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Innovative liquid vaporizing and gas mixing solutions
Operations & Maintenance
Manual
151 South Michigan Street, Seattle, Washington, USA 98108
Tel: 206-789-5410 Fax: 206-789-5414 Web: www.algas-sdi.com
FILE: MANUAL PN 52635 REV 06-02-16 FLARESTACK.DOC
06/14/2016
Introduction 1
DESCRIPTION
Algas-SDI FLARE STACK burns unwanted combustible hydrocarbon gases.
When the flare stack starts, a flame safeguard controller energizes an ignition
transformer, opens a pilot valve, and ignites a gas pilot. A flame detector then
verifies the pilot flame. After the flame is detected, the status contacts in the
control panel close, allowing primary gas valves (by others) to open. Gas flows
through the fire check and out the flare stack. The unwanted gas is then lit by
the pilot flame.
When the flare stack is stopped, the status contacts in the control panel are
open, allowing the primary gas valves to close. The pilot valve closes,
extinguishing the pilot flame. If the pilot flame is not detected, the status contacts
in the control panel open, allowing the primary gas valves to close. The system
activates an alarm and must be manually reset.
Algas-SDI Operations & Maintenance Manual – P/N –52635 1-1
Introduction
Figure 1 – Components (Typical)
Components.wmf
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Introduction
PILOT ASSEMBLY DETAIL
1. Spark igniter rod
2. Spark igniter cable
3. Flame rod
4. Flame rod cable
5. Adjustable orifice assembly
MAIN COMPONENTS
6. Control box
7. Flare stack upper assembly
8. Flare stack lower assembly
9. Mounting base
10. Pilot gas supply tubing
11. Pilot Solenoid Valve
12. Pressure gauge
13. Pilot regulator
14. Pilot shut-off valve
15. Fire check valve (Optional)
16. Drain plug
Algas-SDI Operations & Maintenance Manual – P/N – 52635 1-3
Installation 2
WARNING
The equipment described in this manual is designed to operate with
LP-gas, a flammable fuel under pressure. The nature of the
application involves inherent hazards that could result in injury.
ONLY a trained and fully qualified person should service this
equipment.
WARNING
Before starting, be sure control box and Flare Stack assembly have
a good ground connection. The ignition transformer requires a
good ground connection. Grind paint off mounting panel and
transformer mounting foot for a good connection. Use locking star
washers to mount transformer.
Install the flare stack in accordance with applicable codes and local regulations,
as required.
Installation requirements vary according to local, provincial and state
requirements. Consult state, provincial, and local authorities as well as
insurance carriers for installation requirements.
ASSEMBLY OF COMPONENTS
The following separate items compose the flare stack and require assembly by
the installer. Refer to the installation/equipment drawing assembly.
1. Base, lower assembly and control box.
2. Upper assembly with stainless steel head, flame rod, and spark ignitor.
3. Fire-check valve. (Optional)
4. Copper tubing for gas pilot.
Clamps, screws, and nuts for mounting the copper tubing to the stack.
Mounting brackets are included.
5. Wiring for spark ignitor and flame rod.
Clamps and fasteners for mounting the cable to the stack.
Mounting brackets are included.
Additional items not supplied but required for installation are:
1. Automatic shut-off valve.
2. Manual shut-off valve.
3. Reinforced concrete pad at least four inches thick, with “J” bolts.
Algas-SDI Operations & Maintenance Manual – P/N –52635 2-5
Installation
Figure 2 – Installation (Typical)
Installation.wmf
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Installation
WARNING
DO NOT use TEFLON tape or compounds with TEFLON content as
an oil or gas pipe sealant. TEFLON can cause valves to fail,
creating a SAFETY HAZARD. Warranties are nullified and liability
rests solely with the installer when evidence of TEFLON is found.
LOCATION
Install the assembled flare stack outside on an appropriately sized level concrete
pad. A typical installation of a flare stack is shown in Figure 2 – Installation.
PIPING
Prior to making final piping connections, clean all foreign material from the pipes.
Connect the waste gas piping to the flare stack. Piping thread sealant
conforming to AGA No. 4-90 is recommended.
Connect the pipe inlet to the LPG vapor from the first stage regulator, See Data
Sheet for regulator setting.
NOTE
Thread sealant conforming to AGA No. 4-90 is recommended.
ELECTRICAL SERVICE
Make electrical service connections to the control box. Bring conduit through the
side or bottom of the control box’s enclosure. Connections to the control box
must be watertight. The installer should provide a disconnect. See Data Sheet
for electrical service requirements.
