Technical Training Manual v2

1 TECHNICAL TRAINING

TECHNICAL TRAINING


July 2013

PLATINUM CONTROL TECHNOLOGIES 2822 West 5th Street, Fort Worth, TX 76107

Toll Free: 1-877-374-1115

www.platinumcontrol.com

Technical Training


TABLE OF CONTENTS SECTION I: INTRODUCTION 9 TRAINING OBJECTIVES ------------------------------------------------------------------------------------------------------------------------- 10 ABOUT PLATINUM ------------------------------------------------------------------------------------------------------------------------------ 11 PLATINUM CONTROL: IMS & BMS ---------------------------------------------------------------------------------------------------------- 11 HOW IT WORKS ---------------------------------------------------------------------------------------------------------------------------------- 12 THE BRAINS --------------------------------------------------------------------------------------------------------------------------------------- 13 APPLICATIONS ------------------------------------------------------------------------------------------------------------------------------------ 14 INSTALLATIONS ---------------------------------------------------------------------------------------------------------------------------------- 15 ADDITIONAL CONSIDERATIONS ------------------------------------------------------------------------------------------------------------- 15 THE OLD WAY------------------------------------------------------------------------------------------------------------------------------------- 16 POTENTIAL CONSEQUENCES ----------------------------------------------------------------------------------------------------------------- 16 THE BETTER WAY: BMS & IMS --------------------------------------------------------------------------------------------------------------- 17 PAIN POINT CONSIDERATIONS --------------------------------------------------------------------------------------------------------------- 17 PLATINUM CONTROLS PRODUCTS --------------------------------------------------------------------------------------------------------- 18 ROI EXPECTED COSTS ------------------------------------------------------------------------------------------------------------------------ 19 ROI POTENTIAL UNANTICIPATED COSTS ------------------------------------------------------------------------------------------------ 20 WHO BENEFITS FROM BURNER MANAGEMENT ---------------------------------------------------------------------------------------- 21 COMPETITORS ------------------------------------------------------------------------------------------------------------------------------------ 21 SUPERIOR MANUFACTURING ---------------------------------------------------------------------------------------------------------------- 22 PLATINUM CONTROL BENEFITS ------------------------------------------------------------------------------------------------------------- 23 THE PLATINUM WAY---------------------------------------------------------------------------------------------------------------------------- 24

SECTION II: COMBUSTION FUNDAMENTALS 25 FIRE TRIANGLE ----------------------------------------------------------------------------------------------------------------------------------- 26 CONTROLLED COMBUSTION ----------------------------------------------------------------------------------------------------------------- 28

CONTROL BY DESIGN ----------------------------------------------------------------------------------------------------------------------- 29 CONTROL BY INSTRUMENTS -------------------------------------------------------------------------------------------------------------- 30

TYPES OF BURNER ASSEMBLIES ------------------------------------------------------------------------------------------------------------- 31 DIRECT FIRED UNITS ------------------------------------------------------------------------------------------------------------------------ 32 INDIRECT FIRED UNITS --------------------------------------------------------------------------------------------------------------------- 33

BURNER CATEGORIES -------------------------------------------------------------------------------------------------------------------------- 34 LIQUID FUELED BURNERS ------------------------------------------------------------------------------------------------------------------ 34 GAS FUELED BURNERS---------------------------------------------------------------------------------------------------------------------- 34 FORCED DRAFT BURNERS ----------------------------------------------------------------------------------------------------------------- 34 NATURAL DRAFT BURNERS---------------------------------------------------------------------------------------------------------------- 35

TYPES OF OILFIELD EQUIPMENT WITH BURNER ASSEMBLIES ----------------------------------------------------------------------- 38 HEATER TREATER ---------------------------------------------------------------------------------------------------------------------------- 38 ELECTROSTATIC TREATER ------------------------------------------------------------------------------------------------------------------ 38 HEATED SEPARATOR ------------------------------------------------------------------------------------------------------------------------ 38 GLYCOL DEHYDRATOR ---------------------------------------------------------------------------------------------------------------------- 39 AMINE UNIT ----------------------------------------------------------------------------------------------------------------------------------- 39 LINE HEATER ---------------------------------------------------------------------------------------------------------------------------------- 40 GAS PRODUCTION UNIT ------------------------------------------------------------------------------------------------------------------- 40 COMBUSTOR ---------------------------------------------------------------------------------------------------------------------------------- 41 COMBINATION UNIT ------------------------------------------------------------------------------------------------------------------------ 41


