martinsville user manual
TRANSCRIPT
-
8/12/2019 Martinsville User Manual
1/116
User Manual
Unit # 2171
Martinsville
Model # PCFT828I6
-
8/12/2019 Martinsville User Manual
2/116
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
4/116
-
8/12/2019 Martinsville User Manual
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:
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User 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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
22/116
3
Vacuum /Flow
maintainedunder
control?
Any FaultMessages
?
Flow / Pressurecontrol loop may needto be tuned for currentconditions.
Auto StartupComplete
F
Yes
No
Yes
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
34/116
13. DEFAULT SET POINTS
This operator screen allows the operator to restore all user adjustable setpoints to the factory defaults.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
38/116
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User 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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User 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.
-
8/12/2019 Martinsville User 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
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
51/116
-
8/12/2019 Martinsville User Manual
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
Customer Service Representative
Replacement Parts:Harry Zernechel (419) 425-6141
Materials Manager
Lori Recker (419) 424-4938
Customer Service Representative
3. Service Technician Support
Ron Silbaugh (419) 957-6696
Kurt Plapp (419) 957-6518
Jim Wisinski (419) 957-6519
Troy Childress (419) 957-0157
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
55/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
56/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
57/116
FT-3, 4, 5, 6 Annunciated Alarms
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
58/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
59/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
60/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
61/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
62/116
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
63/116
Alarm Type Alarm Descript ion
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
Alarm Type Alarm Descript ion
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
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
67/116
2. Guard-it 4 Channel Auto dialer
-
8/12/2019 Martinsville User Manual
68/116
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
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.
-
8/12/2019 Martinsville User Manual
72/116
APPENDIX B PROPOSAL
-
8/12/2019 Martinsville User Manual
73/116
APPENDIX C - DRAWINGS
-
8/12/2019 Martinsville User Manual
74/116
-
8/12/2019 Martinsville User Manual
75/116
-
8/12/2019 Martinsville User Manual
76/116
-
8/12/2019 Martinsville User Manual
77/116
-
8/12/2019 Martinsville User Manual
78/116
-
8/12/2019 Martinsville User Manual
79/116
-
8/12/2019 Martinsville User Manual
80/116
-
8/12/2019 Martinsville User Manual
81/116
-
8/12/2019 Martinsville User Manual
82/116
-
8/12/2019 Martinsville User Manual
83/116
-
8/12/2019 Martinsville User Manual
84/116
-
8/12/2019 Martinsville User Manual
85/116
-
8/12/2019 Martinsville User Manual
86/116
-
8/12/2019 Martinsville User Manual
87/116
-
8/12/2019 Martinsville User Manual
88/116
-
8/12/2019 Martinsville User Manual
89/116
-
8/12/2019 Martinsville User Manual
90/116
-
8/12/2019 Martinsville User Manual
91/116
-
8/12/2019 Martinsville User Manual
92/116
-
8/12/2019 Martinsville User Manual
93/116
-
8/12/2019 Martinsville User Manual
94/116
-
8/12/2019 Martinsville User Manual
95/116
-
8/12/2019 Martinsville User Manual
96/116
-
8/12/2019 Martinsville User Manual
97/116
-
8/12/2019 Martinsville User Manual
98/116
-
8/12/2019 Martinsville User Manual
99/116
-
8/12/2019 Martinsville User Manual
100/116
-
8/12/2019 Martinsville User Manual
101/116
-
8/12/2019 Martinsville User Manual
102/116
-
8/12/2019 Martinsville User Manual
103/116
-
8/12/2019 Martinsville User Manual
104/116
-
8/12/2019 Martinsville User Manual
105/116
-
8/12/2019 Martinsville User Manual
106/116
-
8/12/2019 Martinsville User Manual
107/116
-
8/12/2019 Martinsville User Manual
108/116
-
8/12/2019 Martinsville User Manual
109/116
APPENDIX D MISC.
-
8/12/2019 Martinsville User Manual
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