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Product

High-temperature wireAPI 537 Flare Ignition15 to 25 kV Pulse+450 °C / +540 °C Peak

Thermo-Trex Flare Stack Cable+450 °C / 15–25 kV high-energy flare stack pilot ignition cable with Ni-Cu / Nickel core

High-temperature high-voltage flare stack ignition cable combining a 27 % nickel-plated copper or pure Nickel 200 core, phlogopite mica thermal barrier, HV dielectric, and E-glass or SS316L stainless-steel armour braid for +450 °C (+540 °C peak) flare tips.

Flame-retardant
Outdoor & humid
Ozone, UV & moisture
Approved
Order designation
Flare-HV 1×12 AWG SS316 (25 kV)
Outer Ø ≈
9.80 mm
Wall thickness
3.10 mm
Total weight ≈
168.0 kg/km
Min. bend R (fixed)
59 mm
All sizes (8)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Ignition voltage
15 to 25 kV
High-energy HEI & spark pulse
Continuous temp
+450 °C
+540 °C (1000 °F) flare tip peak
Conductor
27 % Ni-Cu / Ni
16 to 8 AWG nickel-clad/pure Ni
Dielectric
Mica + HV VMQ
Composite thermal & kV barrier
Outer armour
E-glass / SS316
Fibreglass + optional 316L braid
Min bend radius
8 × OD fixed
12 × OD vertical stack pulling

Typical values for this cable type, based on API 537 / IEEE 383 / UL 1581 VW-1 — confirmed in the datasheet and quotation for your order.

Application fit

Is Thermo-Trex Flare Stack Cable right for your machine?

Engineered specifically for vertical riser conduits and pilot igniter lances near the flame tip of refinery, LNG, petrochemical, and offshore production flare stacks.

Furnace, kiln & high-temp zone

Suitable

Survives intense +450 °C continuous heat and +540 °C radiant thermal shock below elevated and ground flare tips.

Offshore platform & shipboard deck trays

Suitable

Available with AISI 316L stainless-steel wire armour braid to resist offshore salt spray, sour gas (H2S), and high-wind stack vibration.

Free-hanging vertical run

Suitable

Reinforced glass and stainless-steel braids support vertical conduit pulls up 60 m to 150 m flare derricks with appropriate clamping.

Motorised monospiral reel

Not suitable

Designed for stationary vertical flare risers and pilot lances, not continuous motorized reeling.

Use NSHTÖU for drum reeling
Typical machinesRefinery & Petrochemical FlaresOffshore Oil & Gas PlatformsLNG Terminals & Gas PlantsBiogas & Landfill Flare SystemsSteelmill Blast-Furnace Bleeders

Construction

Layer by layer

Multi-barrier flare stack build: 27 % nickel-plated copper or Nickel 200 conductor, phlogopite mica tapes, HV silicone/PTFE composite dielectric, E-glass braid, and optional SS316L armour.

12345
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1High-temp nickel-clad / pure nickel coreStranded 27 % nickel-plated copper (ASTM B355 Class 27) or pure Nickel 200 (16 AWG to 8 AWG)Delivers high-joule capacitor-discharge (HEI) or transformer spark pulses at +450 °C
2Phlogopite mica dielectric wrapOverlapping synthetic/phlogopite mica-glass tapesMaintains dielectric spacing up to +800 °C even during direct flare blow-down
3HV composite silicone / PTFE wallHeavy-wall high-voltage silicone elastomer sealed with fluoropolymer moisture barrierPrevents condensate flashover inside vertical flare conduits during rain/steam injection
4Heat-treated E-glass thermal jacketHeavy braided continuous-filament E-glass sleeve with high-temp saturantProvides thermal insulation and abrasion protection during conduit pulling
5AISI 316L stainless-steel braid (optional)Interwoven corrosion-resistant 316L stainless-steel wire armourProtects against mechanical crushing, wind whip, and offshore corrosive atmospheres

Flare-HV-GL (Glass Jacket)

Single- or twin-core 15–25 kV flare stack cable with heavy heat-treated E-glass outer braid

Flare-HV-SS316 (Armoured)

With outer AISI 316L stainless-steel wire braid armour for offshore platforms and exposed flare tips

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on API 537 / IEEE 383 / UL 1581 VW-1. Values for your order are confirmed in the datasheet and quotation.

Electrical

High-voltage ignition rating
15 kV to 25 kV peak (HEI / spark pulse)
Continuous AC rms rating
3000 V to 10,000 V AC rms
Dielectric breakdown voltage
≥ 35 kV DC (dry) · ≥ 20 kV (wet)
Spark test voltage
25 kV AC rms in-line

Thermal

Continuous operating temp.
-60 °C to +450 °C (upper stack zone)
Radiant flare peak temp.
+540 °C (+1000 °F) intermittent
Mica barrier survival temp.
+800 °C inorganic dielectric retention

Mechanical

Conductor gauges
16, 14, 12, 10, 8 AWG (1.3 to 8.4 mm²)
Min. bending radius (fixed)
8 × overall cable diameter
Min. bending radius (pulling)
12 × overall cable diameter

Resistance

Flame propagation
IEEE 383 / UL 1581 VW-1 / IEC 60332-1-2
Steam & condensate resistance
Fluoropolymer/silicone core resists steam
Sour gas & salt spray
Ni-Cu + SS316L resists H2S and marine air

Reference standards

Flare system reference
API Standard 537 pilot ignition practice
Conductor standard
ASTM B355 Class 27 (Ni-Cu) / ASTM B160 (Ni)
RoHS & REACH
RoHS 3 & REACH compliant

Identification

Outer jacket appearance
Tan/white E-glass braid or metallic SS316L
Tag / marker legend
TEBAOFLEX FLARE STACK HV 450C [AWG] 25KV
Customs tariff (HS)
8544.49

Sizes

8 standard configurations (Thermo-Trex Flare Stack Cable)

Engineering dimensions, conductor stranding, mass and electrical ratings for Thermo-Trex Flare Stack Cable per API 537 / IEEE 383 / UL 1581 VW-1.