MULTI-WELL UNIT --------------------------------------------------------------------------------------------------------------------------- 42 TANK HEATER --------------------------------------------------------------------------------------------------------------------------------- 42 FLARE -------------------------------------------------------------------------------------------------------------------------------------------- 42

THE FIRETUBE ------------------------------------------------------------------------------------------------------------------------------------ 43 HEAT FLOW IN THE FIRETUBE ------------------------------------------------------------------------------------------------------------ 45 FIRETUBE RETURN BEND DESIGNS ------------------------------------------------------------------------------------------------------ 47 THE FIRETUBE STACK ----------------------------------------------------------------------------------------------------------------------- 47 FLASH ARRESTOR/STACK HEAD ---------------------------------------------------------------------------------------------------------- 48 TURBULATORS -------------------------------------------------------------------------------------------------------------------------------- 49

THE COMBUSTION CHAMBER ---------------------------------------------------------------------------------------------------------------- 50 THE FLAME ARRESTOR --------------------------------------------------------------------------------------------------------------------- 52 BENEFITS OF FLAME ARRESTORS -------------------------------------------------------------------------------------------------------- 54 TYPES OF FLAME ARRESTORS ------------------------------------------------------------------------------------------------------------ 55 FLAME ARRESTOR OPERATIONS --------------------------------------------------------------------------------------------------------- 56 STANDARD FLAMECO NOMENCLATURE ----------------------------------------------------------------------------------------------- 57

MAIN & PILOT BURNER ASSEMBLIES ------------------------------------------------------------------------------------------------------- 58 THE BURNER NOZZLE ----------------------------------------------------------------------------------------------------------------------- 60 THE MIXER ------------------------------------------------------------------------------------------------------------------------------------- 61 THE PILOT -------------------------------------------------------------------------------------------------------------------------------------- 62

THE FUEL GAS TRAIN --------------------------------------------------------------------------------------------------------------------------- 64 FUEL GAS TRAIN DRAWING --------------------------------------------------------------------------------------------------------------- 68 FUEL GAS TRAIN DRAWING WITH BMS ------------------------------------------------------------------------------------------------ 68 CANADIAN B149. 3 FUEL GAS TRAIN DRAWING ------------------------------------------------------------------------------------- 69 STANDARD FUEL GAS TRAIN P&ID WITH BMS --------------------------------------------------------------------------------------- 69

VESSEL/BURNER EQUIPMENT INSPECTION ---------------------------------------------------------------------------------------------- 70 OPERATIONAL INSPECTIONS -------------------------------------------------------------------------------------------------------------- 70 INTERNAL COMPONENTS INSPECTIONS ----------------------------------------------------------------------------------------------- 70 CORROSION ----------------------------------------------------------------------------------------------------------------------------------- 71 LEAKS -------------------------------------------------------------------------------------------------------------------------------------------- 71 OBSTRUCTIONS ------------------------------------------------------------------------------------------------------------------------------- 72 FLAME ARRESTOR CELL -------------------------------------------------------------------------------------------------------------------- 72 GASKETS ---------------------------------------------------------------------------------------------------------------------------------------- 73 FUEL GAS TRAIN ------------------------------------------------------------------------------------------------------------------------------ 73 BURNER SYSTEMS --------------------------------------------------------------------------------------------------------------------------- 74 THE STACK ------------------------------------------------------------------------------------------------------------------------------------- 75 GAUGES AND TEMPERATURE CONTROLS --------------------------------------------------------------------------------------------- 75

INITIAL BURNER STARTUP --------------------------------------------------------------------------------------------------------------------- 76 SHUTDOWN PROCEDURE --------------------------------------------------------------------------------------------------------------------- 78 RECOMMENDED MAINTENANCE ----------------------------------------------------------------------------------------------------------- 79

SECTION III: PLATINUM CONTROLS BMS 81 PRE-INSTALLATION QUESTIONS ------------------------------------------------------------------------------------------------------------- 83 WARRANTY STATEMENT ---------------------------------------------------------------------------------------------------------------------- 84 INTRODUCTION ---------------------------------------------------------------------------------------------------------------------------------- 85 COMPONENTS AND SPECIFICATIONS ------------------------------------------------------------------------------------------------------ 86

