Martinsville User Manual

8/12/2019 Martinsville User Manual

1/116

User Manual

Unit # 2171

Martinsville

Model # PCFT828I6


2/116


3/116

Table of Contents

Volume I

I. SYSTEM DESCRIPTION ......................................................................................................... 5A. Landfill Gas Utility Flare.................................................................................................. 5B. Control Systems ............................................................................................................. 8

II. QUICK START GUIDE: .......................................................................................................... 14A. Manual Startup ............................................................................................................. 14B. Automatic Startup ......................................................................................................... 15

III. CONTROL SYSTEM OPERATION: ....................................................................................... 16A. Detailed Startup Sequence .......................................................................................... 16B. Utility Flare FT-3 Automatic Startup Flow Chart ........................................................... 19C. Operator Interface Operation and Screen Descriptions ............................................... 23

IV. MECHANICAL OPERATION.................................................................................................. 37A. Drains ........................................................................................................................... 37

V. MAINTENANCE ..................................................................................................................... 39A. Utility Flare Maintenance .............................................................................................. 39B. BLOWERS AND FANS LUBRICATIONS ..................................................................... 40C. Flare Routine Maintenance Schedule .......................................................................... 47D. Service Contacts .......................................................................................................... 52

VI. TROUBLE SHOOTING .......................................................................................................... 53A. Flare Alarms ................................................................................................................. 53B. Possible Alarm Causes ................................................................................................ 54

APPENDIX A CHEAT SHEETS ..................................................................................................... 66A. Auto dialers .................................................................................................................. 66B. Chart Recorders ........................................................................................................... 70C. Controllers .................................................................................................................... 73D. PLC .............................................................................................................................. 76E. Timers .......................................................................................................................... 77

APPENDIX B PROPOSAL .............................................................................................................. 78APPENDIX C - DRAWINGS .............................................................................................................. 79APPENDIX D MISC. ....................................................................................................................... 80APPENDIX E EQUIPMENT CUT SHEETS .................................................................................... 81

A. Components List .......................................................................................................... 81B. Component Literature ................................................................................................... 82


4/116


5/116

I. SYSTEM DESCRIPTION

The below sections are a general description of flare systems and their associatedequipment. Please refer to APPENDIX B - PROPOSAL and APPENDIX C - DRAWINGS forfurther details specific to this system.

A. Landf il l Gas Uti li ty Flare

1. Standard Equipment

The following items come standard on all utility flare stacks:

Flare Stack Schedule 40 carbon steel stand pipe with self supporting baseand ANSI 150-lb. flanged inlet.

Burner AssemblyThe Triton Twister burner assembly is all 304 stainlesssteel construction and includes an integral windshield. The Twisters uniqueside nozzle design aids in flame stability and provides a 10:1 turndown range.(Proper blower and drive selection may be required to realize the full 10:1turndown range). Also includes the Auto Carb, an automatic throttling deviceadded to the burner design to further improve flame stability. This helpsprevent nuisance shut downs under low flow, high wind conditions.

Igniter Assembly The igniter is a small burner used to light the mainburner. Typically fueled with bottled propane gas, the igniter assemblyconsists of a 304 stainless steel burner tube with spark plug ignition and typeK thermocouple for flame confirmation. The spark plug is supplied with hightemperature leads and a transformer in a NEMA 4 enclosure.

Flame SupervisionConsists of both a thermocouple and ultraviolet flamedetector used to confirm flame integrity.

Flare system controllers Utility flares use either the Flame-Trol I relay

based or III PLC based control systems. These are technically advanced, fullyautomatic flare system controllers specifically designed to obtain themaximum operating flexibility and efficiency.

Freestanding Support Support base is designed to be anchored to asuitable concrete foundation, supplied by others, and does not rely upon guywires for additional support. Guy wires may be required if concrete foundation(by others) is not suitable to support free standing flare.

Flame Arrestor This device prevents flame flash back in the event of highoxygen concentrations in the landfill gas. The standard flame arrestor isequipped with an aluminum tube bank assembly.

Hinged Stack The flare stacks are typically provided with a hinge to assist

in shipping skid mounted units. Non skid mounted flares are shippedhorizontally and do not require a hinge.

2. Optional Equipment

The following standard options are available on utility flare stacks:

Corrosion Resistance This option should be used when handling landfillgas which contains more than 1000 ppmv of H2S, which is corrosive.Selecting this option changes the following equipment selection:


6/116

Burner construction upgraded from Schedule 10, 304 stainless steel toSchedule 40, 310 stainless steel.

Flame arrestor tube bank assembly upgraded from aluminum to 304stainless steel.

Conduit may be upgraded from galvanized steel to PVC coated steel.

Guy Wire Support- Guy wire mounting points for use of guy wires to providelateral support from wind loading.

Continuous Pilot An auxiliary pilot may be operated in a continuous fashionto keep the flare operating under low or intermittent flow conditions. Suchconditions are typical on systems which deliver gas to off-site users. Toreduce propane consumption, continuous pilots are sometimes operated onlandfill gas.

Fuel Enrichment Landfill gas which contains methane at concentrationsbelow the recommended low limit of 30% (or 300 Btu/scf) may still be reliablyburned by enriching the gas stream with supplemental fuel, such as natural

gas or propane.3. Standard options are available on blower skids:

Ai r Compressor The inclusion of a small air compressor and dryer may bedesired when a shut off valve or modulating valve is equipped with apneumatic actuator. The air compressor includes an air receiver and the dryeris a heatless regenerative type.

Blower Bearing Temperature Measurement Blower bearings may havetheir temperatures measured to aid in maintenance operations. High bearingtemperature is an indication of lubrication problems or excessive wear.

Blower Vibration Monitoring Blowers may be monitored for excessivevibration. Vibration is usually caused by out of balance impellers and maycause premature bearing failure. The vibration monitor is a switch with anadjustable set point.

Condensate Transfer The condensate collected by the knock out pot(KOP) needs to be drained occasionally. If the KOP is to be drained to alocation at atmospheric pressure during times of normal flare operation, thenpumps may be required to move the condensate out of the KOP. Thecondensate transfer system contains all the necessary pumps, switches,valves and associated piping to accomplish this task.

Corrosion Resistance This option should be used when handling landfillgas which contains more than 1000 ppmv of H2S, which is corrosive.Selecting this option changes the following equipment selection:

The KOP would be changed from carbon steel to HDPE plastic.

Process piping is upgraded from Standard Schedule carbon steel toSchedule 10, 304 stainless steel.

Conduit would be upgraded from galvanized steel to PVC coated steel.


7/116

Demister Pad The 20 micron demister pad normally supplied in the KOPmay be replaced with a 10 or 5 micron pad for greater mist capture efficiency.Capturing smaller particles will result in greater pressure drop across thedemister pad.

Flow Control Flow control is sometimes required when delivering gas to 2

flares or other gas users. Flow control is typically accomplished by using amodulating damper in one or more of the gas delivery lines.

Gas Analyzer Used to determine concentrations of O2, CH4, CO and CO2inthe landfill gas stream. The analyzers can be used as a diagnostic tool to aidin running the landfill and the flare system, and are also useful in identifyinggas composition when delivering gas to an off-site gas user. Analyzers areavailable to monitor any combination of the above mentioned gas species andare mounted in a separate enclosure.

Gas Delivery Landfill gas has a high concentration of methane (30% to 60%vol), and may be considered a valuable fuel source. A gas delivery systemdiverts landfill gas from the flare to a gas delivery line at a specified pressurefor use by others. Modulating valves with pneumatic actuators are typicallyused to control the gas delivery pressure.

Heat Tracing and Insulation Landfill gas is saturated with water vapor, andcondensate collected in the knock out pot (KOP) and drain lines can freezeunder cold weather conditions. The KOP and drain lines may be equippedwith heat tracing and insulation to prevent freezing.

Pressure Control The well field header may have its pressure (vacuum)controlled to improve the performance of the landfill as a gas generator.Pressure control is typically accomplished by using a VFD on the blowermotor.

Process Pipe Coating The inside of carbon steel process piping may be

coated to prevent rust or corrosion. Coatings are best applied to systems withmultiple blowers where one or more blowers may be unused for extendedperiods of time. Such unused blowers will act like condensate traps, and themoisture will promote rust within the associated piping.

Process Pipe Stainless Construction The process piping material ofconstruction is AISI 304 stainless steel. This material resists most forms ofcorrosion, inside and out, and does not need to be painted or coated on eitherits inside or outside surfaces.


8/116

B. Control Systems

1. Standard Equipment

LFG Specialties offers several standard control systems, each one designedfor a particular product and option selection. Each control system type has its

own list of standard equipment, and PLC based systems have their ownprograms unique to their specific applications. The following equipmentcomes standard with each indicated Flame-Trol (FT) system.

