Date post: | 07-Aug-2018 |
Category: |
Documents |
Upload: | hector-saavedra |
View: | 215 times |
Download: | 0 times |
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 1/62
Hero Flare Model : F51U8R
Hero Job No. : H15028
Customer : Gases Del Caribe
Jobsite: Cesar, Columbia
n s t a l l a t i o n &
O p e r a t i o n M a n
u a l
Utility Flare
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 2/62
Installation & Operations Manual (Utility Flare)
T ABLE OF CONTENTS
Section 1: General Overview of Equipment
Section 2: Foundation
Section 3: Stack Assembly
Section 4: Pilot & Pilot Retraction System
Section 5: Stack Assembly & Erection
Section 6: Guy Wire Installation
Section 7: “Best Practices” Operational Considerations
Section 8: Start-up General Guidelines
Section 9: Troubleshooting
Section 10: Preventative Maintenance
Appendix A: Reference Documentation
a. General Arrangement Drawing
b Pil t / I iti S t
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 3/62
Installation & Operations Manual (Utility Flare)
Section 1: General Overview of Equipment
The Utility Flare System is designed to provide operators with a safe and reliablemethod of flaring waste gas produced from tank cleaning operations, pipelineevacuation, drilling operations, tank battery facilities, etc. Utility flares arecommonly used where the flare gas does not smoke or as emergency flares.
Review the Bill of Material on the General Arrangement drawing located inAppendix A for the project equipment scope. Some parts of this manual may notapply.
The Hero Flare Installation and Operations Manual is intended to give theowner/operator a general overview of how this equipment operates. If you areunsure or have specific questions that are not outlined within this manual, please
consult Hero Flare. Please note, the installation and operation personal shouldhave a strong fundamental knowledge of this type of equipment.
Before proceeding, it’s important that you review the flare drawings located inAppendix A of this manual before proceeding. It is critical that you understand thecomponents that were provided with your system as some of the content in thismanual may not apply to your specific equipment if some of the optionalequipment were purchased.
Flare Location
Correct placement of the flare system is important to ensure a safeoperation. There are several factors that deserve consideration before aninstallation site is chosen.
1. Must have access to electrical power to operate the blowers.
2. Must be placed within a safe working distance from personnel andprocess equipment - Sudden and unexpected release of processgas to the flare can generate a tremendous amount of heatcreating a hazardous condition for personnel and processequipment. Please refer to API standards to determine a safe
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 4/62
Installation & Operations Manual (Utility Flare)
Section 1: General Overview of Equipment
Smokeless Operation
Utility flares do not have any special features to prevent smoke, however inmany cases Hero Flare optimizes the tip size to enhance mixing and reduce
smoke formation. Many light hydrocarbons do not smoke when burned inour standard utility flare tip.
Hero Utility Flare System
The standard Hero Utility Flare System consists of three (3) maincomponents. The Stack, HES Pilot Ignition System and Flame Arrestor. The
below provides a brief overview of these components to give a fundamentalunderstanding of each component.
Stack
The flare stack can be either free standing or guy wire supporteddepending on which option was purchased. In addition, the flarestack may be shipped in a single piece or multiple stack sections
depending on the total height of the flare stack and / or the finaldestination of the equipment. It is important that you refer to theFlare General Arrangement Drawings located in Appendix A of thismanual to identify the type of flare stack support system your flarestack was designed for as well as the number of stack section thatmust be field assembled.
In addition, the flare stack base may include a liquid knock out pot in
the base for select Air Assist Flare models. For those flare modelsthat includes a knock out pot in the base section, connections aretypically provided by Hero to allow for level sight gauges, levelcontrollers, etc. to be connected to the stack.
HES Pilot (Ignition System)
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 5/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 6/62
Installation & Operations Manual (Utility Flare)
Section 1: General Overview of Equipment
Site Utilities Required
The following utilities will be required to operate your Air Assisted
Flare System.
Utilities
Pilot Gas (per pilot) 78 scfh at 5 psig. Clean, dry natural gas.