SHIPPING BOX CONTENTS ----------------------------------------------------------------------------------------------------------------- 86 MICROPROCESSOR BOARD ------------------------------------------------------------------------------------------------------------ 87 PLATINUM BMS-731 PROCESSOR BOARD --------------------------------------------------------------------------------------- 87 VALVES/TERMINATION BOARD ------------------------------------------------------------------------------------------------------ 88

PLATINUM BMS-731 IGNITION MODULE ---------------------------------------------------------------------------------------------- 88


PILOT ASSEMBLY ----------------------------------------------------------------------------------------------------------------------------- 89 INSTALLATION ------------------------------------------------------------------------------------------------------------------------------------ 90

PRE-INSTALLATION REQUIREMENTS --------------------------------------------------------------------------------------------------- 90 MOUNTING THE MAIN CONTROL BOX ------------------------------------------------------------------------------------------------- 91 INSTALLING SOLENOID VALVES ---------------------------------------------------------------------------------------------------------- 92 MOUNTING THE PILOT ASSEMBLY ------------------------------------------------------------------------------------------------------ 98 SETTING-UP THE IGNITION MODULE ------------------------------------------------------------------------------------------------- 102 MOUNTING THE IGNITION MODULE ------------------------------------------------------------------------------------------------- 102 INSTALLING THE TEMPERATURE DEVICE -------------------------------------------------------------------------------------------- 108

INSTALLING THE RTD ------------------------------------------------------------------------------------------------------------------ 108 INSTALLING THE TYPE K THERMOCOUPLE -------------------------------------------------------------------------------------- 111

CONNECTING EXTERNAL DEVICES ----------------------------------------------------------------------------------------------------- 114 CONNECTING EXTERNAL ESD (STATUS OUT) --------------------------------------------------------------------------------------- 116 GROUNDING WIRES ----------------------------------------------------------------------------------------------------------------------- 116 CONNECTING VALVES/TERMINATION BOARD TO MAIN CONTROL BOX --------------------------------------------------- 118 CONNECTING POWER TO THE MAIN CONTROL BOX ----------------------------------------------------------------------------- 118

OPERATING-------------------------------------------------------------------------------------------------------------------------------------- 121 POWERING UP ------------------------------------------------------------------------------------------------------------------------------ 121 FACTORY SETUP ---------------------------------------------------------------------------------------------------------------------------- 122

SOFTWARE REVISION NUMBER ---------------------------------------------------------------------------------------------------- 123 TEMPERATURE CONTROL ------------------------------------------------------------------------------------------------------------ 123 LOW PRESSURE SWITCH-------------------------------------------------------------------------------------------------------------- 123 HI PRESSURE SWITCH ----------------------------------------------------------------------------------------------------------------- 124 ESD SOLENOID -------------------------------------------------------------------------------------------------------------------------- 124 ESD VALVE SWITCH (POC) ----------------------------------------------------------------------------------------------------------- 124 MAIN VALVE SWITCH (POC) --------------------------------------------------------------------------------------------------------- 125 TEMP SENSOR TYPE ------------------------------------------------------------------------------------------------------------------- 125 SPARE SWITCH -------------------------------------------------------------------------------------------------------------------------- 126 SET REMOTE ON/OFF ----------------------------------------------------------------------------------------------------------------- 126 PILOT OPERATION---------------------------------------------------------------------------------------------------------------------- 127 ENABLE THE HIGH FIRE VALVE ------------------------------------------------------------------------------------------------------ 127 SET THE MODBUS BAUD RATE ------------------------------------------------------------------------------------------------------ 127 SET MODBUS PARITY ------------------------------------------------------------------------------------------------------------------ 128 SET NUMBER OF MODBUS STOP BITS -------------------------------------------------------------------------------------------- 128 SET MODBUS ADDRESS --------------------------------------------------------------------------------------------------------------- 128 BACKLIGHT ALWAYS ON -------------------------------------------------------------------------------------------------------------- 129