Dimensions & weights
Order designationCross-section / sizeConductor buildWall ≈
mm		Outer Ø ≈
mm		Metal
kg/km		Weight ≈
kg/km		Min. bend R
fixed mm		Enquiry
Standard Thermo-Trex Flare Stack Cable configurations
Flare-HV 1×16 AWG GL (15 kV)16 AWG (1.31 mm²)19×0.30 mm 27% Ni-Cu2.206.8013.064.041
Flare-HV 1×14 AWG GL (20 kV)14 AWG (2.08 mm²)19×0.37 mm 27% Ni-Cu2.507.8020.586.047
Flare-HV 1×12 AWG GL (25 kV)12 AWG (3.31 mm²)19×0.47 mm 27% Ni-Cu2.809.0032.5118.054
Flare-HV 1×10 AWG GL (25 kV)10 AWG (5.26 mm²)37×0.43 mm 27% Ni-Cu3.0010.2051.5156.061
Flare-HV 1×14 AWG SS316 (20 kV)14 AWG (2.08 mm²)19×0.37 mm 27% Ni-Cu2.808.6020.5128.052
Flare-HV 1×12 AWG SS316 (25 kV)12 AWG (3.31 mm²)19×0.47 mm 27% Ni-Cu3.109.8032.5168.059
Flare-HV 1×10 AWG SS316 (25 kV)10 AWG (5.26 mm²)37×0.43 mm Pure Ni3.3011.0051.5215.066
Flare-HV 2×14 AWG SS316 (15 kV)2×14 AWG (2.08 mm²)19×0.37 mm 27% Ni-Cu3.0013.8041.0265.083
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Outer diameters and weights are nominal engineering values for Thermo-Trex Flare Stack Cable subject to standard manufacturing tolerances per API 537 / IEEE 383 / UL 1581 VW-1.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Dielectric spark / high-voltage withstand test100 % in-line spark and AC/DC dielectric withstand per API 537 / IEEE 383 / UL 1581 VW-1Every manufactured length
Conductor DC resistance & continuity checkWithin maximum 20 °C resistance limit specified for Thermo-Trex Flare Stack CableEvery spool or drum length
Sample tests
Thermal ageing & dimensional verificationWall thickness, concentricity and post-ageing elongation per API 537 / IEEE 383 / UL 1581 VW-1Per production batch
Flame, outgassing or high-temperature enduranceQualified to API 537 / IEEE 383 / UL 1581 VW-1 thermal and environmental performance criteriaType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

API 537 / IEEE 383 / UL 1581 VW-1CE (2014/35/EU) & RoHS 3 (2015/863/EU) CompliantREACH SVHC & Halogen/Asbestos Compliance Verified

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX FLARE-HV 1×12 AWG 25KV +450C SS316
Delivery form
Precision spools, coils or export wooden drums
Standard lengths
50 m · 100 m · 500 m · 1000 m (or cut harnesses)
MOQ
100 m (stock sizes) · 300–500 m (custom build)
Lead time
2–4 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFThermo-Trex Flare Stack Cable – technical datasheet8 sizes · construction, technical data, approvalsXLSXThermo-Trex Flare Stack Cable spec data (Excel)All 8 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why do ordinary high-temperature furnace wires fail in flare stack pilot ignition conduits?
Flare stack ignition conduits combine two opposing hazards: +450 °C to +540 °C radiant heat at the flare tip and condensing moisture/steam inside the vertical riser pipe. Porous mica-glass wires absorb moisture and short out at 15–25 kV, whereas standard silicone melts near the tip. Our composite mica + sealed HV elastomer construction solves both.
Is this cable compatible with Low-Voltage High-Energy (HEI) capacitor-discharge igniters as well as HV spark transformers?
Yes. The heavy 14 AWG, 12 AWG, and 10 AWG 27 % nickel-plated copper conductors provide the low series impedance required by 1.5–3.0 kV high-energy capacitor-discharge (HEI) exciter boxes while maintaining a 15–25 kV dielectric ceiling for conventional spark transformers.
When should we specify the AISI 316L stainless-steel braided version (SS316)?
Specify the SS316L stainless-steel overbraid for offshore platforms, coastal LNG terminals, and exposed upper flare tip runs where salt spray, H2S sour gas, bird pecking, and wind-induced vibration abrade unarmoured glass braids.
Can TEBAOFLEX supply matching high-temperature thermocouple extension cable for flare pilot flame detection?
Yes. Alongside the high-voltage flare ignition cable, we supply Type K (NiCr-NiAl) and Type N high-temperature mineral- or mica/glass-insulated thermocouple cables with SS316L braiding for API 537 flare pilot monitoring.

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