Plant Air No Plant Air Required
Panel Electricity 120V / 1 Phase / 10 Amps is required to operate pilot ignition system
Blower Electricity 480V / 3 Phase / 60Hz
Ancilliary
Equipment
Offered
Electrical Area Non-classified area
Control Panel Type Nema 4X (Corrosion resistance fiberglass reinforced plastic (FRP))
Blower Motor TEFC, Premium duty suitable for VFD Blower Size: N/A
Pilot(s) Two (2) Retractable High Energy Spark Ignition w/Gas
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 7/62
Installation & Operations Manual (Utility Flare)
Section 2: Foundation
The following installation overview is to be used as a general guideline and specificinstallation practices, safety procedures, heavy equipment selection, equipmenthandling and overall equipment knowledge should be the responsibility of the
installation contractor carrying out the installation of the Flare System.
Step #1: Obtain Foundation Civil Design
The proper Flare Stack foundation is critical to ensure a safe and reliableinstallation is achieved for long-term operation. Because civil engineeringrequirements for the flare foundation vary depending on specific site
conditions, it is the responsibility of the erection / owner / operator toconsult with your civil engineers to ensure the site preparation andfoundation designs will meet the requirements for your specific application.Hero Flare can supply the loads and moments for the flare base and guywireanchor points.
Step #2: Prepare Flare Foundation
When pouring the foundation, refer to the HERO General ArrangementDrawings located in Appendix A for the proper anchor bolt layout for theFlare Base Ring.
Important Note: The Hero Utility Flare Model G30U4 can be purchased
with Optional Ground Anchors that eliminate the need for deadmen.Additionally, Hero offers a pre-cast concrete base that is structurallydesigned to be used in-place of a site formed concrete pad. If the Hero pre-cast concrete base was purchased for your application, the concrete basecan be set directly leveled out chat or placed on stabilized fill or chat
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 8/62
Installation & Operations Manual (Utility Flare)
Section 3: Stack Assembly
Step #1: Review GA Drawings
The flare stack may be shipped as one (1) complete Flare Stack assembly
or shipped in sections.
If the flare stack is shipped in multiple sections, field welding or bolting upstack sections will be required and therefore you should continue to readthis section. If your flare stack was shipped as one (1) complete flare stack,then proceed onto the next section (section 4).
Shipped lose flare stack sections will either require field welding to join thestack section together, or they will have flange connections to allow thestack sections to be bolted together. Review the General ArrangementDrawing located in Appendix A to identify the assembly required for yourflare application.
Step #2: Remove Shipping Braces
All Flare stack assemblies other than the base section will typically havetemporary shipping stops and / or braces installed at the ends to preventthe inner stack riser pipe from sliding out during transportation. Thesetemporary braces / stops must be removed. Refer to the shipping brace
You MUST Verify: Before proceeding, refer to the GeneralArrangement drawing to identify if your flare stack was shipped in
one (1), two (2) or Three (3) stack sections so you can identify if
the following instructions apply.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 9/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 10/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Step #1: Confirm if Pilot was Shipped Lose or On Stack
The HES Pilot assembly and Pilot Retraction System may be installed on the
flare stack for shorter height flare systems. Although, typically the HES Pilotand HES Pilot Retraction System are shipped lose to prevent the PilotSystem from being damaged during handling and shipping of the flare.Therefore, the field will be required to install the HES Pilot System andRetractable Pilot System on the flare in the field.
Step #2: Confirm if Pilot System if Fixed or Retractable
Refer to the General Arrangement drawing to identify if your systemincludes a Fixed HES Pilot Assembly or a Retractable Pilot Assembly.
Fixed Pilot (Included on base flare model)
Fixed Pilot Systems are designed so that the pilot is mountedto the stack and cannot be raised or lowered formaintenance at ground level. Additionally, the Pilot Wiring is
ran through fixed hard conduit and pilot gas supply lineconsist of fixed tubing.
Retractable Pilot (Only included if this option purchased)
You MUST Verify: Before proceeding, refer to the HERO Flare
General Arrangement to identify if your flare system includes aPilot Retraction System or not. The Pilot Retraction System isan optional feature and is only provided if purchased with theoriginal equipment.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 11/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Fixed Pilot Assembly
This section only applies to flare stacks with FIXED pilot systems. If your system
utilizes a RETRACTABLE pilot system then proceed to the section referring toRetractable Pilot Systems.