OPERATING PARAMETERS --------------------------------------------------------------------------------------------------------------- 130 TEMPERATURE SCALE ----------------------------------------------------------------------------------------------------------------- 131 ALARM SETPOINT (HIGH TEMPERATURE SHUTDOWN) ---------------------------------------------------------------------- 132 TEMPERATURE CONTROL SETTING ------------------------------------------------------------------------------------------------ 133 IGNITION DELAY TIME ---------------------------------------------------------------------------------------------------------------- 134 SETTING THE MAIN VALVE DELAY ------------------------------------------------------------------------------------------------- 134 SETTING THE FLAME SENSE DELAY ------------------------------------------------------------------------------------------------ 135 HIGH FIRE DELAY ----------------------------------------------------------------------------------------------------------------------- 135 SETTING THE HIGH FIRE TEMPERATURE SETPOINT --------------------------------------------------------------------------- 136 SPARE SWITCH DELAY ----------------------------------------------------------------------------------------------------------------- 136 TIME LOG --------------------------------------------------------------------------------------------------------------------------------- 137 EXITING THE OPERATING PARAMETERS ----------------------------------------------------------------------------------------- 138

IGNITION PROCEDURE -------------------------------------------------------------------------------------------------------------------- 139 CONFIRM PROPER FUNCTIONALITY OF THE FLAME SENSING PROBE ------------------------------------------------------- 140

TROUBLESHOOTING -------------------------------------------------------------------------------------------------------------------------- 141 DISPLAY ERROR CODES ------------------------------------------------------------------------------------------------------------------- 141 MICROPROCESSOR CODES -------------------------------------------------------------------------------------------------------------- 144


TIPS FOR TROUBLESHOOTING ---------------------------------------------------------------------------------------------------------- 146 PLATINUM RECOMMENDED SPARE PARTS LIST --------------------------------------------------------------------------------------- 149 BMS-731 CURRENT DRAW ------------------------------------------------------------------------------------------------------------------ 150 ADDENDUM DRAWINGS--------------------------------------------------------------------------------------------------------------------- 151

BMS 731/BTEX INTERCONNECT DIAGRAM ----------------------------------------------------------------------------------------- 151 BASIC P&ID ---------------------------------------------------------------------------------------------------------------------------------- 152 FULL P&ID ------------------------------------------------------------------------------------------------------------------------------------ 153

Optional BMS 731-BTEX Addendum 154 COMPONENTS AND SPECIFICATIONS ---------------------------------------------------------------------------------------------------- 155

BTEX ADAPTER BOARD (PIGGYBACK BOARD) -------------------------------------------------------------------------------------- 155 INSTALLATION ---------------------------------------------------------------------------------------------------------------------------------- 156

INSTALLING THREE (3) TYPE K THERMOCOUPLE ---------------------------------------------------------------------------------- 156 OPERATING-------------------------------------------------------------------------------------------------------------------------------------- 158

POWERING UP ------------------------------------------------------------------------------------------------------------------------------ 158 OPERATING PARAMETERS --------------------------------------------------------------------------------------------------------------- 159

ALARM SETPOINT (HIGH TEMPERATURE SHUTDOWN) ---------------------------------------------------------------------- 159

SECTION IV: PLATINUM CONTROLS IMS 161 PRE-INSTALLATION QUESTIONS ----------------------------------------------------------------------------------------------------------- 162 WARRANTY STATEMENT -------------------------------------------------------------------------------------------------------------------- 163 INTRODUCTION -------------------------------------------------------------------------------------------------------------------------------- 164

POWER---------------------------------------------------------------------------------------------------------------------------------------- 164 OPERATION ---------------------------------------------------------------------------------------------------------------------------------- 164 IGNITER MODE ----------------------------------------------------------------------------------------------------------------------------- 164 FLARE MODE -------------------------------------------------------------------------------------------------------------------------------- 164 APPLICATIONS ------------------------------------------------------------------------------------------------------------------------------ 165

COMPONENTS AND SPECIFICATIONS ---------------------------------------------------------------------------------------------------- 166 SHIPPING BOX CONTENTS --------------------------------------------------------------------------------------------------------------- 166 MICROCONTROLLER BOARDS ---------------------------------------------------------------------------------------------------------- 167

PLATINUM-500 DISPLAY BOARD --------------------------------------------------------------------------------------------------- 167 PLATINUM-500 MAIN BOARD ------------------------------------------------------------------------------------------------------ 168 IGNITION MODULE -------------------------------------------------------------------------------------------------------------------- 169 PILOT ASSEMBLY ----------------------------------------------------------------------------------------------------------------------- 169

