alerts personnel if it goes out, which keeps your flare ready and your compliance records defensible.
The Hero Retractable Pilot System uses heavy-duty bearings, machined subcomponents, and stainless steel guide cables for smooth, trouble-free travel from base to tip. Pilots are raised and lowered at grade with a manual winch, eliminating man baskets and crane access. Unlike common Unistrut systems that rust, corrode, and hang up, it is built for long-term reliability in harsh field conditions.
Yes. The Hero retractable pilot system is designed to retrofit onto existing flare stacks with minimal field work and no welding at height. It bolts directly onto the stack, so the flare can stay in service during installation, and afterward pilot maintenance and inspections are done at grade. That eliminates shutdowns, hot-work permits at height, and crane or man basket rentals.
Pricing depends on the technology selected, power and fuel configuration, and whether a retractable pilot is included. The Hotspot Ignition System is the most cost-effective option for most installations and ships from stock. Retractable systems add value by eliminating costly crane or man basket service over the life of the flare. Send us your configuration for a quote.
Hotspot Ignition Systems are kept in stock and ready for immediate shipping, which makes them one of the fastest pilot solutions for new installs or emergency replacements. Installation on existing stacks is straightforward because the system bolts on with no welding at elevation. Our engineers support sizing, selection, and field commissioning. Contact us for lead time.
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We have engineers on standby to assist with any questions or to support you with any upcoming projects. Contact us today!