Step #3: Considering Erecting Stack Before Proceeding
To ensure the pilot is not damaged during the erection of theflare stack the site will need to evaluate if they feel morecomfortable installing the pilot at grade level and avoid damage
during erection of the stack. If there are any concerns withdamaging the pilot during erection of the stack, it is highlyrecommended that you proceed to Section 5 and proceed witherecting the flare stack before continuing on with Step #4 (Pilot
Assembly).
Step #4: Mount the pilot(s) to the mounting bracket(s) that are weldedon the stack in accordance with the General Arrangement
Drawing.
Step #5: Attach a fuel gas line to the ¼” FPT connection on the pilotinspirator. Run a 3/8” stainless tubing to the pressureregulator at the flare base.
Step #6: Wire Pilot by providing following circuits
a. 120 vac 5-amp circuit for the pilot control panel. (AC-UPSonly)
b. 1 pair of type K thermocouple wires (16 – 22 ga) from thepilot control panel to the thermocouple on the pilot
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 12/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Fixed Pilot Assembly
Step #7: Using standard wiring practices:
a. Run conduit and pull wire from the pilot control panel tothe pilot. Grouping the thermocouple and low voltageignition wire into a single conduit is our standard practiceon hundreds of applications. However, client standardsmay mandate separating the thermocouple wire from thelow voltage ignition wire. Either one will work.
For flares with multiple pilots and control panels, werecommend one ¾” conduit per panel/pilot combination.This helps keep wires properly associated.
b. Run conduit and pull wire from the pilot control panel to thecontrol room.
c. Terminate a 120 vac 5-amp pilot control circuit in the pilotcontrol panel. (AC-UPS only)
d. Terminate the thermocouple wires as shown on drawingSOL-2 or AC-UPS-2. Terminate the thermocouple wires atthe thermocouple on the pilot.
e. Terminate the ignition coil wires as shown on drawing SOL-2 or AC-UPS-2. Terminate the ignition coil wires at theignition coil assembly on the pilot.(Red - positive, black - negative, green - ground.)
f. Terminate the pilot failure alarm wires in the pilot controlpanel from the control room (optional) as shown on drawingSOL 2 or AC UPS 2
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 13/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 14/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Retractable Pilot Assembly - Continued
Step #4: Erect Stack Before Proceeding with Step #5
To ensure the pilot is not damaged during the erection of theflare stack. It is highly recommended that you proceed toSection 5 and proceed with erecting the flare stack beforecontinuing on with Step #5 (Pilot Assembly).
Step #5: Retractable System Winch Bracket (RS-WB)
Once the flare stack is erected and in position and securelybolted, bolt the Retractable System Winch Bracket onto theflare stack base in accordance with the General ArrangementDrawing with the mounting hardware supplied by Hero.
Step #6: Thread the upper and lower pilot carriages onto each of the
guide cables as shown in the picture below.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 15/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Retractable Pilot Assembly - Continued
Step #7: Using the shackle provided, connect the draw cable to theupper pilot carriage (use the hole closest to the pilot).
Step #8: Install the eyebolts to the winch mounting plate using the
shock absorber, washers and nuts provided. Thread the nut towhere there are 2-3 threads showing. This will allow for
i t i dj t t f th id bl
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 16/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Retractable Pilot Assembly - Continued
Step #11: Thread the “dead end” of the draw cable into the winch clamp
and secure.
Step #12: Using a 13/16” deep socket & drill, begin winding the drawcable onto the winch drum until all of the slack is out of thedraw cable and the top pilot carriage begins to move up.
Step #13: Locate and unpack the HES pilot and unroll the SS braidedconduit and fuel gas lines.
Step #14: The HES pilot will have the stab bracket already mounted onth il t t th t l ti (32” f th t f th
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 17/62
Installation & Operations Manual (Utility Flare)
Section 4: Pilot Assembly
Retractable Pilot Assembly - Continued
Step #16: Continue raising the pilot with the winch until the lower end ofthe pilot is at a working elevation.
Step #17: Using the U-bolt provided secure the pilot to the bottom pilotcarriage. The bracket should be positioned at about 70” fromthe top of the pilot shield to the top of the bottom pilotcarriage.
Step #18: Continue raising the pilot. Connect the SS braided conduit andfuel gas line guide to the draw cable. These guides have been
placed approximately every 5ft.
Step #19: Once the pilot approaches the pilot receiver assembly, beginusing the hand crank for the final 12” of so of travel. This willreduce the possibility of over tightening the draw cable.