In the U.S., all wiring should comply with U.S. NFPA 70, state and local codes.
In other countries, wiring should comply with applicable governing codes and
standards.
An electrical ground must be connected to the control box. The ground lug is
located on the inside of the control box and identified by a green colored ground
label. Applicable codes and standards determine the size of the ground wire.
A dry contact is provided at the control box for controlling the automatic shut-off
valve.
VALVE REQUIREMENTS
Both an automatic shut-off valve and manual shut-off valve must be installed on
the inlet side of the Firecheck valve. The manual valve must be a full port gas
cock or gate valve. The automatic shut-off valve must have a twenty-five second
opening rate and a five-second closing rate.
Algas-SDI Operations & Maintenance Manual – P/N – 52635 2-7
Startup 3
OPERATIONAL SETTINGS
All operational settings were made at the factory. However, settings may require
minor adjustments.
ELECTRICAL CONNECTIONS
Check that the voltage to the control panel is correct by testing the line with a
voltmeter. Refer to the data sheet for correct voltage.
STARTUP PROCEDURE
1. Close the manual waste gas shut-off valve.
2. Purge the air from the pilot inlet line.
3. Turn on the power at the control cabinet.
4. Rotate control switch to START. This lights the gas pilot.
5. Adjust the regulator per the data sheet and adjust the orifice per the pilot
adjustment procedure.
6. To prepare the Firecheck valve for normal operation, the TEST-SET disk must
be in the SET position. See the setting indicator in the drawing. Insert the
wrench through the hole in the reset stud and pull it to the open position as
shown. This will cock the valve disk.
CAUTION
Do not exceed 15 psig when testing the Firecheck valve. Should
leaks develop between the surfaces of the bottom cover and the
body, disassemble, clean the machined surfaces and re-grease with
Exxon “Andok B” or Shell “Cyprina RA” or any equivalent NLGI
grade3 grease. Refer to the Selas Instruction Bulletin FC-1A
enclosed for instructions.
Figure 3 – Fire Check Valve Settings
Fire Check Valve.wmf
Algas-SDI Operations & Maintenance Manual – P/N –52635 3-9
Operation 4
WARNING
The equipment described in this manual is designed to operate with
LP-gas, a flammable fuel under pressure. The nature of the
application involves inherent hazards that could result in injury.
ONLY a trained and fully qualified person should service this
equipment.
WARNING
LPG is explosive and extremely flammable. Appropriate safety
procedures must be observed when installing, starting, and
operating the system. Any leak anywhere in the system is
extremely dangerous and should not be tolerated. This equipment
produces an open flame so if there is any evidence of unburned
gas, shut down the system. If any leak is detected the entire
system must be shut down, power turned off, lines bled to zero.
The leak must be properly repaired.
CAUTION
Before starting the flare stack, check for leaks. Check all
connections using an appropriate leak detection solution or device.
Even small leaks are unacceptable! ELMINATE ALL LEAKS PRIOR
TO OPERATION!
WARNING
During initial startup, the operator must be on constant alert for
emergency conditions such as fuel leaks, electrical malfunctions,
etc. The location of all manual shutoff valves and disconnect
switches should be clearly in mind so the system can be quickly
shut down if necessary.
Algas-SDI Operations & Maintenance Manual – P/N –52635 4-11
Operation
STARTING THE FLARE STACK
1. Close the manual waste gas shut-off valve
2. Rotate control switch to START. This lights the gas pilot.
3. When the pilot ignites, the run indicator will be lit. Open the manual waste
gas shut-off valve
4. The automatic shutoff valve will open and the flare stack will start burning
gas.
STOPPING THE FLARE STACK
1. Close the manual waste gas shutoff valve.
2. Once all of the gas has burned, turn the power switch to the OFF position.
FIRECHECK VALVE
When a backfire occurs in the flare stack piping, any resulting shockwave
immediately closes the check valve, and the combustion is arrested. The valve
must be reset after a backfire.
If the bimetal strips inside the valves are damaged, they must be replaced. The
valve cannot be re-opened with damaged bimetal strips. The strips can be
inspected by removing the valve cartridge from the bottom of the valve and
inspecting the strips located on the top of the valve mechanism. Refer to the
maintenance section of the Selas Instruction Bulletin FC-1A for replacement of
the strips.