Description FT - 1 FT - 3 FT - 4 FT - 5 FT - 6

Equipment Application

Utility Flares X X X

Enclosed Flares X X

Platform

Relay Logic Based X

PLC Based X X X X

Manual Controls

Hard wired X X X

Soft wired X X

Equipment and Functions

Blower Control X X X X X

Blower Current Monitoring X X

Burn Schedule Timer X X X X X

Chart Recorder X X X X X

Flame Detection X X X X X

Inlet Valve X X X X X

KOP Level Detection X X X X X

Landfill Gas Flow Measurement X X X X X

Operator Display, Text X X X X X

Pilot Ignition X X X X X

Power Quality Monitoring X X X X X

Stack Purge X X

Temperature Control X X

Thermocouple Selection X X


9/116

The following are Standard Equipment and Function Descriptions

Relay Logic Based Control Platform: All FT-1 control systems are made upof more traditional relay logic type control devices. This type of control systemcan meet certain requirements, but does not offer the flexibility to be easilychanged, or reprogrammed, to meet unique site specific needs.

PLC Based Control Platform: All Flame-Trol control systems, with theexception of the FT-1, are controlled with an advanced programmable logiccontroller (PLC). A plc controlled system offers the most flexibility, allowingthe system to be changed and programmed to meet unique site specificneeds.

Hard Wired Manual Controls : Manual controls allow the flare to be operatedunder the supervision and control of an on-site operator. The automatic plccontrol system is completely bypassed. All controls consist of hard wiredselector switches and push buttons.

Soft Wired Manual Controls: Manual controls allow the flare to be operatedunder the supervision and control of an on-site operator. The automaticfunctions of the plc control system are bypassed. The manual controls,however, reside within the plc control system. All controls, including selectorswitches and push buttons, are graphically represented on the color touchscreen display.

Blower Control: Blowers are started and stopped automatically in responseto user commands and system alarms.

Blower Current Monitoring: The electric current flowing to the blowermotors is monitored to ensure operation within safe limits.

Burn Schedule Timer: This device allows the operator to schedule when theflare is to operate, either on a calendar basis, or on a Time On / Time Off

basis. This feature is useful when landfills are producing gas at flow rates ator below the minimum limit of the flare, and continuous flare operation is notpossible.

Chart Recorder: A chart recorder allows for historical process datarecording. Typical recorded variables would be process temperatures andmeasured landfill gas flow. A paperless recorder is standard and records dataelectronically to memory. This data can be viewed at the recorder, or laterretrieved and analyzed using advanced computer software. A circular papertype recorder is also available.

Flame Arrester Temperature Monitoring: Flame arrestor is monitored todetect flame flashback. Flame flashback is a sign of high oxygen levels in the

landfill gas and can damage equipment.Flame Detection: Flare flame detection is accomplished using both UV lightbased detectors and thermocouples. Maintaining a flame within thecombustion zone is important for proper landfill gas combustion, and thereforea requirement for the flare operation.

Inlet Valve: Electric or pneumatic operated butterfly valve is used to admitlandfill gas to the blower skid. Valve is fail closed to ensure safe operation ofsystem in event of power or signal failure.


10/116

KOP Level Detection: Measures condensate liquid level for high levelconditions which can be damaging to blowers.

Landfill Gas Flow Measurement: Landfill gas flow is measured using aprecision flow meter. Typical measurement is done in standard cubic feet perminute (SCFM). The measured flow is displayed and can be recorded on a

chart recorder. Flow totalizing is also available. Standard measurementtechniques include thermal dispersion and averaging Pitot tube type meters.

Operator Display, Text: The text based operator display provides basicaccess to control functions. All control, alarm and scaling set points areavailable for adjustment. Current process conditions and alarm history arealso provided.

Pilot Ignition: All landfill gas flares have a primary ignition system, typicallyusing a propane gas source. This insures the flare temperatures are suitablefor the proper combustion of landfill gas. A pilot thermocouple is used tomeasure temperature.

Power Quality Monitoring: Because electrical power quality can vary at

certain remote sites, monitoring for power dips or surges allows the controlsystem to safely shutdown equipment before potential damage occurs.

Purge Blower: Purge blowers are installed on enclosed flares, complete withflow sensing, to safely remove any landfill gas accumulations prior to ignition.

Stack Purge: This function uses a purge air blower to eliminate anyunwanted, potentially dangerous gases from the enclosed flare stack prior tostartup.

Temperature Control: Automatic temperature control is used to maintain acontrolled temperature within the landfill gas combustion zone of an enclosedflare. A precise temperature controller is used along with motorized louverdampers to permit cooling air flow.

Thermocouple Selection: Enclosed flares are equipped with three or fourthermocouples which monitor the combustion space temperature. Theappropriate thermocouple to be used as the temperature control thermocoupleis automatically selected based on landfill gas flow rate.


11/116

2. Optional Equipment

There are numerous options available for the various Flame-Trol controlsystems. Some options are concerned with the control system itself, andothers are used in conjunction with options selected with the flare or blowerskid products.

The table below identifies which options are available on each Flame-Trol (FT)control system.

Optional Equipment Description FT 1 FT 3 FT 4 FT 5 FT 6

Application Utility Flares X X X

Application Enclosed Flares X X

AC - Air Conditioning X X X X X

AD - Auto Dialer X X X X X

BTM - Bearing Temp. Measurement X X X X X

BVM - Blower Vibration Monitoring X X X X X

CA - Compressed Air X X X X X

CI - Condensate Injection X X

CT - Condensate Transfer X X X X X

CP - Continuous Pilot X X X X X

FC Flow Control X X X X X

FE - Fuel Enrichment X X X X X

GA - Gas Analyzer X X X X X

GD - Gas Delivery X X X X X

HT - Heat Tracing & Insulation X X X X X

ODG - Operator Display, Graphics X X

PC - Pressure Control X X X X X

RDC - Remote Data Collection X X X X X

UPS - Uninterruptible Power Supply X X X X X

The following are optional Equipment and Function Descriptions

AC - Ai r Condi tion ing: Available on both control panels and power panels.Air conditioning may be required when control systems are installed at highambient temperature sites. Air conditioning will also be required when controlsystems are located at cold sites which necessitated the use of insulationinside the enclosures.


12/116

AD - Auto Dialer: These devices are used to automatically call the siteoperator in the event of a flare problem, and indicate the nature of theproblem. Auto dialers are available with 4 to 10 channels (report 4 to 10different kinds of problems), and may use land line or cellularcommunications.

BTM - Bearing Temperature Measurement: Temperature measurement ofthe blower bearings can help detect mechanical wear of the bearing assemblywhich can assist in scheduling system maintenance.

BVM - Blower Vibration Monitoring: Blowers may be monitored forexcessive vibration. Vibration is usually caused by out of balance impellersand may cause premature bearing failure. The vibration monitor is a switchwith an adjustable trip point.

CA - Compressed Air: The inclusion of a small air compressor and dryermay be desired when a shut off valve is equipped with a pneumatic actuator.The air compressor includes an air receiver and the dryer is a heatlessregenerative type.

CI - Condensate Injection: These systems are used to dispose of collectedcondensate by injection into the enclosed flare for thermal destruction. Thesystem includes the necessary pumps, filters, valves, gauges, spray nozzlesand connecting piping to handle 2 gpm of condensate. A flow totalizer is alsoincluded.

CT - Condensate Transfer: The condensate collected by the knock out pot(KOP) needs to be drained occasionally. If the KOP is to be drained to alocation at atmospheric pressure during times of normal flare operation, thenpumps may be required to move the condensate against the vacuum presentin the KOP. The condensate transfer system contains all the necessarypumps, filters and associated piping to accomplish this task.

CP - Continuous Pilot: An auxiliary pilot may be operated in a continuousfashion to keep the flare operating under low or intermittent flow conditions.Such conditions are typical on systems which deliver gas to end users. Toreduce propane consumption, continuous pilots can be operated on landfillgas.

FC Flow Control: Flow control is sometimes required when delivering gasto 2 flares or other gas users. Flow control is typically accomplished by usinga modulating damper in one or more of the gas delivery lines.

FE - Fuel Enrichment: Landfill gas which contains methane at levels belowthe recommended low limit of 30% (or 300 Btu/scf) may still be reliably burnedby enriching the gas stream with supplemental fuel, such as natural gas or

propane.GA - Gas Analysis: Landfill gas analysis can identify the levels of variousgas species present in the landfill gas. Typical gas species monitored includeoxygen, methane, carbon dioxide, and carbon monoxide. In addition tomonitoring these gases, alarm limits (both hi and low) can be set to warn ofunwanted or unsafe process conditions.


