Operating Manual. Safety/Process Flare Pilot

Transcription

1 Operating Manual Safety/Process Flare Pilot Pilot Monitor & Relight 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 2 Prism Integrated Solutions Inc. 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 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 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 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 info@ 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 Table of Content PREMIER PILOT 3 1 Safety Procedures 4 2 Packing List 5 3 Product Summary 6 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 Fuel Option A (Fuel Gas) Fuel Option B (Propane) Electrical Option A (12v/24v) Electrical Option B (110v) Ignition 8 Due Diligence Purge Stack System Position Ignitor Fire Ignitor Safety Flare Wiring Schematic 9 7 Process Flare Wiring Schematic 10 8 Ignition Procedure 11 9 Troubleshooting Maintenance 12

4 4 Prism Integrated Solutions Inc. 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.

5 PREMIER PILOT 5 Job Number: Date: Packaged By: Signature: Qty. Part Number Description Notes

6 6 Prism Integrated Solutions Inc. Preparation Ignitor Remove Ignitor from shipping container. Lay out electrical cord and fuel hose together in a line. Attach fuel hose to fuel assembly on ignitor. (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 Check container for tracking clip. (dia.1.2) dia.1.1 Place tracking clip every 10ft starting 10ft from fuel assembly connection. Place both electrical cord and fuel line together between gear clamp mount points. Secure to tracking clip with provided gear clamps. (dia.1.2) dia.1.2 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.

7 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 check stacking order to ensure proper placement of tracking clips Winch to Ignitor 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.

8 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. Fasten Raising the Ignitor fuel gas line, electrical cord, together at every point where tracking clips are. Keep pull down cable separate. 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 Fuel Option A (Propane) Check container for regulator assembly. Make sure regulator is equipped with bull nose. Attached regulator to ignitor fuel hose line. Attach regulator to customer supplied fuel source. Set regulator to 15-17psi. Make sure fuel source remains off until all final connections are complete Fuel Option B (Fuel Gas) Check container for regulator assembly. Attached regulator to ignitor fuel hose line. Attach regulator to customer supplied fuel source. Set regulator to 25psi - 27psi. Make sure fuel source remains off until all final connections are complete Ignition Due Diligence Check all connections to ensure all fuel lines are tight and there are no faults in the electrical lines. 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 Position Ignitor to purge the stack will result in highly volatile and explosive conditions for ignition Ignitor must be at top of stack as to ensure flame tip does not cause damage to stack or winch cable. Fire Ignitor If low temp or no flame has been sensed unit will begin a continuous relight cycle until a stabilized flame is sensed or unit is manually shut down. Alarm will sound for entirety of warning and relight cycle. Solar Add-on The Premier Pilot Control System can be utilized by adding a solar package for power consumption. This system includes a 55W solar panel,a 100AH AGM battery and a solar regulator. The regulator will charge the battery to full charge and then will shut down as to not overload the battery. When the battery gets low the regulator will sense this and the charging process starts again.

9 PANEL HEATER WATT PREMIER PILOT 9 POWER ON PILOT FAIL PILOT PROVEN TEMPERATURE CONTROL MODULE PRISM INTEGRATED SOLUTIONS INC. 12/24 VDC & 120 VAC PREMIER CONTROL BOX WIRING DIAGRAM SAFETY FLARE NC2 NC1 NO1 C2 NO2 C NC3 NO C1 C HAND / OFF / AUTO HAND AMP AUTO REVISION 1 29/05/ LOW TEMP. ALARM LOW FUEL GAS PRESS. ALARM C NO C NO JUMPER ALARM OUTPUT * INSTALL JUMPER FOR SINGLE ALARM OUTPUT TC+ TC- P+ P- C NO C NO C NO THERMOSTAT PRESS. SWITCH LOW FUEL GAS ALARM OUTPUT LOW TEMP ALARM OUTPUT CABLE TO IGNITER INPUT POWER dia ALL WIRING REMAINS THE SAME, BUT INTERNAL COMPONENTS CHANGE DEPENDING ON THE INPUT VOLTAGE REQUIRED BY END USER WHT RED GRN WHT TEMPERATURE CONTROL CONNECTIONS 1) POWER + 2) POWER - 3) RELAY 2 COM 4) RELAY 2 NO 5) REALY 1 COM 6) REALY 1 NO When the control is switched to the Hand position, the ignition system remains energized until it is manually turned off. The low temp alarm contacts are open. 9) THERMOCOUPLE + When the control is switched to the Auto position, power is applied to the temperature control module and ignition sequence is started. When the burner signal is less than 400ºC, the ignition system is energized, the low temp alarm contacts are open, and the "Pilot Fail" indicator is on. 10) THERMOCOUPLE - When the temperature rises above 400ºC, the ignition system is de-energized, the low temp alarm contacts close, and the "Pilot Proven" indicator is on