INSTALLATION ---------------------------------------------------------------------------------------------------------------------------------- 170 PRE-INSTALLATION REQUIREMENTS ------------------------------------------------------------------------------------------------- 170 EXAMPLE OF A FUEL GAS TRAIN ------------------------------------------------------------------------------------------------------- 171 MOUNTING THE MAIN CONTROL BOX ----------------------------------------------------------------------------------------------- 172 INSTALLING SOLENOID VALVES -------------------------------------------------------------------------------------------------------- 172 MOUNTING THE PILOT ASSEMBLY ---------------------------------------------------------------------------------------------------- 177 INSTALLING THE IGNITION MODULE ------------------------------------------------------------------------------------------------- 179 CONNECTING EXTERNAL DEVICES ----------------------------------------------------------------------------------------------------- 182 CONNECTING EXTERNAL ESD (STATUS OUT) --------------------------------------------------------------------------------------- 182 GROUNDING WIRES ----------------------------------------------------------------------------------------------------------------------- 182 CONNECTING MAIN BOARD TO MAIN CONTROL BOX --------------------------------------------------------------------------- 183 CONNECTING POWER TO THE MAIN CONTROL BOX ----------------------------------------------------------------------------- 183

LINE POWER ----------------------------------------------------------------------------------------------------------------------------- 183


SOLAR POWER WITH BATTERY BACKUP ----------------------------------------------------------------------------------------- 184 LINE POWER WITH BATTERY BACKUP -------------------------------------------------------------------------------------------- 186

SETUP --------------------------------------------------------------------------------------------------------------------------------------------- 188 POWERING UP ------------------------------------------------------------------------------------------------------------------------------ 188 INITIAL SETUP ------------------------------------------------------------------------------------------------------------------------------- 188

POWER SELECTION -------------------------------------------------------------------------------------------------------------------- 189 OPERATING MODE --------------------------------------------------------------------------------------------------------------------- 189 SOLENOID VOLTAGE* ----------------------------------------------------------------------------------------------------------------- 189 ESD SOLENOID* ------------------------------------------------------------------------------------------------------------------------- 189 PILOT SOLENOID* ---------------------------------------------------------------------------------------------------------------------- 190 MAIN SOLENOID* ---------------------------------------------------------------------------------------------------------------------- 190

IDLE STATE ----------------------------------------------------------------------------------------------------------------------------------- 191 OPERATING PARAMETERS SETUP ----------------------------------------------------------------------------------------------------- 192

FIRMWARE REVISION NUMBER ---------------------------------------------------------------------------------------------------- 192 VENT DELAY TIME* -------------------------------------------------------------------------------------------------------------------- 192 SPARK DELAY TIME* ------------------------------------------------------------------------------------------------------------------- 192 MAIN VALVE DELAY TIME* ---------------------------------------------------------------------------------------------------------- 192 FLAME SENSE DELAY TIME ----------------------------------------------------------------------------------------------------------- 193 REMOTE ON/OFF ----------------------------------------------------------------------------------------------------------------------- 193 AUTO ON --------------------------------------------------------------------------------------------------------------------------------- 193 STATUS LED MODE -------------------------------------------------------------------------------------------------------------------- 194 DISPLAY MODE -------------------------------------------------------------------------------------------------------------------------- 194 POWER MODE -------------------------------------------------------------------------------------------------------------------------- 195 OPERATING MODE --------------------------------------------------------------------------------------------------------------------- 195 SOLENOID VOLTAGE* ----------------------------------------------------------------------------------------------------------------- 196 ESD SOLENOID TYPE* ----------------------------------------------------------------------------------------------------------------- 196 PILOT SOLENOID TYPE* --------------------------------------------------------------------------------------------------------------- 197 MAIN SOLENOID TYPE* --------------------------------------------------------------------------------------------------------------- 197 FACTORY RESET ------------------------------------------------------------------------------------------------------------------------- 198 PASSWORD ------------------------------------------------------------------------------------------------------------------------------ 198 TIME AND DATE ------------------------------------------------------------------------------------------------------------------------ 199 CLEAR LOG ------------------------------------------------------------------------------------------------------------------------------- 199 VIEW LOG -------------------------------------------------------------------------------------------------------------------------------- 200