13/116

GD - Gas Delivery: Landfill gas has a high concentration of methane (30% to60% vol), and may be considered a valuable fuel source. A gas deliverysystem diverts landfill gas from the flare to a gas delivery line at a specifiedpressure for use by others. Examples of landfill gas use include using the gasto run generators for the production of electricity, or using the gas in anindustrial environment to produce heat. This option includes the addition of a

modulating valve controlling flow to the flare, and a shutoff valve controllingflow to the gas user.

HT - Heat Tracing: Landfill gas is saturated with water vapor, andcondensate collected in the knock out pot (KOP) and drain lines, or analyzersample lines, can freeze under cold ambient conditions. These lines may beequipped with heat tracing and insulation to prevent freezing.

ODG - Operator Display, Graphics: The graphical operator display allowsfor more detailed graphical symbols representing the flare equipment andprocess measurements. Advanced alarm capabilities, including alarm history,also allow easy access to diagnostic information. Set point adjustments aremade using the display touch screen, lending itself to a user friendly operator

interface.

PC Pressure Control: The well field header may have its pressure(vacuum) controlled to improve the performance of the landfill as a gasgenerator. Pressure control is typically accomplished by using a VFD on theblower motor.

RDC - Remote Data Collection: All data viewable on the Operator Interfacescreens are viewable from a remote location. This allows site operators andmanagers to view process information and change process set points fromtheir office. Also, if the unit is equipped with a paperless chart recorder, theflare process data can be downloaded. This option may be operated withcopper, fiber or wireless broadband communications.

UPS - Uninterruptible Power Supply: Sites with electrical power issues willbe able to ride thru a brief power brown out without incurring a nuisance flareshutdown. During extended power loss a controlled shutdown is initiated,protecting the instrumentation from data loss and potential damage. Uponreestablishing power, the flare will re-start automatically and an alarm willindicate the system has experienced a power related shutdown.


14/116

II. QUICK START GUIDE:

A. Manual Startup

1. Turn the Master switch to the ON position. Place the E-Stop button in the

extended position. Press the Reset button.2. Turn the Control Mode switch to the Manual position.

3. Turn the Pilot Gas switch to the ON position and then to the Ignite position.Return to the On position once the pilot gas has been ignited. This can beconfirmed either visually or by a rising pilot temperature.

4. Turn the Inlet Valve switch to the Open position, which will open the valve andallow the landfill gas to flow to the flare.

5. Turn the desired Blower switch(es) to the Manual position, which will start thegas blower.

Note: It is VERY IMPORTANT to monitor the landfill gas ignition in the

next step, since large volumes of gas can be sent into the flare. If thetemperature does not change within the time specified, discontinue theStartup immediately. Then determine why the landfil l gas failed to ignite.

BEFORE ATTEMPTING ANOTHER START SEQUENCE IT IS VERYIMPORTANT TO PURGE ANY GAS OUT OF THE FLARE STACK BEFOREATTEMPTING TO START IN ANY MODE OF OPERATION. (Enclosedflares only)

6. The landfill gas will be ignited. The flame can be confirmed either visually orby a rising process temperature. The process temperature should begin torise in 1 to 2 minutes.

7. Turn the Pilot Gas switch to the OFF position.

8. The utility flare system is now operating in manual mode.

9. The flare can be shutdown by turning the Master switch to the OFF position orby pushing the E-Stop button.

10. The control system is equipped with a Manual Max Run Timer. This timer isactivated once the system is switched to the manual mode. If the system isleft running for an extended period of time in the manual mode, the timer willeventually shut the system down.

Note: The flare system should not be left operating unattended in manual mode asall system permissives and safety shutdowns are bypassed.


15/116

B. Automatic Startup

1. Check the pilot temperature control set points.

The control system uses two signal outputs which are used to sequenceevents during start-up. These are:

a. Blower-On Temperature - Factory set to 300 F. This is thetemperature at which the blower will be started and the header valveopened.

b. Pilot-Off Temperature - Factory set to 400 F. This is the temperatureat which the pilot gas solenoid will be closed, shutting off the pilot.

2. Check the Pilot Timer set point.

The purpose of the Pilot Timer is to specify a set period of time to allow the pilotsystem to attain the pilot-off temperature. For instance, if the Pilot Timer hasbeen set at five minutes and the pilot-off temperature is set at 400 F, the pilotwill have five minutes to heat the thermocouple to 400 F. If the pilot system

fails, due to an exhausted pilot gas supply or other reasons, to attain the pilot-offtemperature in the time period allotted the entire system will shutdown.

3. Check the Ignition Timer set point.

The purpose of the Ignition Timer is to control the sparking period of the sparkplug during start-up. This timer has been set at the factory at fifteen secondswhich allows a constant sparking action by the igniter for this period of time.This should be adequate time to purge the pilot gas line of air and ignite the pilotgas. This timer should never need to be altered.

4. Turn the Master switch to the ON position and press the Reset button. Placethe E-Stop button in the extended position.

5. Turn the Control Mode switch to the Auto position. The control system will nowrun through the automatic start-up sequence.

Once the automatic startup is completed, all permissives and shutdowns of thesystem are activated. For operation of the system beyond this point refer to theControl System Operation section of this manual.


16/116

III. CONTROL SYSTEM OPERATION:

A. Detai led Star tup Sequence

1. Pre-Start Checklist

The following lists startup conditions that must be met to permit an automaticstartup sequence of the enclosed flare system:

a. Master switch in the ON position

b. E-Stop button in the extended position

c. Absence of any alarm conditions - The red flashing alarm beacon(located on top of the control panel) and the operator display willindicate if there are any alarm or fault conditions present. All faultconditions must be cleared to permit a start sequence.

d. Inlet valve in the closed position

e. Pilot temperature below the Blower-On set point

f. Absence of any flame

g. Control Mode switch in the Auto position

2. Ignition (Pilot ) Cycle

The ignition cycle establishes an initial flame and heat source to generateadequate temperature prior to introducing the flow of landfill gas.

A pilot gas source, in conjunction with automatic spark ignition, is used toestablish the initial flame. Propane is typically used for the pilot gas source.

The Ignition Timer set point is adjustable (typically 15 to 30 seconds.) A pilotthermocouple is used to monitor the pilot gas flame and is used to determinewhen to start the gas blowers (Blower-On set point) and open the headervalve, allowing the flow of landfill gas. The pilot temperature measurement isalso used to determine at what temperature (Pilot-Off set point) to discontinuethe use of the pilot gas.

The Pilot Timer is used to indicate pilot system malfunction or failure and isuser adjustable (typically 5 minutes.) If the pilot temperature does not reachthe Pilot-Off set point before the Pilot Timer times out, a pilot fault will occur.

3. Combustion of Landfill Gas

Landfill gas is drawn from the landfill and sent into the flare stack for properdestruction using gas blowers.

Once adequate heat in the stack (for proper combustion) has been reached,determined by the measured pilot temperature, the gas blowers are startedand the header valve is opened. This event is determined by the Blower-Onset point (typically 300 F) which can be adjusted to meet processrequirements.


17/116

Blower startup and header valve position are monitored to ensure properequipment operation. A blower auxiliary fault or header valve fault will occur ifabnormal operation or positioning is detected.

After the combustion of landfill gas has begun, flame detection and lowtemperature detection are enabled.

4. Continuous Monitoring

Once the combustion of landfill gas has begun, certain conditions must be metto ensure proper combustion under safe operating conditions.

Ultra violet flame detection (UV eye) monitors the presence of a flame in thewind break. In the event the flame is extinguished, the pilot ignition systemwill try to re-ignite the flame. Failure to re-ignite will result in a flame faultand the appropriate shutdown actions will occur.

The landfill gas flow, typically measured in standard cubic feet per minute(scfm), is also monitored, recorded, and displayed to indicate proper flare

operation. High gas flow alarming is also in place to insure the gas flow doesnot exceed the capacity of the flare stack, which may result in and unsafeoperating conditions and equipment damage.


18/116

5. Automatic Re-start

The flare will automatically attempt a re-start under the following faultconditions:

a. Low temperature shutdown

b. Flame failure shutdown

c. Pilot Failure shutdown

An automatic re-start will occur after the Down Timer has elapsed and thetemperature has dropped to allow for a safe startup. A re-start consists of thesame sequence of events as a typical startup, beginning with the purge cycle.

A re-start limit, typically 3, is also used to limit the number of re-starts that canoccur before a successful startup has been accomplished. If the number ofrestart attempts reaches the limit, the system will shutdown and operatorattention is required.


19/116

ControlPowerON?

E-Stop onfront panelextended?

FaultMessagespresent?

Turn Control ModeSwitch to Auto

1

Check FaultMessages.Troubleshootingmay be necessary.

F

Pull E-Stopbutton on front

panel out.

Turn ControlPower SwitchON at front

Yes

No

Utility Flare FT-3

Automat ic Star tu Flow Char t

Yes

No

No

Yes

B. Utility Flare FT-3 Automatic Startup Flow Chart


20/116

Pilot GasON?