10 PANEL HEATER 10 Prism Integrated Solutions Inc. CONTROL COMPONENTS PRISM INTEGRATED SOLUTIONS INC. A) AGC-5A FUSE HOLDER 12/24 VDC & 120 VAC PREMIER CONTROL BOX WIRING DIAGRAM B) OMRON H3CR-A (12-24 VDC) or (120 VAC) PROCESS FLARE C) FUTURE DESIGN C TEMP. CONT. (11-26 VDC), C IS 120 VAC D) TIME OFF DELAY RELAY 12 VDC (TGPL70010A2H) 24 VDC (TGPL40010A1H) 120 VDC (TGPL10010A1H) E) AGC FUSE HOLDER 10 AMP FOR 12VDC AMP FOR 24VDC 11-1 Pilot Fail Pilot Proven Power On 5 AMP FOR 120VAC AUTO B REVISION 3 06/06/2017 OFF C 13-4 HAND A AMP D 2-6 TRIGGER RELAY N.C. N.O. OMRON RELAY BASE CONNECTIONS 1) RELAY 1 - COMMON 2) POWER SUPPLY - GROUND 3) RELAY 1 - N/O 4) RELAY 1 - N/C 5) TIMER GATE INPUT (NOT USED) 6) TIMER START INPUT 7) TIMER RESET INPUT (NOT USED) 8) RELAY 2 - N/C 9) RELAY 2 - N/O 10) POWER SUPPLY - POSITIVE 11) RELAY 2 - COMMON COM G 11-3 COIL + COIL TRIGGER NO C NO C JUMPER ALARM OUTPUT * INSTALL JUMPER FOR SINGLE ALARM OUTPUT 10 AMP DIODE 10 AMP DIODE WATT 1-2 E AMP FOR 12VDC 5 AMP FOR 24VDC 5 AMP FOR 120VAC THERMOSTAT dia.3.1 BLU O R R WHT C + - NC C NO + PILOT - PILOT + T.C. - T.C. + PRESSURE SWITCH CABLE WHT TEMP. ALARM SAFETY SHUT-OFF CABLE FUEL GAS PRESSURE ALARM RED GRN WHT CABLE FROM IGNITOR ALL WIRING REMAINS THE SAME, BUT INTERNAL COMPONENTS CHANGE DEPENDING ON THE INPUT VOLTAGE REQUIRED BY END USER INPUT POWER When the control is switched to the Hand position, the ignition system remains energized until it is manually turned off. The low temp alarm contacts are open at this point. When the control is switched to the Auto position, power is applied to the temperature control module and ignition sequence is started. Until the pilot temp is satisfied or initial starting temperature is less than 400ºC and climbing, the ignition system remains energized, the low temp alarm contacts are closed, and the "Pilot Fail" indicator is on. If after a 4 minute time period on initial start up the burner signal does not reach 400ºC, the alarm contacts open, the pilot fuel gas will close, and spark ignition will shut down. The "Pilot Fail" indicator will remain on. When the temperature rises above 400ºC on initial start up, the ignition system is de-energized, the low temp alarm contacts close and the "Pilot Proven" indicator is on. After the pilot temperature control has been satisfied with a reading of higher than 400ºC on start up, it will continuously monitor for a fall below 400ºC. In the event the pilot temperature falls below 400ºC, the ignition sequence will begin. A 4 minute window is given to satisfy re-ignition and pilot temperature above 400ºC. If after 4 minutes the temperature fails to rise, the alarm contacts open, the ignition system is de-energized, the pilot fuel gas solenoid is de-energized, and the "Pilot Fail" indicator will turn on. FUTURE DESIGN TEMPERATURE CONTROLLER CONNECTIONS 1) POWER - POSITIVE 2) POWER - GROUND 3) RELAY 2 4) RELAY 2 5) RELAY 1 6) RELAY 1 9) THERMOCOUPLE - POSITIVE 10) THERMOCOUPLE - GROUND

