manual utility flare - h15028

8/19/2019 Manual Utility Flare - H15028

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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



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





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





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)





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




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




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.




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.





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





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





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.






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






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






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




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.




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.




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.





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





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.




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





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





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




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




Appendix A

a.

General Arrangement Drawing

b. Pilot / Ignition System

c. Spare Parts List / Contact Information

d. Sub-vendor Drawings / Data Sheets



R E L A Y

D O W N S C A L E

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