Blower Onand Header

ValveOpen?

IgniterON?

1

Igniter will spark for theduration of the ignition cycletime. Pilot gas will remain onuntil Pilot Off Temperature hasbeen reached or Pilot Cycletime has elapsed.

Blower will start and InletValve will open once theBlower ON Temperature hasbeen reached.

Any FaultMessages?

Blower OnTemp

Reached?

Pilot GasOff?

Any FaultMessages

?

Pilot OffTemp

Reached?

2 F

FF

Yes

No

No

Yes

Yes

Yes

No

No

No

No

Yes

Yes

Yes

Yes

No

No


21/116

2

Flare temperature shouldcontinue to rise, withcombustion of landfill gasonly. Flame detection isnow enabled.

Flare LowTemp

Reached?

Any FaultMessages

?

After successfullyexceeding the lowtemperature setting, theflare has started andshould run within normaloperating conditions.

Flare tempmaintained

undercontrol?

Any FaultMessages

?

Temperature controlloop may need tobe tuned for currentconditions.

F

3 F

Yes

Yes

No

No Yes

No

Yes

No


22/116

3

Vacuum /Flow

maintainedunder

control?

Any FaultMessages

?

Flow / Pressurecontrol loop may needto be tuned for currentconditions.

Auto StartupComplete

F

Yes

No

Yes


23/116

C. Operator Interface Operation and Screen Descr iptions

1. MAIN

Blower Cmd

KOP

0.0 % Inlet

0.0 A

1Closed

Screens MAIN

No Flame

0 F

Flare

Pilot

Gas

0 FPilot

0 FProcess

No Fault s

Logging Off

0.00"W.C.Inlet Prs

Outlet Prs0.00"W.C.

This operator screen is a general informative screen indicating the flareoperation and process conditions.

2. SCREENS

Blower 1

Low Temp

Flam e Pilot Inlet

Logon

Logoff

Flare Tre nd

SCREENSMain ###########

System

Day Timer

VFD In PIDIn Prs In Trend

Out Prs Flare Cntr l

ToolsBlw 1 Brng

This operator screen is simply a Main Menu of all the operator screens

available. These pushbuttons will navigate to the configuration screen ofinterest.


24/116

3. PILOT

This operator screen contains configuration input for the pilot / ignition cycle.The pilot cycle establishes an initial flame and heat source before ignitinglandfill gas.

a. Pilot Cycle Time: This time delay set point (min) is the amount oftime allowed for measured pilot temperature to reach the Pilot Offtemperature before a pilot fault will occur.

b. Blower On: This pilot temperature set point (deg F) determines whenthe landfill gas blower (s) will start.

c. Pilot Off: This pilot temperature set point (deg F) determines whenthe pilot cycle is complete.


25/116

4. INLET VALVE

This operator screen contains configuration input for the landfill gas InletValve. The inlet valve position is monitored with limit switches to insureproper operation.

a. Fail Open / Closed Fault Delay Set point: This time delay set point(sec) is the time allowed for the inlet valve to open or close, dependingon commanded position, before an inlet valve fault will occur.

b. Inlet Open Delay Set point: How long to wait prior to opening theinlet valve. Typically used with parallel gas extraction systems where

several appliances extract gas off of a common header. When suctionis applied to the header and another appliance opens its header valve,reverse flow may occur temporarily until the suctions between thesystems stabilize. This delay allows the prime mover to build somespeed / suction prior to opening the valve, limiting the opportunity forreverse flow.


26/116

5. BLOWER 1

This operator screen contains configuration input for the landfill gas blower (s).Each blower is controlled automatically and monitored to insure properoperation.

a. Low / High Amp Fault Monitoring: These set points refer to theblower running amperage. The blower running amperage shouldremain between the low and high set points for proper operation.

b. Low / High Amp Fault Delay: These time delay set points (sec)determine how long the blower running amperage can be outside of

the defined limits, high or low, before a blower fault will occur.

c. Aux Timer Set po in t: This time delay set point (sec) is the timeallowed for the blower to start when commanded to start. If the motorstarter auxiliary contact does not provide feedback that the blower hasstarted a blower fault and will occur.

d. Sequence Timer Set point: This time delay set point (sec)determines the time between blower start commands, when multipleblowers are used. This only applies when more than one blower willrun at the same time.

e. Amps Scal ing: These set points are used to adjust the controllerinstrumentation to match the blower current transmitters. Theseshould only be adjusted at the factory or by qualified personnel.


27/116

6. INLET PRESSURE

This operator screen contains configuration input for the flare inlet vacuumtransmitter. The vacuum transmitter measures the amount of vacuum (- IWC)at the inlet of the flare equipment.

a. High Vacuum Fault Set point: This set point (IWC) is the fault setpoint for the measured vacuum at the inlet to the flare.

b. Fault Delay: This time delay set point (sec) determines how long themeasured vacuum can exceed the high set point before a vacuum faultwill occur.

c. Pressure Scaling: These set points are used to adjust the controllerinstrumentation to match the vacuum transmitter. These should onlybe adjusted at the factory or by qualified personnel.


28/116

7. INLET PRESSURE VFD PID

This operator screen contains configuration input for the inlet pressure /vacuum control loop. By varying the blower speeds using variable frequencydrives (vfds), a steady controlled vacuum can be maintained at the inlet of theflare equipment. This results in a constant, steady vacuum being applied tothe landfill. The Pv (process variable) represents the measured vacuum.The Cv (control variable) represents the speed command being given to theblower (s).

a. Kp, Ki, Kd: These settings are proportional gain, integral, andderivative tuning parameters. These settings determine theresponsiveness of the controller to the process and should only be

adjusted by qualified personnel.

b. DB-, DB+: These settings are the positive and negative dead bandset points. These affect how the controller responds to a processdeviation from set point and should only be adjusted by qualifiedpersonnel.

c. Slew: This time setting (sec) affects the responsiveness of thecontroller to the process and should only be adjusted by qualifiedpersonnel.

d. Set point: This set point (- IWC) is the desired inlet vacuum. Thecontroller will control and maintain this value.

e. PID Manual Command: This is the controller output command (0 100%) when the control loop is put in manual mode. 0 to 100%represents zero to maximum blower speed.

f. PID Mode Selection: This button allows the operator to switch thecontroller mode from automatic to manual operation. While inautomatic mode, the controller will maintain the desired set point.When in manual mode the controller output will be fixed at the valueentered for the PID manual command.


29/116

8. LOW TEMP

This operator screen contains configuration input for low temperaturemonitoring. To insure proper landfill gas combustion, the proper temperaturemust be maintained. If the temperature cannot be maintained, a lowtemperature fault will occur, resulting in a flare shutdown.

a. Low Temp Set point: This temperature set point (deg F) determineswhen a low temperature condition exists, resulting in a lowtemperature fault.

b. Reset Temp Set point: If the temperature drops below the lowtemperature set point (deg F), resulting in a low temperature condition,it must then rise above this set point to clear the fault condition.

c. Start Delay Set point: This time delay set point (min) is the timeallowed, during initial flare startup, for the temperature to rise abovethe low temperature set point.

d. Shutdown Delay Set point: This time delay set point (min) is thedelay before a shutdown will occur if the temperature drops below thelow temperature set point.


30/116

9. FLAME DETECTION

This operator screen contains configuration input for flame detection.Monitoring for the presence of flame is another method of insuring properlandfill gas combustion. An ultraviolet (UV) detector is used for this function.If the flame is lost, a re-light cycle will re-ignite the pilot system in an attemptto re-establish proper combustion. If unsuccessful, a flame fault will occur.

a. Flame Fault Delay Set point : This time delay set point (sec) is delaybefore a flame fault will occur, if the flame is lost.

b. Relight Cycle Set point: This time set point (sec) is the amount oftime the pilot gas system will be used in an attempt to re-ignite the

flare, after the flame has been lost.c. Flame Test Timer Set point: After a re-light cycle has occurred, a

flame check is done after this time delay (sec) has elapsed.

d. Flame Detect On: This button will enable or disable flame detection.The text label on the button will indicate Flame Detect On , or FlameDetect Off.

Note: Flame detection should only be disabled in the event the flame detectioninstrumentation is not functioning properly and in need of replacement.


31/116

10. FLARE TREND

No Fault s

100 F

Flare Temp

Screens FLARE TREND

--:-- --:-- --:-- --:-- --:--

6000

4800

3600

2400

1200

0

This operator screen contains a graphical trend indicating flare temperature.This screen does not contain user configurable settings, but shows a briefhistory of the flare operating conditions.


