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INSTALLATION GUIDELINES

INSTALLATIONGUIDELINESDELINES

Ei

3

A. PRESSURE SWITCH FOR LOSS OF FUEL GAS 10

B. PILOT CONTROL VALVE 12

C. CONDUIT HEADER 14

D. ELECTRICAL CONNECTIONS 15

E. START UP 19

TABLE OF CONTENTS

4PRE-INSTALLATION

91-in. FLAME SMART FUEL TRAIN

10COMPONENT INSTALLATION

6Ei FLARE INSTALLATION

18WIRING DIAGRAM

A. ENCLOSURE INSTALLATION 6

B. FUEL SUPPLY SHUTOFF 7

C. PILOT INSTALLATION 8

20INSTALLATION NOTES

4 PRE-INSTALLATION

PRE-INSTALLATION

A step-by-step installation guide has been provided to assist in ensuring that the

Flame Smart controller and components are properly installed. Proper installation is

imperative as this will eliminate a high percentage of the most common field related

issues. The steps provided are to be used as a guideline to achieve proper installation,

since all equipment does not have an identical design. Installation does allow for some

customization liberties to fit the Flame Smart package to the real-world conditions of

each application. The instructions provided below will ensure that critical aspects of the

installation process are appropriately addressed.

When installing a new Flame Smart package, it is important for the user to first read

through the installation instructions thoroughly and take a quick assessment of the tools

and equipment that are available. Installation procedure shall be followed in the order as

outlined, starting with the location and mounting of the Flame Smart BMS enclosure and

ending with the full start-up of the unit using the Flame Smart automated controls.

Many of the installation steps can be executed by a single person. However, there

may be some areas where two or more personnel are required to handle heavy equipment.

Notes and indicators will be given throughout the instruction manual as a reminder when

these special requirements will take place.

5PRE-INSTALLATION

A quick overview of the order of major tasks is below:

1

2

3

4

Locate and install BMS enclosure

Isolate and bleed the fuel supply line(s) to begin work on the system

Remove the existing fuel supply tubing and replace the manufacturer’s ignition unit with the new Flame Smart ignition unit

Install the

• Pilot Control Valve• Pressure switch Pressure switch calibration shall be performed prior to heading to the field to complete installation. An instructional video is available to assist in setting the pressure switch set point.

5

6

7

Install conduit to run electrical wiring from system components to the Flame Smart BMS enclosure

Make electrical connections in panel, landing wires in designated terminal locations

Startup system and set operating levels

!Detailed instructions for each of the steps mentioned above are provided in the manual

with associated photographs for reference. The step-by-step installation video found on the

Flame Smart website is also a great reference for additional installation instructions.

6 Ei FLARE INSTALLATION

ENCLOSURE INSTALLATION

1. Evaluate where to install the enclosure

2. The installation location of the enclosure should be as close as possible to the flare

3. Remove the enclosure from the packaging

4. The enclosure is to be mounted on a pole or building supported by unistrut and mounting brackets that are capable of supporting 10 lbs

5. Position the enclosure so that the LED displays are clearly visible to operators

6. Use a ½-in. drill bit to create wiring penetrations in the enclosure (A.6)

7. Install conduit seal-off fittings for all electrical connections to the enclosures (A.7)

8. Installation must comply with the local electrical code

An example of a pole-mounted installation is shown to the right. Unistrut clamps and/or u-bolts are used to attatch the upper and lower pieces of the unistrut to the pole while the mounting hardware is used to fix the enclosure to the two sections of the unistrut.

A.6 A.7

A

STEPS 6-7

END of ENCLOSURE INSTALLATION

!When drilling holes in the enclosure, ensure IP66 fittings are used to maintain the IP66 standard. Failure to use IP66 standard fittings nullifies the IP66 certification.

Before any welding is attempted, disconnect all wires going to the circuit board.

7Ei FLARE INSTALLATION

FUEL SUPPLY SHUT-OFF

1. Find the fuel gas supply line and turn the fuel gas supply shut-off valve to the closed position

2. Turn the drain valve on the fuel pot to the open position slowly to release the pressure in the fuel pot

3. Make sure the pressure indicator on the fuel pot is at zero PSI before proceeding to perform any work on the fuel supply lines

B

END of FUEL SUPPLY SHUT-OFF

8 Ei FLARE INSTALLATION

PILOT INSTALLATION

1. Ensure all fuel gas is turned off and locked out/tagged out

2. Using an adjustable wrench loosen the tubing fittings for the fuel gas supply line

3. Remove existing pilot assembly and associated piping

4. Inspect the original pilot piping length and orientation of the pilot assembly

5. Install the Flame Smart ignition unit assembly on the flare application, ensuring the assembly is securely fastened to the pilot raising mechanism

6. Re-install ignition unit to original location with sufficient distance to main burner for consistent light off of main burner

C

!Have a master electrician confirm the proper wire size needed to connect to the igniter

leads based on the total length of wire required to extend back to the control box.

