What Is a Utility Flare and How Does It Work?
A utility flare is an unassisted, open-tip flare that burns waste gas using flame stabilization at the tip and a constantly burning pilot, with no steam, air, or assist gas. It is the economical choice when the gas does not need smokeless treatment, either because smokeless capacity is not required or because the gas burns clean on its own.
A stable flame across the full flow range, from a large emergency release down to purge flow, is what keeps a utility flare safe and compliant. Because there is no blower or steam system, the utility flare has the lowest capital cost and simplest operation of any flare type. Tell us your gas composition and we will confirm whether a utility flare is enough.
When to Choose a Utility Flare vs a Smokeless Flare
If the stream is light and burns clean on its own, or your permit does not require smokeless capacity, a utility flare is the most economical option. If the gas is heavy and would smoke, you need a smokeless design such as an air-assist, sonic, or gas-assist flare.
Many sites use a utility flare as the emergency backup alongside a smokeless flare for routine duty. Send us your routine and emergency cases and we will tell you which combination fits.
Design and Construction
Hero utility flares are built for long life and easy service in the field, so your emergency flare is ready when an upset hits.
Stocked to 20 MMSCFD
Standard utility flares in stock for fast deployment when you need an emergency flare quickly.
Stainless Steel Pilots
Maximum life in high-heat service with stainless steel construction on pilots and tip.
Retractable Pilot System
Service the pilot from grade level , no elevated work required for maintenance.
Guy-Wire or Self-Supported
Flexible stack options to match your site footprint and structural requirements.
Single-Point Lift
Eliminates field welds at height for safer, faster installation.
EPA 40 CFR 60.18
Meets the federal flare performance standard most permits reference.
Pilots and Ignition Reliability
Hero uses stainless steel pilots for long life and a retractable pilot system that lets your crew service the pilot from grade instead of working at height. That means faster maintenance, safer service, and high ignition reliability when it matters most.
Applications and Industries Served
Common uses include emergency shutdowns, compressor blowdowns, pigging operations, well-head testing, and pipeline maintenance. Operators in the Permian Basin, Oklahoma, Marcellus, and Haynesville plays rely on utility flares as a dependable backup. For liquid streams, pair with a knockout system. View all markets.
What Makes a High-Quality Emergency and Utility Flare System
Emergency and utility flares handle pressure relief gas, blowdown events, and process upset flows. Five factors separate equipment that performs reliably from equipment that fails when needed most.
Rated Capacity for Maximum Relief
The flare tip and knockout drum must be sized for the worst-case simultaneous relief scenario, not average operating flow. Undersized emergency flares create backpressure on relief valves that can compromise vessel protection.
Auto-Ignition Reliability
Emergency flares must ignite instantly when a relief event begins, without operator intervention. High-quality systems use continuously burning pilots with high-energy electronic ignition backup and thermocouple-confirmed flame status.
Low-Flow Pilot Stability
Emergency flares spend most of their life in standby mode with only the pilot burning. Pilot designs that cannot maintain a stable flame at low-flow conditions will extinguish between events, leaving the system unlit at the next relief.
Knockout Drum Sizing and Drainage
Relief events often carry liquid slugs that can extinguish a flare tip or create a liquid projectile hazard. The knockout drum must separate liquid from vapor at maximum relief flow rate, with automatic drain or pump-out.
Thermal Radiation Documentation
Emergency flares at maximum relief flow produce significant thermal radiation. Manufacturers should provide site-specific thermal radiation calculations per API 521 confirming safe setback distances for personnel and equipment.
Ready to size your emergency flare system?
Request a QuoteWhy Engineers Choose Hero Process Solutions
Hero Process Solutions is a US-based manufacturer and rental provider serving upstream, midstream, pipeline, and industrial clients. Engineering specifications and rental availability are provided within one business day of inquiry.
| What You Need | How Hero Process Solutions Delivers It |
|---|---|
| 98% DRE documentation for permit compliance | In-house combustion engineers provide site-specific performance certifications backed by tip-specific test data |
| Equipment on-site before the compliance deadline | Rental fleet deployable in 24 to 72 hours across the Permian Basin, Mid-Continent, Appalachia, and Rockies |
| Manufacturer that designs its own tips | All combustion tips designed, fabricated, and tested at Hero Process Solutions’ Kellyville, Oklahoma facility |
| Field service when equipment needs attention | Direct HPS field technicians, not third-party contractors, cover major producing regions |
| Equipment for multiple applications | Air-assist, sonic, gas-assist, low-flow, emergency, and portable flares plus vapor combustors and VRUs from one manufacturer |
Compliance and Safe Disposal
Hero utility flares meet 40 CFR 60.18 EPA requirements. We can reflect this in your permitting documentation. See our OOOOb/c overview. Need a unit fast? Check flare rentals.
Need an Emergency Flare You Can Deploy Fast?
Hero stocks utility flares up to 20 MMSCFD. Send your emergency flow rate and gas data and we will confirm the right unit.
Why Choose Hero Utility Flares
EPA 40 CFR 60.18
Meets federal standards so emergency flaring stays compliant.
Stocked to 20 MMSCFD
In stock for fast deployment on emergency applications.
Stainless Steel Pilots
Long-life pilots with retractable system serviceable from grade.
Flexible Stacks
Guy-wire or self-supported to match your site.
Single-Point Lift
No field welds at height , safer, faster installation.
Lowest Cost Solution
No blower or steam , lowest capital cost of any flare.
Emergency Utility Flare FAQs
Emergency utility flares are required whenever process systems vent or relieve to atmosphere during upset, shutdown, or emergency conditions and the gas stream must be safely combusted to meet regulatory requirements or protect personnel. Common triggers include PSV discharges, blowdown events, compressor shutdowns, and startup/shutdown venting of process units.
Sizing is based on the worst-case coincident relief scenario at the facility, accounting for all relief sources that could discharge simultaneously. Hero Process Solutions performs a flare system study that identifies the design relief load, selects the appropriate flare type and tip diameter, calculates radiation levels, and confirms smokeless capacity for the operating envelope.
EPA regulations under 40 CFR Part 60 and 63 require industrial flares to achieve a minimum DRE of 98% for regulated compounds. Many state and local air permits impose 99%% or higher DRE requirements. Hero Process Solutions designs to the applicable standard for your jurisdiction and provides combustion efficiency documentation.
Yes, continuous ignition is required by most regulations to ensure the flare is ready to combust gas immediately upon relief. Hero Process Solutions provides multi-point ignition systems with electronic or manual ignitors and flame monitoring. High-reliability pilot designs maintain ignition even in adverse wind or weather conditions.
Permitting requirements vary by jurisdiction but typically include an air quality construction permit, dispersion modeling for combustion products, noise assessment, and radiation analysis confirming safe distances from personnel and equipment. Hero Process Solutions provides all engineering documentation needed to support the permitting application.
Permanent installation is preferred for facilities with ongoing venting requirements or where the flare is a critical safety system. Rental flares are appropriate for temporary operations, plant turnarounds, or commissioning periods before the permanent system is in service. Hero Process Solutions offers both options and can provide guidance based on your operational timeline and regulatory requirements.
Ready to Get Started?
Spec Your Emergency Flare System Today
Our engineers size every emergency and utility flare to your relief flow rate, back-pressure, and site requirements. Get a detailed quote in 24 hours.
Kellyville, OK 74039 Midland 2714 East County Road 147
Midland, TX 79706