EXIT SETUP ----------------------------------------------------------------------------------------------------------------------------------- 200 OPERATING-------------------------------------------------------------------------------------------------------------------------------------- 201

FRONT PANEL ------------------------------------------------------------------------------------------------------------------------------- 201 POWERING UP ------------------------------------------------------------------------------------------------------------------------------ 202 SMART START ------------------------------------------------------------------------------------------------------------------------------- 202 RUNNING ------------------------------------------------------------------------------------------------------------------------------------ 203 IGNITER & FLARE MODE ----------------------------------------------------------------------------------------------------------------- 203 RUNNING WITH REMOTE ON/OFF ---------------------------------------------------------------------------------------------------- 204 RUNNING WITH LOW BATTERY CONDITION --------------------------------------------------------------------------------------- 204 CONFIRM PROPER FUNCTIONALITY OF THE FLAME SENSING PROBE ------------------------------------------------------- 205

RATINGS------------------------------------------------------------------------------------------------------------------------------------------ 206 POWER SUPPLY ----------------------------------------------------------------------------------------------------------------------------- 206 POWER CONSUMPTION (RUNNING) ------------------------------------------------------------------------------------------------- 206 FUSE ------------------------------------------------------------------------------------------------------------------------------------------- 206 CLOCK BACKUP BATTERY ---------------------------------------------------------------------------------------------------------------- 206 ESD OUTPUT RELAY ----------------------------------------------------------------------------------------------------------------------- 206

TROUBLESHOOTING -------------------------------------------------------------------------------------------------------------------------- 207 ESD SCREEN MESSAGES ------------------------------------------------------------------------------------------------------------------ 207 ERROR SCREEN MESSAGES -------------------------------------------------------------------------------------------------------------- 211 MISCELLANEOUS MESSAGES ----------------------------------------------------------------------------------------------------------- 212


TIPS FOR TROUBLESHOOTING ---------------------------------------------------------------------------------------------------------- 213 ONLINE TRAINING RESOURCES -------------------------------------------------------------------------------------------------------- 214 AVAILABLE TECHNICAL RESOURCES -------------------------------------------------------------------------------------------------- 215 CONCLUSION -------------------------------------------------------------------------------------------------------------------------------- 215

ADDENDUM DRAWINGS--------------------------------------------------------------------------------------------------------------------- 216 PLATINUM-500 ELECTRIC ---------------------------------------------------------------------------------------------------------------- 216 PLATINUM-500 PNEUMATIC ------------------------------------------------------------------------------------------------------------ 217

Glossary 219


SECTION I: INTRODUCTION


TRAINING OBJECTIVES

1. Gain awareness of fired vessel applications.

2. Work to have an understanding of the components related to natural draft production

equipment.

3. Establish competence in the installation and operations of Platinum Controls Burner

Management Systems.

NOTE

At all times we will consider Safety, Efficiency, and Regulatory requirements. Please consult and follow

appropriate OSHA, NFPA, Canadian Standard, Industry and Company specific safety practices. Always

wear appropriate PPE including, but not limited to the following items:

Hard hat

Safety glasses

FR clothing

Steel-toe boots

Hearing protection


ABOUT PLATINUM

Our team has decades of experience in the oil & gas field and a thorough understanding of all the

production equipment involved. That knowledge has driven our development of the most

technologically advanced, reliable and user-friendly BMS on the market.

Beyond a great product, we value and continue to build strong partnerships with our clients. Always

committed to 100% satisfaction, we provide 24/7 technical support for the life of the unit.

PLATINUM CONTROL: IMS & BMS

Ignition Management System

Platinum Controls Ignition Management System is specifically designed to light, monitor, and re-ignite

natural draft burners used in heating systems for oil and gas production equipment and gas flares.

Burner Management System

Platinum Controls Burner Management System provides remote burner access, automated ignition and

temperature control for oil and gas production. The system records essential data and safely automates

heating processes, decreasing injury risk, maximizing well production and facilitating environmental

compliance.

The above image is of a Burner Management System (BMS), the BMS-731.

The above image is of an Ignition Management System (IMS), the Platinum-500.


HOW IT WORKS

BMS & IMS (IGNITER Mode)

Both the BMS and IMS monitor for the presence of a pilot flame through an igniter rod which feeds the signal back to a microcontroller to determine a safe sequence of events based on the signal.