END of PILOT INSTALLATION

91-in. FLAME SMART FUEL TRAIN

!The diagram above shows typical instrumentation and control devices installed in the fuel and process piping used in flare operations. Detailed installation instructions for these components are given on the following pages to assist in proper installation for

optimal performance.

1

FUEL POT

2

2 3

3

4

PI

1

PRESSURE SWITCH

COALESCINGFILTER

REGULATINGVALVE

SOLENOIDVALVE

PS-1001 PRV-1002 SV-1003 ACV-1003

10-15 PSI

S

4 ACV-1003OPTIONALACTUATOR

VALVE

Flame Smart Ei

ACTUATORVALVE

10 COMPONENT INSTALLATION

PRESSURE SWITCH FOR LOSS OF FUEL GAS * FOR REFERENCE PLEASE SEE LIST OF PHOTOS AT THE END OF THE SECTION

1. Check to ensure the fuel pot does not have any pressure (A.1)

2. Unscrew the pressure indicator off the top of the instrument manifold (A.2)

3. Locate a ¼-in x 1 ½-in nipple and a ¼-in tee (A.3)

4. Apply Teflon tape to the threads and attatch the nipple into one of the runs of the tee and hand tighten

5. Tighten the male thread of the nipple connected to the tee into the fitting where the pressure indicator was previously installed (A.5)

6. Hand tighten the tee and nipple to begin, then use a small pipe wrench to tighten and position the third leg of the tee towards an open area (A.6)

7. Apply Teflon tape to the threads and attatch the pressure indicator into the top of tee. Tighten with a wrench (A.7)

8. Take the pressure switch out of its package

9. Use a ⅛-in. hex wrench to adjust pressure and set pressure at four to five PSI N/O (A.9)

10. Take the ½-in. connection side of the switch and screw into the tee junction box (A.10)

11. Put the junction box in a vise and tighten the pressure switch with a wrench to the desired position. Make sure to install so the wiring diagram is visible (A.11)

12. Take the pressure switch and junction box assembly and attatch the ¼-in. connection on the pressure switch to the ¼-in. tee on the instrument manifold and hand tighten

13. Tighten with an adjustable wrench, position junction box opening for easy wire access (A.13)

The pressure switch wiring diagram is located on the back of the instrument. The Normally Open (N/O) wiring configuration should be used (blue and brown wires).

A

11COMPONENT INSTALLATION

A.1 A.2

A.3 A.5

A.6 A.7

A.9 A.10

A.11 A.13

STEPS 1-13

END of PRESSURE SWITCH FOR LOSS OF FUEL GAS

PILOT CONTROL VALVE

1. Remove the pilot control valve from the packaging

2. Add a nipple to the inlet and outlet of the pilot control valve

3. Create a custom pipe run that will connect gas from the fuel source to the burner. The pipe run will start at the outlet of the pressure regulator that is installed on the fuel pot/scrubber and will end at the inlet of the system burner

4. Once the distance from the pressure regulator to the burner inlet has been measured and cut to the appropriate length, install the pilot control valve assembly to the pressure regulator

5. Complete the installation of the piping run from the outlet of the pilot control valve to the inlet of the burner and ensure a secure connection with no leaks in the piping run

12 COMPONENT INSTALLATION

Based on the flare/burner equipment to be installed, the pilot control valve could be one of the following:

• ASCO ¼-in. solenoid valve • Flame Smart 1-in. solenoid valve • Flame Smart actuator valve

B

!Install stainless steel fittings to the inlet and outlet of the ¼-in. valve instead of pipe

nipples, as ¼-in. valve will be connected to stainless steel tubing.

!Note: Customization of piping is expected on each installation. Users must ensure proper supports and bracing is supplied for all installations to prevent excessive

strain on fuel supply piping.

13COMPONENT INSTALLATION

Solenoid Valve

• Use a ½-in. close conduit nipple to attach a GUA junction box to the solenoid valve electrical housing. • Guide the solenoid wires through the nipple and continue to thread the wires through the side of the junction box, directing the wiring from the solenoid towards the common conduit header • Electrical connection: 2 wires -> Ports 8 & 9

Actuator Valve (Optional)

• From the ½-in. conduit electrical port on the actuator electrical housing, install a short nipple. • Attach a 90-degree ELBY junction to the short nipple to direct wiring from the actuator towards the common conduit header. • Electrical connection: 3 wires -> Ports 1, 2 & 3

END of PILOT CONTROL VALVE

6. Install the junction box to the pilot control valve housing

14 COMPONENT INSTALLATION

CONDUIT HEADER

1. Map out the conduit header connections by identifying locations where electrical connections have been made

2. Cut hard conduit to appropriate lengths and connect to junction box(es) using flexible conduit

3. The final conduit installation will accommodate all electrical instruments installed on the unit

4. Run the conduit to the BMS panel mounting location

5. Pass wires through junction boxes and through conduit to land in the BMS panel. Be sure to use Meyers hub connections to pass wire through the panel enclosure

6. Complete terminations within the junction boxes and land wires at the correct terminals

C

!Make sure to follow local electrical codes with respect to the electrical installation

and running conduit.