32/116

11. TIME OF DAY OPERATION

This operator screen contains configuration input for the day timer function.Flare operation can be scheduled to run during a specific time of day and onspecific days of the week.

a. Acti ve: This button is used to enable or disable the day timerfunction. If disabled the flare is permitted to run continuously. The textlabel on the button will indicate DISABLED or ACTIVE.

b. Ac tual / Start / Stop: These time indicators show the actual time, theflare start time, and the flare stop time. The desired start and stop time(hr : min) are entered in military (24 hr) time.

c. DAY OF WEEK: These buttons are used to select the days in whichthe flare should operate. A button color of GREEN indicates an activeday, RED, indicates an inactive day.


33/116

12. SYSTEM

This operator screen contains configuration input for general system settings.

a. Down Timer Set poin t: This time delay set point (min) is the time thatmust elapse before an automatic re-start will occur. An automaticrestart is initiated after the following faults occur:

1) Pilot Fault

2) Low Temperature Fault

3) Flame Fault

b. Restart Counter Set poin t: This value indicates the number ofautomatic re-starts permitted before a system shutdown will occur.

c. Auto Reset Timer Set po in t: This time delay set point (sec)determines how long an automatic reset occurs during initial power upof the control system. This allow for all instrumentation to properpower up before initiating a flare start up.

d. Maximum Manual Operation Timer Set point: This is the maximumtime (min) in which the flare can be operated in manual mode.

e. Default SPs: This button will only appear if the user is logged in asoperator. This will go to the next screen, DEFAULT SET POINTS,and allow the operator to restore all user adjustable set points to the

factory defaults.


34/116

13. DEFAULT SET POINTS

This operator screen allows the operator to restore all user adjustable setpoints to the factory defaults.


35/116

14. RUNTIME TOOLS

Variable Inspector

Permits authorized users to review change variables. This provides access tovariables that may not be provided on the OIT screen.

Script Debugger

Authorized users can monitor scripts that are run in the background. This is atool typically used during development.

Driver Comms

Allows access to the communication settings. Once the system is functional the

setting typically do not require adjustment.

About Box

Provides information about the program version of the runtime.

Program Revisions

Provides information about the program revision for the runtime.

Edit UsersAllows authorized user to edit log on name, password access level, etc.


36/116

15. OUTLET PRESSURE

Outlet Pressure

20.0

0.0

Scaling

0Raw

Minimum

Maximum

0.0

Scaled

Screens ###########Logon Logoff

High

10.2

1800 Sec

Setpoint

Setpoint

0 Sec

Act ual

Low

0.0

Fault Delay

180 Sec

Setpoint

Setpoint

0 Sec

Actu al

This operator screen contains configuration for the flare outlet pressuretransmitter. The pressure transmitter measures the amount of pressure (+/-IWC) at the outlet of the flare equipment.

Outlet Pressure Monitoring

a. Low Set point: This set point (IWC) is the fault set point for the lowpressure at the skid outlet. Should the pressure remain below the setpoint the fault timer is activated.

b. Fault Delay: This time delay set point (sec) determines how long the

measured pressure can remain low before a low outlet pressure faultand shutdown will occur.

c. High Set poin t: This set point (IWC) is the fault set point for the highpressure at the skid outlet. Should the pressure remain above the setpoint the fault timer is activated.

d. Fault Delay: This time delay set point (sec) determines how long themeasured pressure can remain high before a high outlet pressure faultand shutdown will occur.

e. Pressure Scaling: These set points are used to adjust the controllerinstrumentation to match the vacuum transmitter. These should onlybe adjusted at the factory or by qualified personnel.


37/116

IV. MECHANICAL OPERATION

A. Drains

1. KOP drains, blower drains and piping drains should all be routed back to acondensate sump.

2. If the sump IS located in the landfill gas supply line feeding the KOP, then it isat the same negative pressure as the KOP. The KOP drain line should be leftopen so that it continuously drains into the sump.

3. If the sump IS NOT located in the landfill gas supply line feeding the KOP,then it will be at a different pressure than the highly negative KOP. In thiscase the drain lines may not drain properly to the sump when the blower isturned on. The KOP drain lines should be shut while the blower is on, andtemporarily opened to drain when the blower is off. Care should be taken tocheck the sight gauge on the KOP to determine the required flare shutdownschedule for proper draining.

4. Blower drain lines should always be kept open to continuously drain the

blowers.5. In multiple blower systems, manual isolation valves on either side of the

blower should be opened, and any collected water allowed to drain out, beforestarting the blower. Failure to do so may result in damage to the blowers inthe form of bent or broken impellers.


38/116


39/116

V. MAINTENANCE

A. Uti li ty Flare Maintenance

An LFG Specialties utility flare and controller system requires very little maintenance.A few preventative maintenance steps should be taken, however, to insure the life ofthe flare and proper operation of the system. These steps include:

1. Periodically drain the flare stack, if not piped for continuous draining. Theflare is equipped with a 2" diameter drain port at the base of the stack. Also,check the drain port for obstructions and clean out if necessary.

2. Maintain the finish on the package equipment by cleaning any scratches orchipping with a wire brush and repainting with touch-up paint supplied. Note:no maintenance is required on the stainless steel portion of the flare.

3. Inspect all wiring and connections for any wear and replace as necessary.

4. Inspect spark plug igniter for electrode wear and replace as necessary.5. Check pilot nozzle for obstructions and clean as necessary. Pilot nozzle is a

small jet, which may require a fine wire, needle or brake cleaner to aid incleaning.

6. Check all piping connections for tightness and leaks, replace gaskets asnecessary and re-torque bolts.

7. Check skid and flare alignment, re-shim and level if necessary.

8. For maintenance directions on peripheral equipment, see manufacturer'sinstructions in back of this manual.

9. When blower is included in scope of supply:

a. Lubricate the blower and motor bearings as specified by manufacturer(see lubrication instructions in the blower operation and maintenancesection).

b. Check and adjust tension on drive belts when applicable.

If any problems arise in the operation of your LFG Specialties flare and controllersystem that cannot be easily remedied, please notify us immediately for serviceadvice. If the problem cannot be corrected via phone conversations, a servicerepresentative can be sent to the site to fully investigate and resolve the problem.

All LFG Specialties products are guaranteed for material, workmanship andperformance as outlined in the standard "Terms and Conditions of Sales". The

warranty period is eighteen (18) months from date of shipment or twelve (12) monthsfrom date of start-up, whichever occurs first.

Note: Do not alter the design and/or operation of the LFG Specialties flare andcontroller system without consulting with LFG Specialties, as this could result in thevoiding of the equipment warranty.


40/116

B. BLOWERS AND FANS LUBRICATIONS

MULTI STAGE BLOWER LUBRICATION

(INCLUDES HSI, LAMSON HOFFMAN & GARDNER DENVER)

The Manufacturers recommended lubricant for Grease lubed Blowers is

NLGI #2 .

Mixing of Lubricants is NOTrecommended due to the possibility of chemical incompatibility,which may cause break down of the grease and also cause the formation of sludge or acidsthat would destroy the bearings and or equipment.

Signs of chemical incompatibility could be, but are not limited to; watery or soupy

consistency, discoloration and/or foul smell.

Care should be taken to avoid over lubrication which is as much a factor of bearing failure asis under lubrication, grease contamination or grease incompatibility.

Normal Bearing Temperatures may approach 200 to 230 degrees Fahrenheit; this does notnecessarily indicate a failure and should not immediately be cause for concern.

If the data tag on the unit specifies a particular lubricant type, the tag information willsupersede this written document.

Storage (also includes periods of non use) of the Blower should be in an environment toprevent condensation of moisture in the bearings/blower. The Blower drive shaft should alsobe hand rotated at least 10 revolutions once a week to avoid flat spotting of the bearing andto keep the grease from possible settling in the bearing which could allow rust. Mark the shaftto avoid parking it in the same spot when done.

All Landfill Gas BlowersAREconsidered to be operating in a harsh environment undersevere conditions when consulting your maintenance schedule for frequencies of lubrication.


41/116

A Schedule

Lubrication requires that once a month or every one thousand hours of blower run time, whichever occurs first. This is considered to the MINIMUM frequency.

NOTE Site specific circumstances may necessitate increased maintenance frequency.

Be sure all appropriate lock out tag out procedures are applied for safety and with the equipmentcompletely stopped

Remove the lower outside drain plug of the bearing housings, grease should be addedthrough the upper inside plug hole

If using a zerk style pressure grease gun take care not to force grease into the bearingtoo quickly or grease may be forced passed the seal into the blower cavity.

The blower should be warm and at operating temperature when adding grease to thebearing, while hand rotating the blower shaft.

Consult the appropriate manual for your blower for specific quantity to be added. Operatethe blower for 30 to 60 minutes afterward with the lower plug removed to allow for excessgrease to drain after thermal expansion.

With blower at a complete stop following all local lock-out procedures, replace bottomplug.