Both the BMS and IMS control the pilot, main solenoids and ESD solenoids. In the absence of a lit pilot, the system will shut all gas sources feeding the pilot and main burner and wait for a user set wait time before attempting a re-ignition sequence.

Both systems, in the event of a positive ignition will sense the flame and proceed with monitoring. If either system senses a flame ignition failure, they will lock out the ignition process after three failed attempts and wait for an operator to troubleshoot and reset the system.

IMS (FLARE Mode)

In flare mode, the IMS does not control solenoids. In the absence of a flame, the IMS will wait for a fixed delay time of 5 seconds before attempting a re-ignition sequence.

In the event of a positive ignition, the system will sense the flame and proceed with monitoring. In the event of flame ignition failure, the IMS will restart automatically without any limitations.

BMS

In addition to the features shared with IMS, the BMS has temperature control to establish and maintain operator adjustable temperature set points.

Remote capability allowing personnel to monitor and adjust operations from off site. The ability to communicate an alarm in shutdown conditions to notify operators of upset

conditions.

Image of Platinums ignition module, wiring, and pilot installed in a flame arrestor.


THE BRAINS

Manufactured under the strictest production parameters, the control panel is the brain of our BMS/IMS.

Each is precision engineered and rigorously tested to withstand the harshest weather conditions, while

ensuring reliable uptime. We simply do not take shortcuts in the quality we put into every controller.

The system is designed to easily integrate with your other monitoring and data systems to allow

complete visibility into your production site.

A simple interface with intuitive alerts, the system is designed to be very user-friendly in the field and

provide the control to remotely manage your production site.

Platinums BMS-731 microprocessor and valves/termination board.

Platinums IMS Platinum-500 display and main board.


APPLICATIONS

Platinum Controls Burner Management Systems support any natural draft burner up to 10MMBtu/Hr

on oil & gas production equipment. Whether you need one unit or want to integrate all of your burner

systems, Platinum Control can give you the insight to manage your:

Production Units

Treaters

Dehydrators

VOC Combustors

Heated Separators

Oil Stabilizers

Line Heaters

Amine Plants

Combination Units

Multiwell Units

Tank Heaters

Flares

Platinum BMS-731 installed on a gas production unit.


INSTALLATIONS

In yard installations are easier, but will require adjustments in the field after final installation. On

location installations are more involved, but maximize the opportunity for optimum operations.

In yard: Primarily during the manufacturing or refurbishment process

On location: During refurbishment or as an upgrade

The above image is of a new treater with a Platinum BMS-731 installed in the equipment manufacturer yard.

Above is an example of a retrofit installation of a Platinum BMS-731 on a glycol dehydrator in the field.

In retrofit applications always examine flame arrestor to insure free of plugging, check burner fuel train

for proper operations in addition to inspecting firetube for obstructions, sooting, or hot spots.

All of these items can lead to issues with burner capability and flame quality.

The end result can be improper operation, damage to production equipment, lost revenue or injury.

Carbon debris inside of firetube.

Collapsed hotspot inside of a firetube.

Sooting accumulation inside of a firetube.

ADDITIONAL CONSIDERATIONS

Burner manifold components

Inspection of burner systems for installation

Continuing PM of burner systems

Parts and service


THE OLD WAY

Much of the field is using antiquated methods, such as using a rag on a stick to light burners.

Information compiled from OSHA, Federal Bureau of Labor, NIOSH, API, and CDC tells us.

From 2006-2010, the Oil and Gas Industry experienced:

o 15% of incidents fire and explosion related o Injury claims > $47m o Over 81,350 lost work hours

Rag on a stick used to light a burner.

POTENTIAL CONSEQUENCES

Failure to use Burner Management Systems could result in damaged equipment, lost revenue, legal

claims, injury or fatality.

Image of a burned glycol dehydration unit.

Treaters and battery on fire in West Texas.


THE BETTER WAY: BMS & IMS

INCREASE SAFETY GAIN PRODUCTION EFFICIENCIES MINIMIZE ENVIRONMENTAL

IMPACT Prevents serious injury or

death from manually lighting and re-lighting burners

BMS provides temperature control that protects and preserves equipment

Limits loss of revenue due to claims or suits

Reduces production shut-downs due to burner failure

Remote control of the BMS decreases need for field engineers to go on site to monitor systems

Increases visibility into your systems performance

BMS temperature controlled burning prevents explosions

Positions your company for current and future compliance requirements

BMS delivers accurate temperature and pressure control to ensure complete incineration of unusable or harmful gases

Prevents harmful gases from releasing into the environment

PAIN POINT CONSIDERATIONS

A Yes response to any of the below questions warrants the use of a BMS or IMS.