Step #20: Slowly crank the winch until the pilot is in position and thedraw cable reasonably tight. Do not over tighten.Step #21: Connect the SS braided pilot fuel gas line (JIC to ¼” MPT
fitting provided) to the fuel gas supply from the pilot controlrack provided. Interconnecting fuel gas piping is byothers.
Step #22: Connect the SS braided conduit (1/2” union provided) to the
supplied terminal conduit body.
Step #23: Attached the pilot ignition wires and thermocouple wires tothe correct terminals
Step #24: Refer to the SOL or AC schematic for wiring to the control
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 18/62
Installation & Operations Manual (Utility Flare)
Section 5: Stack Erection
Confirm if Stack is Guy Supported or Free Standing. Refer to General ArrangementDrawings.
Step #1: Locate and attach the guy wires (supplied) to the guy wire lugs
using the shackles provided. Not required for self-supported flares, only applies to Guy Supported Stacks.
Step #2: Using standard lifting practices, erect the flare into position. Inmost cases, Hero flares are designed for a single point lift. Referto the HERO Flare structural calculation package to obtain thelifting details before proceed.
Step #3: Do not allow the lifting straps to be placed around the SparkIgnited Pilot. If the 1” pipe on the pilot is bent, the pilot will notfunction properly. Remove pilots and conduit as necessary toavoid damage during the lift.
Step #4: Attach the guy wires to the dead men anchors using theturnbuckles and clips provided. Plumb the flare by tensioningthe turnbuckles.
Step #5: Torque the anchor bolts per standard construction practice.
Step #6: Reinstall pilots / conduit and other items if left off during stacklifting.
Step #7: Attach a fuel gas line to the ¼” NPT connection on the pilot gasregulator located at the base of the flare.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 19/62
Installation & Operations Manual (Utility Flare)
Section 6: Guy Wire Instructions
If your stack is a free standing stack this section does not apply. Guywires,clips & turnbuckles have been supplied to support the flare stack. While guy wireinstallation is common, there are a few areas to keep in mind.
Step #1: Use swaging sleeve and clevis at stack connection. This avoids
clips at high elevations where they cannot be inspected. Ensurethat the clip size matches the wire rope size.
Step #2: Use clips and thimble at turnbuckle connection point. Herosupplies an extra clip for safety, normally 3 total per wire rope.
Step #3: Position and torque clips per the drawing.
Step #4: Clips are located approximately 2” apart and torqued to 30 ft-lb.
Step #5: To attach clips, first turn back wire rope over a thimble. Applythe first clip near the dead end of the wire rope. The second clipshould be as close as possible to the thimble. Add the remainingclips at equal intervals.
Step #6: The live end rests in the clip saddle. In other words, the clipnuts are on the guy wire side, not the “dead” side.
Step #7: Tighten nuts. Alternate from one nut to another whiletightening. After 30 days, check torque again.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 20/62
Installation & Operations Manual (Utility Flare)
Section 7: Operational Considerations
When operating flares all safety safe guards should be taken to ensure a safeand reliable operation. The following are “best practice” operational safe guardsthat should be implemented into the flare operation procedures.
Flare Purging
All flare systems can flashback if not properly purged to keep air out of theflare header and flare stack. Air can enter the flare system from four (4)separate entry points:
Contained in the Flare Gas: It is imperative that the hydrocarbon flare gas be
free from oxygen at all times. If oxygen can be present, a flashback protectionsystem is required to protect the plant and personnel.
Upstream Tanks and Vessels: Atmospheric tanks without a natural gas
blanket will “breath” in air at night, during rainstorms, when the temperaturedrops or when liquid is removed from the tank.
Leaks in the Vent Header: The vent header piping must be kept tight. It is
common to flare headers to operate under a slight vacuum. Any leaks, looseconnections or open valves may allow air to enter the vent header and mix withthe hydrocarbon flare gas. If the mixture reaches the combustible range, the
flare pilot will ignite the gas/air mixture which will burn inside the flare
tip/header. Damage can include hot spots on equipment or a catastrophicfire/explosion.