END of CONDUIT HEADER

15COMPONENT INSTALLATION

ELECTRICAL CONNECTIONS

1. Battery installation

2. Solar Panel installation

3. The igniter has two, non-polar, white wires. Connect the igniter wires to the Flame Smart terminals 27 and 28

D

!NOTE: Igniter wires are not polarity sensitive.

Install a 12 VDC SLA battery in an enclosure separate from the Ei BMS

• Make a connection from the negative side of the battery to the negative terminal (port 31) • Make the connection from the positive side of the battery to the positive terminal (port 32)

!NOTE: Flame Smart recommends a battery rating of 100 Ah for cold weather areas

and 35 Ah for warmer locations.

Install a 12 VDC, 20-75 watt, solar panel, mounting the unit to face in the southeastern direction

• Make the connection from the negative side of the solar panel to the negative terminal (port 29) • Make the connection from the positive side of the solar panel to the positive terminal (port 30)

!Standard solar panel rating for cold weather states is 40W, while 20W is in most cases

sufficient for warmer weather states.

16 COMPONENT INSTALLATION

4. Terminate the pressure switch on the “Loss of Fuel,” “Spare/Standby,” “ESD” or the “Shutdown Interlock” terminals

5. Terminate the solenoid valve wires in ports 8 and 9

6. Terminate the actuator valve wires (1, 2 and 3) at the actuator valve ports on the terminal (ports 1, 2 and 3)

7. PLC/Scada Connection

!The appropriate port locations will depend on which shutdown/standby function the pressure

switch should control.

!The green wire will not be utilized. Cut the green wire and cap with a wire nut.

• Terminate connections from the RTU/PLC at the Alarm Out Terminal• Terminate the connections from the RTU/PLC at the Remote On and Remote OFF terminals• Terminate the connections from the RTU/PLC at the Run Status terminals

17COMPONENT INSTALLATION

INSTRUMENT TERMINAL

Pressure Switch 1 Blue Wire -> Port 171 Brown Wire -> Port 18

NOTE: Pressure switch wires can also be installed in the “Spare Standby” ports (19 & 20), “ESD” ports (21 & 22), and the “Shutdown Interlock” ports (23 & 24)

1/4-in. or 1-in. Solenoid Valve 2 Red Wires -> Ports 8 & 9

NOTE: Trim the green wire short and cap it off with a wire nut

Actuator Valve Wire 1 -> Port 1Wire 2 -> Port 2Wire 3 -> Port 3

Igniter 2 White Wires -> Ports 27 & 28

Battery Negative Wire -> Port 31Positive Wire -> Port 32

Solar Panel / 24 VDC Power Supply Negative Wire -> Port 29Positive Wire -> Port 30

NOTE: No wire strands (loose wire) should be left outside of terminal connection. Wires shall be twisted tightly and completely before installing in terminal block.

18 WIRING DIAGRAM

FLAME SMARTFS

END of ELECTRICAL CONNECTIONS

FLAME SMART2

19COMPONENT INSTALLATION

START UP

1. Apply pressure back to the fuel supply line by cracking open the inlet fuel supply line

2. Close the drain valve, allowing the pressure to build in the drip pot. Once the pressure reaches 60 psig, fully open the valve to the fuel supply line

3. Set the pressure regulators between 10-15 PSIG

4. Go to the BMS keypad and press the “On” button

5. The unit BMS will display Code 01, indicating a purge prior to startup. This should last 20 seconds

6. The BMS will next display Code 04 and a 5-second alarm will initiate sounding that the ignition process is about to begin

7. The BMS will display Code 05, indicating the igniter is on and attempting to light the pilot. At the same time the pilot control valve will open releasing gas to the pilot burner

8. The igniter will wait 30 seconds to confirm pilot flame presence. Once the pilot flame has been established, the unit will display ON and Code 00, showing that the system is running

Ensure the drain valve to the drip pot is still open, purging the drip pot for approximately two to three minutes.

E

!NOTE: Upon pressurizing the fuel gas lines, perform one final soap test at all connection

points to identify any leaks in the system.

END of START UP

20 INSTALLATION NOTES

Commissioning Date:

Igniter Ohms:

Pilot Pressure:

Main Burner Pressure:

Battery Volts:

Software Version:

Controller Serial Number:

Ignition Unit Serial Number:

Notes: