Operating Manual. Electri-Lite

Transcription

1 Operating Manual Prism Integrated Solutions Inc. Electri-Lite Elevated Flare Ignition System By Prism Integrated Solutions Inc. For product support please contact us at: Toll Free Fax Box 366, Street Forestburg, Alberta T0B 1N0

2 Copyright Prism Integrated Solutions Inc. This copyright notice SEQ Legal supplied the copyright notice template upon which this document is based. Other SEQ Legal documents include employment agreement templates. Technical Support PREMIER PILOT 1 If instruction in manual are followed and problems occur please call our technical support team. Toll Free: Local: Ownership of copyright The copyright in this document (including without limitation the text, artwork, photographs, images, in this document) is owned by Prism Integrated Solutions Inc. and its licensors. Permissions You may request permission to use the copyright materials in this document by writing to b_rajewski@prismcorp.net or Box 366, Street, Forestburg, Alberta, Canada, T0B 1N0. Enforcement of copyright Prism Integrated Solutions Inc. takes the protection of its copyright very seriously. If Prism Integrated Solutions Inc. discovers that you have used its copyright materials in contravention of the license above, Integrated Solutions Inc. may bring legal proceedings against you seeking monetary damages and an injunction to stop you using those materials. You could also be ordered to pay legal costs. If you become aware of any use of Prism Integrated Solutions Inc. copyright materials that contravenes or may contravene the license above, please report this by to b_rajewski@prismcorp.net or by post to Box 366, Street, Forestburg, Alberta, Canada, T0B 1N0. Infringing material If you become aware of any material in this document that you believe infringes your or any other person s copyright, please report this by to b_rajewski@ prismcorp.net or by post to Box 366, Street, Forestburg, Alberta, Canada, T0B 1N0. Warranty Prism Integrated Solutions Inc. guarantees all Prism flare systems for a period of one year from installation or 14 months from sale date against defects in manufacturing and workmanship. Wear items are excluded. Thank You Prism Integrated Solutions Inc. is proud of their products and would like to thank you for your purchase.

3 2 Prism Integrated Solutions Inc. Table of Content 1 Safety Procedures 3 2 Packing List 4 3 Product Summary 5 4 Preparation 6 Ignitor Cable Clamp Operation 6 Warning Critical Application Information Installation Instructions Installation 7 Ignitor to Tracking Winch to Ignitor Pull Down Cable Raising the Ignitor Electrical Wiring (12v Wiring) Ignition 8 Due Diligence Purge Stack System Position Ignitor Arc Ignitor v Wiring Schematic 9 8 Maintenance 10

4 Safety Procedures If instruction in manual are followed and problems occur please It is your responsibility and obligation as the owner/user of this equipment to ensure that all persons around this equipment are trained and familiar with its operation, maintenance and safety requirements. Only qualified personnel knowledgeable in the safe operation and maintenance aspects of this equipment should approach and operate this equipment. If hydrocarbon vapors are released into the air, they may become explosive. Smoking and open flame must be prohibited anywhere near this equipment due to the risk of fire or explosion. To reduce electrical shock, any circuit on which work is being performed should be disconnected from the power source. Be sure all electrical equipment is adequately grounded prior to turning on the power. Gas under pressure can be dangerous. Never expose piping, vessels, regulators or other equipment to pressures higher than their design pressure. Excessive pressure can result in lines leaking, bursting and rupturing. Keep all gas connections tight to stop gas from leaking and potentially cause a fire or explosion. Do not vent gas pressure by loosening a component connection. Use vent and drain valves provided for this purpose. Even gas trapped at a low pressure can pose a hazard. PREMIER PILOT 3

5 4 Prism Integrated Solutions Inc. Job Number: Date: Packaged By: Signature: Qty. Part Number Description Notes

6 PREMIER PILOT 5 The Prism Electri-Lite Ignitior has been developed by taking 30 years of ignitor design and field results and combining them into the Electri-Lite arcing ignitor. The superior design gives you an air induced arc gap that is shielded from the intense heat of the burning flare gas. The outer body of the Electri-Lite allows air to travel to the arcing zone and protects the center high voltage electrode. The electrode insulator is 10 below the heat zone in an ambient environment that supports a long lasting service life. Air Inducted Arc Gap SS Ignitior Body Internal Electrode Insulator High Voltage Coil and Exiter The arc generating unit is a proven design that will give you a long service life also. The coil is cased in a 3R enclosure that protects the coil from the weather conditions. This Electri-Lite ignition system can either be operated by 12 volt solar/110 volt single phase/110 volt over 12 volt. Coil Cable Retracting Rail Coil Cable Stablizer 55 Watt Solar Panel Charge Regulator Hand/Off/Auto Switch Spark Duration Controller Control Cable to Ignition Head