Backflow through the Flare Tip: Under “no flow” conditions, air will slowlydiffuse into the flare stack through the open flare tip. Light MW hydrocarbons,
tall stacks and high winds speed up this process. A continuous purge preventsair from entering the flare tip. Purge reduction seals minimize the continuouspurge rate. Note: In lieu of a continuous purge many production field clients
protect the upstream equipment from flashback by installing a flame arrestor.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 21/62
Installation & Operations Manual (Utility Flare)
Section 7: Operational Considerations
Flare Purging (Startup)
It is essential to remove all air from the process vessels, vent header and
flare stack before igniting the flare pilot. The recommended initial purge gasis nitrogen, although any dry, non-combustible inert gas will suffice. It isessential to avoid a hydrocarbon/air interface at any point.
Do not use steam as a purge gas. Steam will condense in the flare header.This pulls air into the flare system through the flare tip.
Purge at least 10 system volumes. The oxygen level in the flare headermust be under 8% (volume) to stay below the Minimum Oxygen Content(MOC). We recommend purging the flare header to a 1% oxygen level.
Flare Purging (Normal Operation)
A small continuous sweep of nitrogen or natural gas will prevent air fromentering the flare tip. The minimum flow rate is normally around 0.04 ft/secbased on flare tip flange diameter. Many facilities operate at 0.10 – 0.50ft/sec flow rate so that the operator can see a small flame on the flare tip.In many cases, leaks from the plant relief valves are greater than theminimum purge rate. Note: In lieu of a continuous purge many production
field clients protect the upstream equipment from flashback by installing aflame arrestor.
Important Highlights
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 22/62
Installation & Operations Manual (Utility Flare)
Section 7: Operational Considerations
Flame Arrestor
It is common practice to use a flame arrestor on production field flares. Theflame arrestor provides an additional level of protection if air enters theupstream tanks or vent header. The flow rates are relatively small and thearrestor may be removed from service for inspection and cleaning.
On larger flares, flame arrestors are rarely used. As long as air does notenter the upstream process, the flame cannot flashback. Tank blanketingsystems are effective are preventing air infiltration into atmospheric tanks.
The flare gas must be dry and free from condensate and other liquids. Ifliquid in the flare gas stream is expected, a knock out drum or other liquidentrapment device must be provided or the flame arrestor will plug.
The flame arrestor should be inspected regularly for plugging.
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 23/62
Installation & Operations Manual (Utility Flare)
Section 8: Start-up Procedures
Step #1: The on/off switch on the pilot control panel(s) should be turnedto the “OFF” position.
Step #2: Turn on the main power supply to the pilot control panel if you
ignition system is AC powered. If your system is Battery SolarPowered proceed to next step.
Step #3: Begin purging the flare gas line with fuel gas or nitrogen.
Step #4: Purge all air from the fuel gas line. The pilot inspirator has a1/16” orifice for natural gas and 3/64” for propane. If air isnot purged from the fuel gas line, it will take a substantial
amount of time to purge the line through the orifice.
Step #5: Turn on the fuel gas line supply and adjust the gas pressure to5 psi for natural gas or 3 psi for propane.
Step #6: Turn on the pilot control panel. The green power-on LED onthe spark module will illuminate. The pilot will begin sparkingevery 2 seconds as indicated by the red spark LED on the spark
module. The LED’s may not be easily visible during daytime.
Step #7: Verify the thermocouple controller reads ambient temperature.
Step #8: Verify that a pilot failure signal has been sent to the controlroom (if applicable).
Step #9: After a short length of time, the air in the fuel gas line will be
purged and the pilot will ignite. Pilot ignition can be verifiedby observing the thermocouple controller located inside of theignition panel and by listening for the sound of combustion.The flame from the pilot may not be visible during daylighthours. After the thermocouple reaches 300°F, verify that thepilot failure signal has been cleared (if applicable) and that the
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 24/62
Installation & Operations Manual (Utility Flare)
Section 9: Troubleshooting
The HES High Energy Spark Ignited Pilot is manufactured using the highest quality parts
available. It is then thoroughly tested at the factory before shipment, and should provideyears of trouble free service. If any malfunction should occur, investigate the following:
Problem Possible Cause Solution
Power light not ONPower Switch in Off position Turn ON PowerLoss of power to panel Check for blown fuses
Bulb Failure
Check for loose wiringconnectionsReplace bulb
Pilot will not light No spark is madeCheck ignition system forproper connection.