11 Ignition Procedure In event of flame failure/pilot alarm Turn selector switch to OFF If controlled remotely, open Remote Pilot Ignition contacts and continue with the following steps. (Remote Pilot Ignition) Ensure sufficient fuel gas is supplied and all valves are open. Ensure appropriate voltage is supplied to Main Power input terminals. Specific voltage required is stamped on serial number plate on the side of control panel. Manual Pilot Ignition Turn selector switch to HAND Hold until visual recognition that pilot ignition has occurred. Once pilot has successfully ignited, turn selector switch to AUTO. Once Low Temp Set-point (400 C) is reached, constant monitoring of pilot begins and ensures pilot re-light on loss Auto Pilot Ignition Turn selector switch to AUTO Re-light will continuously ignite until Low Temp Set-point (400 C) is reached. Once Low Temp Set-point is reached, re-light ignition stops and continuous monitoring of pilot temp. Ensures relight on loss of flame. Remote Pilot Ignition Turn selector switch to AUTO Remotely enable/close Remote Pilot Ignition contacts. Re-light will continuously ignite until Low Temp Set-point (400 C) is reached. Once Low Temp Set-point is reached, re-light ignition stops and continuous monitoring of pilot temp. Ensures relight on loss of flame. Troubleshooting Flare ignitor will not light. Refer to Pilot Ignition Procedure PREMIER PILOT 11 Ensure proper field voltage supplied to control panel terminal connections. Check fuse. If fuse is blown further investigation may be required. Specific voltage required is stamped on serial number plate on the side of control panel. Ensure sufficient supply of fuel gas is being supplied, all valves are open, and connections are properly tightened. Natural Gas-25-27PSI/ Propane 15-17PSI Check for proper wiring from control panel up the stack to igniter. Refer to electrical schematics. Venturi hood may be out of alignment giving poor air/ fuel mixture to the re-light tube. Call our service line for assistance. Check electrode for good connection, electrode may need adjustment or replacement, Call our service line for assistance. Flare ignitor often goes out or has hard time staying lit. Severe wind may temporarily snuff the pilot; however the temperature sensing thermocouple will continuously monitor pilot temperature and relight the pilot after it has sensed a drop in pilot temperature of more than 400 Celsius. The pilots are designed to stay lit under the most extreme environments, however these events do occur. If repeated failure occurs call our service line for assistance. Ensure sufficient supply of fuel gas is being supplied and all valves are open. Natural Gas-25-27PSI/ Propane 15-17PSI Fuel filters on the fuel gas assembly at the base of the flare stack, or the fuel filter attached to the base of the pilot may be plugged and need replacing. Orifices may be plugged on fuel gas injectors located in the venturi assembly. One is located just left of the sparker module at the base of the igniter, the second is attached to the fuel gas tubing that runs to the igniter tip through the body of the igniter. Loosen adjustment nut on the fuel gas attachment at the base of igniter and slide out for inspection. Refer to Pilot Ignition Procedure.

12 12 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. Change fuel filter. Annual minimum inspection. If using contaminated fuel inspection must be done every six months. Solar Panels Use multi meter to confirm solar panel is delivering a charge to the batteries annually. Batteries Batteries must be load tested and inspected to confirm they are in proper working condition annually.