7 6 Prism Integrated Solutions Inc. Preparation Ignitor Remove Ignitor from shipping container. Lay out electrical cord in a line. Check container for tracking clip. (dia.1.1) Place tracking clip every 10ft starting 10ft from base of ignitor. Place electrical cord between gear clamp mount points. Secure to tracking clip with provided gear clamps. (dia.1.1) Cable Clamp Operation Warning Failure to read, understand, and follow these instructions may cause death or serious injury. Read and understand these instructions before using clips. Match the same size clip to the same size wire rope. Prepare wire rope end termination only as instructed. Do not use with plastic coated wire rope. Apply first load to test the assembly. This load should be of equal or greater weight than loads expected in use. Next, check and retighten nuts to recommended torque dia.1.1 Critical Application Information Efficiency ratings for wire rope end terminations are based upon the catalog breaking strength of wire rope. The efficiency rating of a properly prepared loop or thimble eye termination for clip sizes 1/8" through 7/8" is 80%. For sizes l" thru 3-1/2" it is 90%. The number of clips shown (see Table 1 ) is based upon using RRL or RLL wire rope, 6 x 19 or 6 x37 Class, FC or IWRC; IPS or XIP. If Seale construction or similar large outer wire type construction in the 6 x 19 Class is to be used for sizes 1 inch and larger, add one additional clip. If a pulley (sheave) is used for turning back the wire rope, add one additional clip. The number of clips shown also applies to rotation resistant RRL wire rope, 8 x 19 class, IPS, xip, sizes l-l/2 and smaller; and to rotation-resistant RRL wire rope, 19 x 7 Class, IPS, XIP, sizes 1-3/4 and smaller. Installation Instructions Step 1. Refer to Table 1 in following these instructions. Turn back specified amount of rope from thimble or loop. Apply first clip one base width from dead end of rope. Apply U-Bolt over dead end of wire rope.- live end rests in saddle (Never saddle a dead horse) Tighten nuts evenly, alternate from one nut to the other until reaching the recommended torque. Step 2. When two clips are required, apply the second clip as near the loop or thimble as possible. Tighten nuts evenly, alternating until reaching the recommended torque. When more than two clips are required, apply the second clip as near the loop or thimble as possible, turn nuts on second clip firmly, but do not tighten.

8 Step 3. When three or more clips are required, space additional clips equally between first two - take up rope slack - tighten nuts on each U-Bolt evenly, alternating from one nut to the other until reaching recommended torque. Installation Ignitor to Tracking Open tracking gate. (dia.2.1) PREMIER PILOT 7 dia.2.1 Load tracking clips bottom to top. Ignitor will be closest to flare tip. Place ignitor on top of tracking clips. Close tracking gate and secure tracking gate lock. Double Winch to Ignitor check stacking order to ensure proper placement of tracking clips Using provided stack winch cable, attach winch cable clevis to mounting hole on top leg of ignitor. (dia.2.2) Pull down cable applies to stacks over 90ft in length or stacks equipped with ignitors that have 45 heads. dia.2.2 dia.2.2 In accordance with good rigging and maintenance practices, the wire rope end termination should be inspected periodically for wear, abuse, and general adequacy.

9 8 Prism Integrated Solutions Inc. Pull Down Cable Assemble pull down cable from supplied parts. Attach pull down cable to lower leg mount hole. Pull down cable is used in cases where the ignitor gets hung up on the stack. The bottom end is to be secured at the base of the stack and not left to dangle. (dia.2.2) Fasten Raising the Ignitor Use winch to raise ignitor slowly. Watch tracking clips to ensure they do not bind. If binding occurs back the ignitor down to relieve pressure and raise again once binding stops. Raise until ignitor hits stop. Once fully raised secure winch. Check all connection and ensure they are secure before raising ignitor Electrical Wiring (12v Wiring) Connect power cable from ignitor as indicated. (dia.3.1) Make electrical cord together at every point where tracking clips are. Keep pull down cable seperate. sure electrical switches are off until all final connections are complete Ignition Due Diligence Check all connections to ensure the electrical line is tight and there are no faults. Purge Stack System Run waste gas through stack to ensure all oxygen has been purged from the stack interior. Refer to stack design for run time on purge Failing to purge the stack will result in highly volatile and explosive conditions for ignition Position Ignitor Ignitor must be at top of stack. (dia.3.1) Arc Ignitor Turn on ignitor electrical source. Set switch on side of control box to auto. Ignitor will make buzzing sound on successful arc. Buzzing sound will occur in a pattern of 2 seconds on and 40 off. If ignitor will not arc, turn off for 30 seconds, turn back to auto. If ignitor continues to not arc call technical support. dia.3.1

10 PREMIER PILOT 9 Electri-Lite CONTROL BOX ASC 12/16 REGULATOR * ELECTRONIC IGNITOR + - BAT ARRAY ARRAY BAT OMRON TIMER H 3CR-F OR BLK R R 3-1 BLK OR BL X BATTERY SOLAR PILOT O H A R 8-1 CABLE FROM IGNITOR OMRON H3CR-F TIMER 10A FUSE ASC 12/16 REGULATOR SWITCH FUSE dia.3.1

11 10 Prism Integrated Solutions Inc. Maintenance Ignitor Lower ignitor and inspect tip for cracks, burns, and deformities. Check entire unit for wearing of parts or cracking in steel. Solar Panels Use multi meter to confirm solar panel is delivering a charge to the battery annually. Batteries Batteries must be load tested and inspected to confirm they are in proper working condition annually.