Pilot fuel gas failedConfirm fuel gas is perspecifications
Air inspirator is restricted Confirm that the air
inspirator has no restrictionsWiring failed
No 12 VDC
Inspect and confirm integrityof wiringCheck Battery & Solar Panelreplace if necessary.
Pilot gas pressure incorrect Pilot orifice is dirty Clean pilot orifice
Incorrect pilot fuel/orifice Install correct orifice forcurrent fuelSet pilot gas pressure toproper setting
Cannot regulate air or gaspressure to pilot
Pressure regulators notinstalled
Install pressure regulators
Pressure regulators notinstalled correctly
Inspect and correct regulatorinstallation
Gas lines plugged Inspect and blow out linesGas supply pressure too low ortoo high
Confirm supply pressure areper specification
Pilot will not stay lit Pilot wind shield damaged Repair/replace pilot shieldPilot orifice restricted Clean pilot orifice
Pil i i d hi ld l Pil i i l N i
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 25/62
Installation & Operations Manual (Utility Flare)
Section 9: Troubleshooting
Problem Possible Cause Solution
Pilot will not light flare High nitrogen in vent gas Purge nitrogen from systemImproper pilot position Reposition pilotPilot not lit Light pilot
Flare gas heating value too low Inject assist gas and confirmcomposition
Waste gas flow too low Increase flow to minimumpurge rate
Fuel gas supply failed Confirm fuel gas is availableat correct pressure
Panel lights not ON Bulb failure Replace bulbs Loose wiring Check for loose connections
Panel indicates pilots arenot burning Pilots damaged / mixers
unpluggedInspect pilots for tip/mixerfailure
Pilot fuel lines plugged Inspect and blow out pilotfuel gas lines
Pilot thermocouple failed Perform check onthermocouple at grade
Pilot thermocouple wiringfailed
Perform check on TC wiringat grade and inspect
Pilot temperature switch failed Perform check ontemperature switch in panelPanel pilot temperaturesettings not correct
Correct temperature setpoints
Pilot Lights butThermocouple does not
respond
Pilot thermocouple failed Perform check onthermocouple at grade
Pilot thermocouple wiringfailed
Perform check on TC wiringat grade and inspect
Pilot temperature switch failed Perform check ontemperature switch in panel
Panel pilot temperaturesettings not correct
Correct temperature setpoints
Flare Smokes Excessive vent flow Slow vent flow to flareInsufficient air flow Increase blower air flow
Flare gas composition changed Confirm flare gascomposition
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 26/62
Installation & Operations Manual (Utility Flare)
Section 10: Preventative Maintenance
1. Pilot Ignition System
To ensure a reliable ignition source is present at all times, it is recommendedthat the following checks occur monthly.
Check#1: Turn off the pilot fuel gas supply.
Verify: When pilot is turned off, the pilot alarm circuit should openwhen the pilot temperature falls below 300º F. Therefore,this check will confirm if the thermocouple temperaturecontroller and / or the thermocouple are operatingproperly.
Action: If no low temperature alarm occurs, then the system isworking properly. If not alarm occurs, then check thethermocouple and temperature controller are in good
working order. Replace as needed.
Check #2: Turn back on the pilot fuel gas supply.
Verify: The pilot lights should illuminate and the thermocoupletemperature controller should read above 300F.
Action: If temperature controller does not read above 300F, thencheck the thermocouple and temperature controller toensure they are in good working order. Replace as needed.
Check #3: Disconnect the main power supply.
Verify: Confirm that the control panel continues to operate onbattery power.
A ti If d t ti t t R l b tt
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 27/62
Installation & Operations Manual (Utility Flare)
Appendix A
a.
General Arrangement Drawing
b. Pilot / Ignition System
c. Spare Parts List / Contact Information
d. Sub-vendor Drawings / Data Sheets
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 28/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 29/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 30/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 31/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 32/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 33/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 34/62
R E L A Y
D O W N S C A L E
1 D 2 D
F
K
. 1
1
3
2
2 1 9 2
1 D E G R E E
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 35/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 36/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 37/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 38/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 39/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 40/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 41/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 42/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 43/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 44/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 45/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 46/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 47/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 48/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 49/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 50/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 51/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 52/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 53/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 54/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 55/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 56/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 57/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 58/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 59/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 60/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 61/62
8/19/2019 Manual Utility Flare - H15028
http://slidepdf.com/reader/full/manual-utility-flare-h15028 62/62