If you notice during this procedure that the grease in the bearing is excessively fouled, youshould increase the lubrication frequency at your discretion.

The gas contents at a particular site may necessitate more frequent lubrication than anotherseemingly identical site.

CONSULT THE BLOWER MANUFACTURERS WEBSITE AND STAY CURRENT WITHALL TECHNICAL BULLETINS AND POSSIBLE RECALL OR SAFETY INFORMATION


42/116

B schedule

Lubrication requires that every six months or every six thousand hours of blower run time whichever comes first.

NOTE Site specific circumstances may necessitate increased maintenance frequency.

Be sure all appropriate lock out tag out procedures are applied for safety and with the equipmentcompletely stopped

Remove the bearing covers and clean out all the existing grease by hand, using lint freecloth.

While turning the blower shaft by hand, install fresh grease to force out (PURGE) oldgrease from behind the bearing, wipe off this old grease and fill the bearing cover with theremainder of the amount of grease specified by the appropriate manual for your specificblower and reinstall the bearing covers.

Leave the drain plugs out and operate the blower for 30 to 60 minutes to get the greaseand bearing to operating temperature and allow the grease to expand and drain out theexcess, then the plugs may be reinstalled.

NOTE After adding fresh grease the bearing housing may seemingly run warmer thannormal, this should not last longer than a day.


43/116

BLOWERS WITH OIL LUBRICATED BEARINGS

The oil used for these blowers is SAE 30WT NON-DETERGENT. The use of any other typeof oil without written approval from the blower manufacturer will void the warranty.

The level of the oil inside the bearing housing is adjusted by the height of the micrometeradjusting rod under the Trico oil reservoir bottle. This distance is dependent on the model ofthe blower and explained in greater detail in the manufacturers manual for your blower.Consult the manual before adjusting this rod.

The bearing housing may actually hold three or four times the capacity of the Oil reservoirbottle. After filling the reservoir, be absolutely sure the bottle has stopped bubbling and thebearing housing is full to the appropriate level. DO NOT ASSUME ONE BOTTLE IS

ADEQUATE! In cold weather this may be difficult to tell as the oil will flow from the reservoirvery slowly.

The Oil Rite Oilers are factory set.

In either case, temperature and humidity play a big role in oil life, even if the blower isntconsuming oil or isnt running. The oil reservoir breathes and the oil will becomecontaminated over time. The oil should be completely drained and replaced at a minimum ofevery six months (possibly more often dependent on site specific conditions).

NOTE This is a GENERALIZED document to help make you aware of the requirements ofyour blower. Due to the number of different blowers used on flare systems it is yourresponsibility to familiarize yourself with the blower manual.


44/116

AMERICAN FAN AND AEROVENT CENTRIFUGAL FANS

The Manufacturers recommended lubricant for grease lubed fans is

NLGI #2 .

Mixing of Lubricants is NOTrecommended due to the possibility of chemical incompatibility,which may cause break down of the grease and also cause the formation of sludge or acidsthat would destroy the bearings and or equipment.

Signs of chemical incompatibility could be, but are not limited to, watery or soupyconsistency, discoloration, foul smell.

Care should be taken to avoid over lubrication which is as much a factor of bearing failure asis under lubrication, grease contamination or grease incompatibility.

Normal Bearing Temperatures may approach 200 to 230 degrees Fahrenheit; this does notnecessarily indicate a failure and should not immediately be cause for concern.

If the data tag on the unit specifies a particular lubricant type, the tag information willsupersede this written document.

Storage (also includes periods of non use) of the Blower should be in an environment toprevent condensation of moisture in the bearings/fan. The fan drive shaft should also be

hand rotated at least 10 revolutions once a week to avoid flat spotting of the bearing and tokeep the grease from possible settling in the bearing which could allow rust. Mark the shaft toavoid parking it in the same spot when done.

All Landfill Gas fansAREconsidered to be operating in a harsh environment under severeconditions when consulting your maintenance schedule for frequencies of lubrication.

Be sure all appropriate lock out tag out procedures are enforced for safety.

CONSULT THE FAN MANUFACTURERS WEBSITE AND STAY CURRENT WITH ALL

TECHNICAL BULLETINS AND POSSIBLE RECALL OR SAFETY INFORMATION

When lubrication is required, add grease slowly while the shaft is rotating until clean greasecomes out of the bearing. Wipe off excess grease to avoid accumulation of particulatecontamination of the grease.

NOTE. Some fans with a directly coupled motor use a mechanical motor coupling thatALSOREQUIRES GREASE! Dont forget to grease this coupling also.


45/116

Do not allow old grease to accumulate on the bearings, contamination will result destroyingthe bearings.

NOTE This is a GENERALIZED document to help make you aware of the requirements ofyour blower. Due to the number of different blowers used on flare systems it is your

responsibility to familiarize yourself with the blower manual.


46/116

ELECTRIC MOTORS USED ON LANDFILL GAS BLOWERS AND FANS

Most Electric Motors require periodic lubrication. Motors can be ordered with sealed bearingsthat will not accept the addition of grease.

DO NOT ASSUME THAT THE ABSENCE OF GREASE ZERKS ON YOUR MOTORINDICATES SEALED BEARINGS.

Some motor manufacturers do not install zerks to avoid OVER lubrication, but still requireperiodic lubrication, at which time you will have to install the Zerks. Read the Motormanufacturers manual or call the Manufacturer directly if you are not sure.

Some larger Motors have weep or drain ports under the shaft. When it is time to lubricateyour motor, these ports MUST be opened. They may be a pipe plug or may be a plate, butany excess grease must be allowed to drain. When greasing the motor, it should be atoperating temperature and turn the shaft by hand while adding only one pump of greaseSLOWLY. Once every two months.

Be sure all appropriate lock out tag out procedures are enforced for safety.

NOTE This is a GENERALIZED document to help make you aware of the requirements ofyour motor. Due to the number of different motors used on flare systems it is your

responsibility to familiarize yourself with the motor manual.


47/116

C. Flare Routine Maintenance Schedule

Components Frequency of Service

Daily Weekly

Bi-

Weekly Monthly

Bi-

Monthly

Semi-

annually Annually

As

Needed

Condensate Knock-out Pot

Check liquid level

Drain KOP

Inspect Internal Coating, cover gasket andclean demister pad

Retighten cover bolts

*Pneumatic Header, if appl icable

Check Nitrogen supply

Check Supply Pressure (25 psig)

Check valve performance

Check supply lines for leakage

*LFG Blower

Inspect Foundation & correct deficiencies

Check Conditions of isolation pads

Check blower motor alignment

Check bearing temperature

Check vibration levels

Re-lubricate bearings per specification

Inspect drive belts and flex coupling

Clean ventilation openings of blower motor

Re-lubricate motor bearings

Check wire connection for corrosion &tightness

Drain any Condensate from housing

Piping

Check all valves for proper operation

Retighten all flange bolt connections

Check all flange gaskets for leakage

Check rubber expansion joints for wear

Check piping alignment

*Flow Meter

Clean flow meter probe

Calibrate flow meter


48/116

Components Frequency of Service

Daily WeeklyBi-

Weekly MonthlyBi-

MonthlySemi-

annually AnnuallyAs

Needed

*Flame Arrester

Clean internal bank per spec.

Check back pressure & clean bank assy.

Propane Pilot System

Check propane supply

Check propane supply pressure (5 psig)

*Check solenoid manual override

*Clean solenoid valve per specifications

*Clean pressure regulator vent

Check all connections for leaks

Enclosed flare assembly Daily WeeklyBi-

Weekly MonthlyBi-

MonthlySemi-

annually AnnuallyAs

Needed

Check louver for smooth operation

Check linkage condition & tightness on linkageconnections

Maintain oil level in louver actuator

Check purge blower for proper operation

Clean purge blower motor vents

Check purge blower inlet for restrictions andclean if needed

Check purge flow switch for proper operation

Lubricate purge blower per specifications

Remove and clean ultra-violet scanner

Check UV scanner for proper operation

Inspect igniter plug, lead-wire, & connections

Inspect condition of tip

Inspect condition of insulation, pins, & keepers Align and retighten foundation bolts

Check electrical enclosure for moisture

Tighten conduit connections

Check wire connections for tightness &corrosion

Check paint & touch-up / repaint

Check thermocouple elements


49/116

Check pressure, vacuum & temp. gauges

Inspect foundation & correct deficiencies

Flare control panel Daily Weekly Bi-Weekly Monthly Bi-Monthly Semi-annually Annually AsNeeded

*Clean & maintain instruments perspecifications

*Replace recorder chart paper

*Replace recorder pen tip

Check enclosure for moisture

Check wire connections for corrosion &tightness

Check panel light bulbs

Check emergency shutdown Check system permissive

Please refer to the manufactures O & M manualduring any replacement of parts

Cut sheets are included in the LFG manual

* - Maintenance recommendations stated in the user manual, provided by the original equipmentmanufacturer should supersede the stated maintenance recommendations. Verify the originalmanufacturer O&M recommendations in Appendix E.


