A flare stack, knock-out drum preventive maintenance schedule lists the checks and jobs done on the equipment at fixed intervals, how long each takes, and in what order of frequency, so problems are found before the flare stack, knock-out drum fails. This page gives the schedule used in the PlantOps360 task library for flare stack, knock-out drum (and ignition system), which follows common industry practice for general-purpose equipment. It is also searched for as flare, flare stack, flare tip, pilot.
The maker’s manual and your site safety procedures always come first where they differ. Intervals set by law differ by state.
Flare stack, knock-out drum preventive maintenance schedule and checklist
| How often | Task | Estimated time |
|---|---|---|
| Daily | Check pilot flames and flare gas flow; check knock-out drum and seal drum levels | 10 min |
| Weekly | Check the ignition panel, thermocouples and pilot gas supply | 20 min |
| Monthly | Check smokeless steam or air system, purge gas flow and seal | 45 min |
| Quarterly | Check flare line and support structure visually; check obstruction lights | 90 min |
| Half-yearly | Test the ignition system and flame detectors; calibrate gas flow meters | 150 min |
| Annual | Annual shutdown inspection of flare tip, pilots and stack | 480 min |
Flare stack, knock-out drum maintenance frequency and yearly workload
At the estimated times, one flare stack, knock-out drum needs about 106 hours of preventive maintenance a year. The biggest single job is “Annual shutdown inspection of flare tip, pilots and stack” at 480 minutes, done annual. Multiply by the number of units you have to see the workload for your plant.
| Frequency | Tasks | Time per round | Hours per year |
|---|---|---|---|
| Daily | 1 | 10 min | 60.8 h |
| Weekly | 1 | 20 min | 17.3 h |
| Monthly | 1 | 45 min | 9.0 h |
| Quarterly | 1 | 90 min | 6.0 h |
| Half-yearly | 1 | 150 min | 5.0 h |
| Annual | 1 | 480 min | 8.0 h |
What goes wrong on a flare stack, knock-out drum without preventive maintenance
- Pilot flame loss
- Ignition panel faults
- Knock-out drum level problems
- Smokeless steam or air system faults
What to watch between services
- Pilot flame and flare gas flow
- Knock-out drum level
- Ignition system and purge gas
Safety and statutory notes for flare stack, knock-out drum maintenance
The flare is a safety system. Test pilots and ignition on the schedule and follow the permit system for any work.
Where a flare stack, knock-out drum preventive maintenance schedule is used
This equipment is used in the industries below. Each link opens the preventive maintenance schedule guide for that industry, and the maintenance software page where we have one.
- Preventive maintenance schedule for chemical, fertiliser and petrochemical plants · maintenance software for chemical
- Preventive maintenance schedule for oil, gas and refinery facilities · maintenance software for oil and gas
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Browse the full list of equipment preventive maintenance schedules (317 types).
Run this flare stack, knock-out drum schedule in maintenance software
In preventive maintenance software, each row above becomes a recurring task on the asset with its checklist, time estimate and parts. Tasks can be triggered by calendar date, running hours, meter readings or production cycles, each completed task is recorded with the person and date, and a failed check can open a work order. For the method behind it, read the guide to the preventive maintenance schedule, or use the free generator to get a 12-month plan for your whole equipment list.
Build my preventive maintenance schedule (free Excel)
Frequently asked questions
How often should a flare stack, knock-out drum be serviced?
In our schedule a flare stack, knock-out drum has 6 tasks: 1 daily, 1 weekly, 1 monthly, 1 quarterly, 1 half-yearly, 1 annual. The biggest job is “Annual shutdown inspection of flare tip, pilots and stack”, which is done annual. Always follow the maker’s manual where it gives a different interval.
What is included in flare stack, knock-out drum preventive maintenance?
It covers routine checks and jobs such as “Check pilot flames and flare gas flow; check knock-out drum and seal drum levels”, “Check the ignition panel, thermocouples and pilot gas supply”, “Check smokeless steam or air system, purge gas flow and seal”, up to the annual overhaul or inspection. The full list with times is in the table above.
How many hours of maintenance does a flare stack, knock-out drum need per year?
About 106 hours per unit per year at the estimated times in our library, including the daily checks done every day. Use it to plan workload, not as a benchmark.
Is there a free flare stack, knock-out drum maintenance checklist?
Yes. The table on this page is a ready checklist. The free preventive maintenance schedule generator turns it into a 12-month Excel schedule for your list of equipment, with monthly workload hours.