Product Overview: TEBAOFLEX 25 kV Igniter Flare Stack Cable is a single-core high-voltage ignition cable rated for 25 kV DC / 10 kV AC and continuous conductor temperatures up to 250°C, combining finely stranded nickel-plated copper (18–10 AWG), high-voltage silicone rubber insulation, mica thermal tape, fibreglass braid, and a sealed fluoropolymer outer coating.
1. Application Scope in Flare Stacks & High-Energy Ignition
Refinery, petrochemical, LNG, and offshore flare pilot igniters deliver high-voltage capacitive-discharge or transformer sparks close to intense radiant heat zones where standard elastomeric ignition leads crack or track electrically:
- Refinery, LNG & Offshore Flare Stacks: High-voltage lead-in runs between grade/platform ignition exciter cabinets and elevated flare tip pilot igniters or retractable ignition lances.
- High-Energy Igniters (HEI) & Process Burners: Fired heaters, sulfur recovery thermal reactors, Claus furnace burners, and boiler pilot spark rods.
- Harsh Chemical & Conduit Pulling Duty: Fluoropolymer-sealed glass braid resists conduit pulling friction, hydrocarbon condensates, moisture, salt spray, and UV exposure.
High-Voltage Ignition vs. Low-Voltage 250°C Hook-Up Wire: Specify this 25 kV DC / 10 kV AC multi-barrier cable exclusively for high-voltage spark/exciter circuits. For 600 V 250°C thermocouple/control wiring or 300 V 200°C appliance leads, compare UL 10362 PFA 250°C 600V Wire, UL 3122 Silicone Fibreglass 200°C Wire, or browse High-Temp & Specialty Cables and Oil, Gas & Marine Cables.
2. Five-Layer High-Temperature Cable Construction
Each concentric layer addresses a distinct failure mode—conductor oxidation, dielectric corona breakdown, thermal radiation, conduit abrasion, and chemical ingress:
3. Electrical, Thermal & Mechanical Ratings
Verify conduit fill, standoff clearance, and high-voltage termination boot ratings against your ignition exciter manufacturer specification:
| Technical Parameter | Listed Engineering Value |
|---|---|
| Voltage Rating | 25 kV DC / 10 kV AC |
| Maximum Conductor Temperature | 250°C continuous |
| Core & Shielding Configuration | Single core (18 AWG to 10 AWG); Unshielded (Shielding: None) |
| Minimum Bend Radius (Static) | 10 × overall cable diameter (fixed conduit / tray routing) |
| Minimum Bend Radius (Dynamic) | 12 × overall cable diameter (retractable lances / expansion loops) |
| Environmental Compliance | RoHS compliant; resistant to heat, oil, process chemicals, abrasion, and weather |
4. Single-Core AWG Dimensions & Ordering SKU Table
Nominal Imperial values with reference metric conversions (1 in = 25.4 mm; 1 lb/1,000 ft ≈ 1.488 kg/km) for international EPC conduit and cable gland sizing:
| Part SKU | Conductor Size (AWG / Approx. mm²) | Cores | Outer Jacket System | Nominal Overall Diameter | Approximate Cable Weight | Shielding |
|---|---|---|---|---|---|---|
TF-IGN-18AWG | 18 AWG (~0.82 mm²) | 1 | Glass-fibre / fluoropolymer | 0.236 in (6.0 mm) | 36 lb/1,000 ft (~54 kg/km) | None |
TF-IGN-16AWG | 16 AWG (~1.31 mm²) | 1 | Glass-fibre / fluoropolymer | 0.242 in (6.1 mm) | 42 lb/1,000 ft (~63 kg/km) | None |
TF-IGN-14AWG | 14 AWG (~2.08 mm²) | 1 | Glass-fibre / fluoropolymer | 0.281 in (7.1 mm) | 53 lb/1,000 ft (~79 kg/km) | None |
TF-IGN-12AWG | 12 AWG (~3.31 mm²) | 1 | Glass-fibre / fluoropolymer | 0.306 in (7.8 mm) | 65 lb/1,000 ft (~97 kg/km) | None |
TF-IGN-10AWG | 10 AWG (~5.26 mm²) | 1 | Glass-fibre / fluoropolymer | 0.340 in (8.6 mm) | 85 lb/1,000 ft (~126 kg/km) | None |
5. Frequently Asked Questions
What voltage and conductor temperature is TEBAOFLEX flare stack igniter cable rated for?
It is rated for 25 kV DC / 10 kV AC high-voltage ignition circuits with a 250°C maximum continuous conductor temperature.
Why is nickel-plated copper used instead of tin-plated copper?
Tin plating degrades above 150°C, whereas finely stranded nickel-plated copper preserves stable surface conductivity and flex strength continuously at 250°C near flare tips and burner throats.
Why combine silicone rubber, mica tape, fibreglass braid, and fluoropolymer?
HV silicone provides flexible primary dielectric strength, mica tape blocks radiant thermal spikes, fibreglass braid resists conduit pulling abrasion, and the fluoropolymer outer seal prevents moisture wicking and chemical attack.
How do I choose between 18 AWG and 10 AWG?
Smaller gauges (18–16 AWG) suit compact burner housings and short exciter leads; heavier gauges (14–10 AWG) provide higher pulling strength and lower capacitance/resistance losses on tall elevated or offshore flare stacks.
Does this cable have a metallic shield?
No—the standard listed series is unshielded single-core (Shielding: None) for routing inside metallic flare stack conduit or flexible stainless hose. Contact TEBAOFLEX if your ignition system requires a custom overall stainless or nickel-copper overbraid.
What details are needed for an igniter flare stack cable quotation?
Send your peak pulse voltage (DC/AC), AWG size, flare stack height/run length, ambient radiant temperature, conduit inner diameter, total footage/meterage, and destination port.
Request 25kV Igniter Flare Stack Cable Datasheet & Factory Quote
Share your ignition exciter voltage, AWG size (18–10 AWG), stack run length, and operating temperature profile. Our engineering sales team will confirm cable OD and lead time.
