Signs Your Flare Tip Needs Replacing
Flare tips run through rapid thermal cycling, corrosive gas and high winds. Over time that damage shows up as performance and compliance problems. If you see any of these, it is time to review your tip.
Cracking or fatigue
Repeated cold-to-hot cycling cracks lower-grade tip metal.
Burnback & distortion
Internal burning at low flow warps the tip and changes exit geometry.
Visible smoke
Poor air mixing from a damaged tip leads to smoking and opacity issues.
Pilot outages
Damaged shrouds and pilots fail to hold a flame in wind.
Corrosion
H2S, moisture and siloxanes eat away at tip and pilot metal.
Changed conditions
New flow rates, gas composition or OOOOb rules the old tip was not sized for.
Flare Tip Types We Replace
Sonic & Coanda (variable slot) tips
Wide turndown, smokeless at about 30 psig and up
Fixed orifice sonic tips
Steady flows in the 15 to 100 psig range
Air-assisted tips
Blower-driven mixing for low-pressure gas
Gas-assisted tips
Uses on-site fuel gas as the assist medium
Utility & emergency tips
Sized for peak relief and intermittent flaring
Steam-assisted tips
Replacement tips for steam-assisted systems
Replacing an Aging Callidus or Honeywell Flare Tip
Many refineries, gas plants and midstream sites still run sonic and Coanda flare tips originally supplied under the Callidus name, now part of Honeywell UOP. Hero builds comparable sonic and Coanda tip technology and can engineer a compatible replacement for your existing stack.
- Comparable sonic and variable slot (Coanda) designs
- Matched to your existing flange, stack diameter and pilot layout where data allows
- Sized to your current gas composition, pressure and flow, not just the original spec
- Direct engineering contact from quote to start-up
Callidus and Honeywell are trademarks of their respective owners. Hero Process Solutions is not affiliated with or endorsed by them.
What to send us
- Photos of the existing tip and its nameplate
- Original drawings or datasheet, if available
- Flange size, rating and stack diameter
- Number and type of pilots
- Gas composition, normal and peak flow, available pressure
- Any current issues: smoke, burnback, pilot outages
Missing some of this? Send what you have. We can design an adapted tip or measure on site.
Direct-Fit or Adapted Replacement
Direct-fit replacement
With drawings, nameplate data or flange details, we engineer a tip that bolts to your existing connection and stack.
Adapted replacement
When information is limited, we design an adapted tip with the transitions needed, or our field team measures the existing tip on site.
Our Flare Tip Replacement Process
- 01
Share your tip details
Photos, nameplate, drawings or dimensions. Whatever you have.
- 02
Engineering & quote
We size the tip to your conditions and send a quote with lead time within 24 hours.
- 03
Fabrication & testing
Built and tested at our Kellyville, Oklahoma facility.
- 04
Installation & start-up
Our field crews install, check pilots and support start-up.
Engineered to Outlast the Tip It Replaces
A replacement is a chance to fix what wore out the original. Every Hero tip is reviewed in five areas.
Orifice sizing
Matched to your real pressure and flow range.
Tip metallurgy
316L stainless or Alloy 625 for thermal shock and corrosion.
Combustion stability
Multi-orifice geometry that holds through pressure swings.
Pilots & shrouds
Shielded pilots for reliable ignition in high wind.
Compliance
98% destruction efficiency per 40 CFR 60.18 and OOOOb, API 537 pilots.
Replacing the tip? Upgrade the pilots and ignition at the same time. One lift, one outage.
Flare ignition systemsWhy Replace Your Flare Tip With Hero
| What you need | How Hero delivers |
|---|---|
| A tip that fits your existing flare | Direct-fit or adapted designs, with on-site measurement when records are missing |
| Fast answers | Quote and confirmed lead time within 24 hours |
| A manufacturer, not a reseller | Tips designed, fabricated and tested in Kellyville, Oklahoma |
| Installation support | Hero field technicians, not third-party contractors |
| Permit-ready documentation | Compliance language and performance data for your permit package |
Flare Tip Replacement FAQs
Can you replace a Callidus or Honeywell UOP flare tip?+
Yes. Hero builds sonic and Coanda flare tip technology comparable to Callidus and Honeywell UOP designs, and engineers a compatible direct-fit or adapted replacement for your existing stack.
How do I know if my flare tip needs replacing?+
Common signs are cracking, burnback or distortion, visible smoke, frequent pilot outages, corrosion, and operating conditions the tip was never sized for.
Do I need the original drawings?+
No. Drawings help us build a direct-fit tip. Without them, we design an adapted replacement or measure the existing tip on site.
How long does a flare tip replacement take?+
It depends on tip size, type and materials. You get a quote with a confirmed lead time within 24 hours of sending your details.
Should I repair or replace my flare tip?+
Minor pilot or ignition issues can often be repaired. Cracked, distorted or burned-back tips usually need replacement to restore smokeless, compliant performance.
Will the new tip meet EPA OOOOb requirements?+
Yes. Every replacement is engineered for 98% destruction efficiency under 40 CFR 60.18 and OOOOb, with API 537 aligned pilots and documentation for your permit package.
Can you install the replacement tip?+
Yes. Hero field technicians based in Oklahoma, Texas and New Mexico handle installation, pilot checks and start-up across the lower 48.
Get a Flare Tip Replacement Quote
Send what you have. You will hear back from an engineer within 24 hours.
Send your tip details, photos or drawings, and an engineer will reply within 24 hours with a quote and lead time.
Request a Quoteor call (918) 941-2166