When safety and reliability are non-negotiable, your flare system must perform flawlessly. At Liberty Flare, we understand that even small failures can lead to major operational, environmental, and financial consequences. Here are five early warning signs to be aware of.
1. Cracks & Fatigue in Tip or Stack
Why it matters: Repeated thermal cycling, corrosion, and material stress can induce cracks or metallic fatigue in flare tips and stacks. These weakened areas may fail, leading to unplanned shutdowns and costly repairs.
Watch for: Visual signs of stress, unusual smoke patterns, or visible distortions.
2. Unusual Flare Tip Smoke or Flame Instability
Why it matters: Poor mixing, low pressure, or damaged burner tips often trigger smoky or erratic flames. These conditions harm efficiency and may violate environmental regulations .
Watch for: Dark plumes, drifting smoke, or flame lift-off/downward flashback.
3. Pilot Burner Flicker or Failure
Why it matters: A consistent pilot flame is critical as it’s the spark that ensures safe ignition of flare gas. If it falters, the flare could ignite improperly or blow out entirely.
Watch for: Any momentary outages, inconsistent flame patterns, or alerts from flame sensors.
4. Knock-Out Drum Overflows or Liquid Carryover
Why it matters: Knock-out drums separate liquids before they enter the flare stack. If they overflow or fail, liquid droplets can reach the flame, causing flare tip damage and compromised combustion .
Watch for: Unexpected liquid at the tip, fluctuating drum levels, or unusual flame behavior.
5. Excessive Pilot or Sweep Gas Use
Why it matters: These gases keep the system safe and stable but sudden spikes in consumption usually signal inefficiencies, leaks, or impaired combustion air intake .
Watch for: Rising gas costs, inconsistent flow rates, or frequent alarms.
Best Practices: Catch Problems Early
| Strategy | Why It Helps |
| Regular visual inspections | Spots visible cracks, corrosion, and drift signs |
| Thermal-imaging monitoring | Detects hot spots and thermal fatigue before failure |
| Combustion-performance tests | Ensures consistent flame quality and efficient burning |
| Sweep/purge gas tracking | Flags leaks and inefficiencies before they escalate |
Why It Pays to Act Now
Ignoring minor flare issues can lead to:
- Monetary losses from a single tip failure event
- Environmental non-compliance and permit violations
- Costly unscheduled downtime
Addressing red flags early reduces risk, protects personnel, and saves money.
How Liberty Flare Can Help
With decades of industry expertise, we offer:
- Comprehensive inspections (visual, thermal, combustion)
- Flare tip and burner servicing
- Emergency response services
Don’t wait for your system to fail. Let us help you detect and fix flare issues before they escalate. Contact Liberty Flare today to schedule your inspection or maintenance plan for the coming months.