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Maintenance 5
WARNING
Improper installation, adjustment, alteration, service, or
maintenance can cause injury or property damage. Refer to this
manual and the manuals in the Appendix for information. For
assistance or additional information, consult a qualified installer or
Algas-SDI directly.
CAUTION
In accordance with OSHA standard 1910.147, all equipment,
machines, and processes shall be locked out prior to servicing.
ONLY FULLY TRAINED AND QUALIFIED PERSONNEL MUST DO
SERVICING.
CAUTION
When performing any service, shut off all electrical power, close all
supply valves, bleed the gas lines to zero pressure, purge them,
and vent any gas to a safe location.
WARNING
LPG is explosive and extremely flammable. Appropriate safety
procedures must be performed when all maintenance procedures
are performed.
Algas-SDI Operations & Maintenance Manual – P/N –52635 5-13
Maintenance
Table 1 – Flare Stack Maintenance Schedule
DESCRIPTION WEEKLY MONTHLY ANNUALLY
Firecheck valve Remove cartridge, clean
Test for freedom of
screen, inspect bimetal
(see Selas Instruction movement –
strips, and check pressure
Bulletin FC-1A) valve should snap shut.
loss.
Check operation, flame
Pilot flame signal strength, recycle Check operation.
controls.
Flame rod Check operation.
Spark ignitor Check operation.
Check operation of switch Remove cover and
Control box
and push buttons. check wiring.
Visually check for broken
Wiring Check voltage.
or loose wires.
Solenoid valve Check operation. Check, Rebuilt if required.
Pilot regulator Check settings, operation. Clean, Rebuild if required.
Visually inspect and clean if Check operation and adjust
Orifice assembly
necessary. if necessary.
Automatic shut-off valve Check operation. Rebuild if required.
Piping Check for leaks.
Bleed lines and
Drain plug
drain heavy ends.
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Maintenance
Firecheck Valve
MONTHLY CHECKS
NOTE
All checks of valve operation must be made without the LPG/air
mixture in the piping. Bleed all lines before conducting the test.
DETERMING THE FREEDOM OF VALVE MOVEMENT
Conduct the test by loosening the two socket head cap screws which hold the
manual test disk secure, then turn the disk as far as the slots will allow to TEST
position, whereupon the valve should snap shut. If the valve is sluggish or fails
to shut, the valve stem and screen busing should be cleaned and the test
repeated.
After a satisfactory test, the manual disk must be returned to the SET position
and locked by tightening the two socket head cap screws. The valve is now
ready to be reset. Check the clearance between the reset stud and the TEST-
SET disk. Sufficient clearance is required to prevent binding.
ANNUAL CHECKS
DETERMINE PRESSURE LOSS THROUGH THE VALVE
Pressure loss through the Firecheck valve can be measured by using the two-
plugged pipe connections located near the inlet and outlet of the valve. If there is
a pressure drop of more than five inches of water column, the screen should be
removed and cleaned. Refer to the Selas manual for cleaning instructions.
BIMETAL STRIPS
Inspect the bimetal strips annually by unscrewing the hex head screws and
pulling the cartridge from the valve body. Check for distortion or discoloration
(light blue to blue-black) due to over-heating. Discolored or distorted strips must
be replaced. The strips can be inspected by unbolting the valve assembly from
the valve body, allowing the valve assembly to be lowered and checking the
bimetal strips on the top of the valve mechanism. Refer to the Firecheck manual
for details.
Algas-SDI Operations & Maintenance Manual – P/N –52635 5-15
Maintenance
Checking the Pilot Pressure Regulator and Inlet Solenoid
( Applies to models built before December 31, 2007 )
MONTHLY CHECKS
1. Both the regulator and inlet solenoid can be tested with a pressure gauge
inserted in the plug fitting above the pilot regulator.
2. To test both the regulator and solenoid valve, close the manual shutoff valve,
turn off the power, remove the NPT plug above the regulator and install a
suitable pressure gauge.
3. Open the manual shutoff valve, turn on the power and start the flare stack.
See Data Sheet for regulator setting value. A correct pressure reading
indicates that both the regulator and solenoid are working properly.
4. With the system operating, turn the power switch to OFF, shutting down the
flare stack. The pressure should drop to “0”. If there is any pressure
reading, the solenoid is not closing and must be repaired.
5. If either component malfunctions, shut down the system, bleed the lines, and
repair or replace them.
NOTE
When re-installing the plug, use an appropriate sealer to ensure that
it does not leak.
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