50/116

Spare Parts Common to Utility and Enclosed Flares

DESCRIPTION LFG SPECIALTIES PART NO. COST

Pilot Gas Solenoid Valve PFS012Y120VEXP $ 343.42

Spark Plug Igniter ESPI64 $ 80.00

Igniter Transformer EIGNTRNS $ 95.00

Thermocouples ETCA14W060SK $ 234.63

(underlined is length in inches) ETCA14W072SK $ 281.06

ETCA14W084SK $ 305.79

ETCA14W096SK $ 338.25

ETCA14W108SK $ 372.40

ETCA14W120SK $ 420.00

Actuator Solenoid Valve PFS014Y120V3B $ 211.65U.V. Flame Detector EUVSCNRA $ 214.00

Pressure Gauge PFG025H20P $ 227.21

Temperature Gauge PFGT300400 $ 83.95

Vacuum Gauge PFG100-0H2OV $ 227.21

Panel Indicator Light Bulbs EPFTBULB $ 10.00

(box of 10)

Valve Actuator 3-Way PFS014Y120V3B $ 211.65

Solenoid Valve**

KOP Sight Gauge Tube PFSG*** (specify length in inches) $ 2.75/ft

Blower Bearing Grease: HSI blowers $ 46.00

**For Pneumatic Style Header Valves

NOTE: List prices subject to change. CallLFG Specialties for current pricing.

Minimum Order - $100.00

Revised 05/09


51/116


52/116

D. Service Contacts

1. Mailing Address

LFG Specialties, LLC

16406 US Route 224 E

Findlay, OH 45840-9761

2. Office Support

Proposals and Engineering Support:

Louis Kalani (419) 425-6299

Product Manager

Lee Zink (419) 425-6190

Sr. Applications Engineer

George Morgan (419) 425-6106

Electrical Engineering Manager

Heather Ogg (419) 424-4964

Customer Service Representative

Start-up, Field Service, and Warranty Issues:

Heather Ogg (419) 424-4964


Replacement Parts:Harry Zernechel (419) 425-6141

Materials Manager

Lori Recker (419) 424-4938


3. Service Technician Support

Ron Silbaugh (419) 957-6696

Kurt Plapp (419) 957-6518

Jim Wisinski (419) 957-6519

Troy Childress (419) 957-0157


53/116

VI. TROUBLE SHOOTING

A. Flare Alarms

There are three types of alarm conditions that can occur in a Flame-Trol control

system. The first is a Soft Shutdown. In this situation, the flare will automatically tryto restart itself after a user adjustable timer period as set in the Down Timer.

The second is a Component Specific Fault. For example, if the system is equippedwith more than one blower, a Blower X auxiliary fault will only disable Blower X. Thesystem will continue to operate with any non-faulted blowers.

The third is a Hard Shutdown. In this situation, the system will shutdownimmediately and will only restart if the Reset button is pressed, or if control power iscycled.


54/116

B. Possib le Alarm Causes

FT-1 Annunciated Alarms

Alarm Type Alarm Descript ion

1. Flare Shutdown This alarm will occur if the flare shuts downfor any reason. If this alarm light is on withno other alarm lights lit, then the flareshutdown on a Low Temp fault. Anautomatic restart will follow a Low Tempshutdown.

Low(wh

2. Pilot Failure This alarm will occur if the pilot temperaturedoesnt reach the Pilot-Off Temperaturewithin the time specified in the Pilot Timer.

Inco Out Wa Ign Bre Loo Inco

Hig BloEquipm

Bro Fai

Af ter S

Flow


55/116


3. Flame Out This alarm will occur if flame is not detectedat any time after the pilot temperaturereaches the Pilot-Off Temperature. TimerTR204 allows for a user adjustable delaybefore a Flame Out alarm will occur. An

automatic restart will follow a Flame Outshutdown.

Hea (low Isol Stu Hig

Anypat Low Hig Hig

flow Low Hig Hig

senEquipm

UV

Opesen

Fai

Corros

4. Inlet Gas High Temp This alarm will occur if the temperatureswitch in the base of the flare stack istripped. This alarm can occur in bothManual and Automatic mode.

Exc Unu

gas Gas BloEquipm

Ope

Bad

Bad


56/116


5. High High Condensate Level This alarm will occur if the level switch inthe Condensate Knock-Out Pot is tripped.This alarm can occur in both Manual and

Automatic mode.

Con Deb Bui

swiEquipm

Ope Bad Bad Inco LevAf ter S

Inco

6. Blower Failure Blower did not report sufficient amps toexceed the low amp set point

Bro Han Inle Blo

Stu Mot Pilo Too

flow Low Ope


57/116

FT-3, 4, 5, 6 Annunciated Alarms


1. Blower X inner bearing temp fault This alarm will occur if the inner bearingtemperature is above the Bearing TempFault set point for the time specified in the

Bearing Inner Temp Fault Delay timer.

Lac

Exc

Sur

Mis

2. Blower X outer bearing temp fault This alarm will occur if the outer bearingtemperature is above the Bearing TempFault set point for the time specified in theBearing Outer Temp Fault Delay timer.

See

3. Blower X auxiliary fault This alarm will occur if the motor starter orVFD doesnt indicate operation after beingcommanded to start within the timespecified by the Aux Timer.

Motor S

Mot PhaVFDSp Ove

Ope Bad FaiEquipm

OveAf ter S

Set Con Bre Acc


58/116


4. Blower X high amp fault This alarm will occur if the blower amps areabove the Blower High Amp set point forthe time specified in the Blower High AmpFault Delay timer.

Proces Exc Wa Any

suc thro

arre hun (recEquipm

Bea Fai

Bad

5. Blower X low amp fault This alarm will occur if the blower amps arebelow the Blower Low Amp set point for thetime specified in the Blower Low Amp FaultDelay timer.

Proces

Blo com Con Che Blo Res Inle Hea (low

VFD Sp Pre Spe

poin


59/116


6. All blowers off This alarm will occur if no Blower switchesare in the Auto position when the ControlMode switch is placed in the Auto position.

Motor S

Sel

7. All blowers faulted This alarm will occur if all blowers in thesystem have been faulted.

Thisothe

Loc

8. Flame monitoring disabled This alarm will occur if flame monitoring hasbeen disabled.

Nonis dthe Fla

9. Flame lost This alarm will occur if the flame is lost anytime after the pilot temperature has reachedthe Pilot-Off Temperature.

Low Hig Hig

flow Low Hig Higsen

Equipm

UV Cor

10. Flame not established This alarm will occur if a flame is notdetected when the pilot temperaturereaches the Pilot-Off Temperature.

Hea (low Isol Stu Hig Any

pat

Equipm UV Ope

sen Fai Cor


60/116


11. Flame monitoring fault This alarm will occur if the flame monitoringsystem detects a flame at a time when noflame should be present.

Che Che

pos

12. KOP high high level fault This alarm will occur if the level switch inthe Condensate Knock-Out Pot is tripped.This alarm can occur in both Manual and

Automatic mode.

Con Deb

Buiswi

Equipm

Ope Bad Bad Inco LevAf ter S

Inco

13. Flare inlet high temperature fault This alarm will occur if the temperature

switch in the base of the flare stack istripped. This alarm can occur in bothManual and Automatic mode.

Exc Unugas

Equipm

Ope Bad Bad

14. Maximum manual operation fault This alarm will occur if the Control Modeswitch is in the Manual position for the timespecified in the Maximum ManualOperation timer.

Pre

15. All flare restarts done This alarm will occur if the flare has

attempted the number of restarts specifiedin the Restart Counter and failed to achievethe Low Temp temperature set point.

Detcor


61/116


16. Flare process high temperature fault This alarm will occur if the Thermocouple#1 temperature exceeds 2000 F. Thisalarm can occur in both Manual and

Automatic mode.

Exc

Ma

Lou

17. Flare high flow fault This alarm will occur if the flare flow isabove the High Flow Fault set point for thetime specified in the High Flow Fault Delaytimer.

Exc Flow

18. Power fault This alarm will occur if the powermonitoring relay indicates that the incomingpower is out of tolerance.

Util

Loo

Exc

19. Inlet X failed open This alarm will occur if the inlet valvedoesnt indicate the closed position whencommanded to close within the time

specified in the Fail Open Fault Delay timer.

SwoElectric

Val BloPneum

Blo WaEquipm

Fai Lim Ope

20. Inlet X failed closed This alarm will occur if the inlet valvedoesnt indicate the open position whencommanded to open within the timespecified in the Fail Closed Fault Delay

timer.

SwoElectric

Val Blo

Pneum No WaEquipm

Fai Lim


62/116


21. Flare inlet valve failed open When commanded to close, the valve did

not indicate closed within the time allowed.

SwoElectric

Val BloPneum

Blo WaEquipm

Fai Lim Ope Fai Fai

22. Pilot fault This alarm will occur if the pilot temperaturedoesnt reach the Pilot-Off Temperaturewithin the time specified by the Pilot CycleTime Set point. An automatic restart willfollow a Pilot Fault shutdown.

Inco Out Wa Ign Bre Loo Inco

Hig BloEquipm

Bro FaiAf ter S Flow


63/116


23. Pilot thermocouple open This alarm will occur if the pilotthermocouple is determined to be faulty.

Concirc

CheMet

RepEquipm Bad

24. All process T/Cs are open This alarm will occur if all of thethermocouples are determined to be faulty.

Loc

25. Thermocouple X Open This alarm will occur if the thermocouple isdetermined to be faulty.

Concirc

CheMet

Rep


26. Temperature not made This alarm will occur if the processtemperature doesnt reach the Low Temp

setpoint after the pilot cycle is completewithin the time specified in the Low TempStart Delay timer.

Utility

Hig Hig

flow (an

outs Hig

T/CEnclos


64/116

Pre WroAl l Flar

Low

27. Temperature lost This alarm will occur if the processtemperature falls below the Low Temp setpoint after the Low Temp set point for the

time specified in the Low Temp ShutdownDelay timer.

Utility

Hig Hig

flow (an

outs Hig

T/CEnclos

Tem AutAl l Flar

Low


65/116

General Problems

Symptom Cause

1. The flare is consuming an unusuallylarge amount of propane.

The pilot temperature is taking longerperiods of time to achieve the Pilot-OffTemperature

Improper thermocouple location

LowTem

Plathe

2. Landfill gas flow is significantly belowits usual level.

Landfill gas flow is being restricted. Mothe blowapp

If tthethe

Conope

3. Landfill gas flow is significantly aboveits usual level.

Mothe blowappoxyinle(abwelthe


66/116

APPENDIX A CHEAT SHEETS

A. Auto dialers

1. RACO Guard IT 4 Channel Auto dialer

a. Acknowledging an Alarm from the Front Panel

To acknowledge an alarm from the front panel, move the selector switchto the DISARMED position, and then return it to the READY position. Theproduct must Not be in programming mode or presently placing a phonecall, for the alarm to be acknowledged in this way.

b. Clearing an Acknowledged Alarm from the Front Panel

To force a clearing of the acknowledged alarm status in advance of thetime when the alarm reset timer would otherwise do it, select choice [7]from the top menu, or simply turn the product off and then on again. Ifthere is still a fault being detected, then after the expiration of the alarmtrip delay, a new unacknowledged alarm will occur with new alarm callsbeing placed.

c. Receiving and Acknowledging an Alarm Call

When you receive an alarm call from your Guard-it TM auto dialer, listento the message to learn what alarm(s) exist. At certain points in themessage round, a prompting beep will be issued. This is your cue topress a 9 immediately after the tone to acknowledge the alarm.


67/116

2. Guard-it 4 Channel Auto dialer


68/116


69/116

B. Chart Recorders

1. Yokogawa FX and DX 106 Paperless Chart Recorder

Main Display Screens

Bar Trend Digital

Information Overview Trend History

The six main display screens you will be using on the Yokogawa Chart Recorderare displayed above. Further more, the Information or Data displayed in thesescreens are called groups. The groups are just a way to say which data you wantto see, the displays above shown data gathered from all six channels of theYokogawa. They may consist of all six, only one, or any of all of the channels.The exception to this is the Information screen, which holds data about anyalarms which may have occurred if they have been setup.

The Bar, Trend, Digital & Overview are displaying current data real time.

The Trend History view is used if you want to see what has happened say, lastnight after every one went home.

You can get to these screens by pushing the Display/Enter button and thenselecting the view you want.


70/116

As an Operator, You will also need to know how to start and stop the process ofDATArecording, This is done with the start / stop buttons shown above. Whenyou push stop, it will ask which process you would like to stop, just push enter toaccept. **** NOTE, It is not necessary to stop recording to remove the media,but it must be replaced before the chart recorder can make its next scheduled filewrite.

Most likely the only other function you may be concerned with is down loading orextracting the recorded data from the media which could be either an ordinary1.44 Megabyte floppy disc, A One Hundred Megabyte Zip Disc, or a 32Megabyte Compact Flash Card.

The compact Flash is most common and may be upgraded without anyprogramming changes to a 512 Megabyte Card, any larger than a 512 will work,but the extra space is not recognized and it will not be utilized.

The Media can be removed while the Yokogawa is recording, but needs to bereplaced before the Yokogawa can make its next scheduled file save, which maybe every eight hours or once a day.

To remove the Media, open the front door of the Chart Recorder and push the

eject button located to the side of the media, It may now be put into a desktop PCor a Laptop with the proper hardware adapter so that the files can be extractedand viewed from the Yokogawa Daq Standard software.

Depending on the Media used, you will need a 3-1/2 inch floppy drive, a Zipdrive, or a compact flash card reader.


71/116

C. PLC

1. GE Versamax PLC

a. Backup Battery Replacement

Using a small screw driver, catch edge of battery holder, which is locatedon top of the CPU on the left side of the PLC block, and pry upward torelease. Reinstall new battery, Panasonic BR2032 or GE ACC001.

b. Clear PLC Fault Table Using Operation Mode Switch

The CPU Run/Stop mode switch is located behind the module door. Thisswitch can be used to place the CPU in Stop or Run mode.

If the CPU has non-fatal faults and is in STOP/FAULT mode, placing theswitch in RUN position causes the CPU to go into run mode. FAULTSare not cleared.

If the CPU has fatal faults and is in STOP/FAULT mode, placing theswitch in RUN position causes the RUN LED to blink for 5 seconds.While the RUN LET is blinking, the CPU switch can be used to clear thefault table and put the CPU in RUN mode. After the switch has been inRUN position for at least second the faults are cleared and the CPUgoes to RUN mode. The LED stops blinking and stays on. This can berepeated if necessary.

If the switch is not toggled, after 5 seconds the RUN LED goes off and theCPU remains in STOP/FAULT mode. Faults stay in the fault table.

The LED lights are on the left and are, from top to bottom: Power (PWR),OK, RUN, FAULT, FORCE, PORT1, and PORT2.


72/116

APPENDIX B PROPOSAL


73/116

APPENDIX C - DRAWINGS


74/116


75/116


76/116


77/116


78/116


79/116


80/116


81/116


82/116


83/116


84/116


85/116


86/116


87/116


88/116


89/116


90/116


91/116


92/116


93/116


94/116


95/116


96/116


97/116


98/116


99/116


100/116


101/116


102/116


103/116


104/116


105/116


106/116


107/116


108/116


109/116

APPENDIX D MISC.


110/116

Datasheet No. : 36874Design Date : 9/30/2009Quote/Job No.:Prepared By : mwells

Customer

Shaw enviromental

Findlay, OH 45840

Project

Site Data

Elevation: 918 ft a.s.l.

Gas Data

MW : 30.026 RH: 0.0%

k : 1.2728 Cp: 0.3087

Gas Pct

Carbon Dioxide (CO2) 50.000Methane (CH4) 50.000

DISCHARGETEMP

(F)

DIFFERENTIALPRE

SSURE

(PSI)

STANDARD VOLUME (SCFM @ 60F)

Curve Da

ta

ModelConfigurationImpeller 1Impeller 2

EXHAUSTER

Impeller 3DriverControl Method

Op. Speed [RPM ]Inlet Throttling [valve/%closed]Bar. Pressure [PSIA ]Disch. Pressure[ inWC ]

CONDITIONS

Inlet Temp. [F ]Inlet Humidity [% RH ]

MW / k / CpVolume (Std.) [SCFM@60F ]Volume (Inlet) [CFM ]Inlet Vacuum [ inWC ]Diff. Pressure [PSI ]Power [BHP ]

PERFORMANCE

Efficiency [% ]Disch. Temp. [F ]Pressure Rise [PSI ]Turndown [% ]

Surge Pressure [PSI ]Surge Volume [SCFM ]

SURGE

1. Primary Curve

HSI 5203

(1) 5021(2) 5011

3,904none14.21515.00100.00100.0

29.132/1.267/0.32361000.01316.440.001.98521.9248.69135.241.0682.58

3.05174.2

HSI, Inc 7901 Hansen Rd Houston, Texas 77061 Office 713-947-1623 Fax 713-947-6409 Toll Free 800-725-2291 www.hsiblowers.com [email protected]

Print Date: 10/5/2009 ISO 9

Martinsville User Manual

Documents

Transcript of Martinsville User Manual