1. Are personnel using an open flame (torch, rag on a stick) to light burners?

2. Have you ever had a burner related near miss, recordable, or lost time incident?

3. Have you ever had a burner failure cause continuous gas venting to the atmosphere?

4. Has a burner failure ever prevented you from selling oil or natural gas?

5. Have you ever had a burner failure cause call-outs for the lease operator or service personnel to

relight the burner?

6. Have you ever risked or had production equipment damage due to a burner failure?

7. Have you ever been fined because of fugitive emissions?


PLATINUM CONTROLS PRODUCTS

MODEL Platinum 500 BMS 731 BMS BTEX

Applications Gas Flares Production Equipment Production Equipment Production Equipment

Operation Mode Flare Igniter --- ---

Ignition Control Yes Yes Yes Yes

Valve Control --- Yes Yes Yes

Temperature Control --- ---

RTD K-Type Thermocouple

K-Type Thermocouple (Can be used to measure temperature at three different points)

Typical Power Connections (Not including valves)

12/24 V 0.08 W

12/24 V 0.19 W

12/24 V 9.6 W

12/24 V 9.6 W

Internal Battery Option

12 V sealed lead-acid Up to 14 AH --- ---

Internal Solar Charge Controller

Vmp: 17.3 V Power: Up to 30 W usable --- ---

Solar Enabled Yes Yes Yes

Redundant Shutdown Yes Yes Yes

Event Record Log Yes --- ---

Auto-Restart After Power Failure Yes --- ---

Input(s) for Safety Devices Yes Yes Yes

Communications --- Yes Yes

Certification Pending

CSA/UL Certified for its intended use (Model SF 731) NFPA 87 Standards

CSA/UL Certified for its intended use (Model SF 731) NFPA 87 Standards

Classification Class I, Division II Class I, Division II Class I, Division II


ROI EXPECTED COSTS


ROI POTENTIAL UNANTICIPATED COSTS


WHO BENEFITS FROM BURNER MANAGEMENT

Distributors

o Providing customer needed product and service OEMs

o Leadership and credibility with customers End Users

o Field Personnel o Corporate Engineering o Corporate Management o Safety Officer

COMPETITORS

Canalta

ACL Manufacturing

Profire

SureFire

Patton

Platinum Control offers a more consistent, technologically advanced product with the following

benefits:

CSA/UL Certified for its intended use the entire unit versus components

Extremely high commitment to service, customer relationship

Superior quality manufacturing

Platinum personnel strategically located around the US and Canada

Remote monitoring

Centrally located


SUPERIOR MANUFACTURING

State-of-the-art ISO 9001:2008, CSA/UL certified facility

Best quality assurance in the industry

Use only the highest rated component parts

65,000 square feet of manufacturing space virtually unlimited capacity to produce upon

demand

Typically we can meet the demand for nearly any order quantity in days, not weeks, in

conjunction with our distribution network

Main distribution hub and is centrally located near the Dallas-Fort Worth International Airport

The above three images are of Variosystems, Platinums manufacturer site.


PLATINUM CONTROL BENEFITS

Proven ability to integrate with the ROC system

CSA/UL Certified for its intended use the entire unit versus components

Extremely high commitment to service, customer relationship

Superior quality US manufacturing

Platinum personnel strategically located around the US and Canada

LBP network throughout the US and Canada

Comprehensive technical training program

Centrally located

24/7 customer support hotline- 877-374-1115


THE PLATINUM WAY

We succeed. No Excuses.

We strive to exceed our clients expectations.

We provide our clients with excellent experiences.

We solve our clients problems, even if they are not directly our problems.

We obsess about service.

We dont assume, we listen.

We always operate with integrity.

We are not always right. We admit it when we are wrong and act to solve the problem

as quickly as possible.

Success is never a solitary venture.


SECTION II:

COMBUSTION FUNDAMENTALS


FIRE TRIANGLE

Energy Energy is defined as the ability by work or heat to provide usable power.

It is our goal to incite usable power (energy) to affect a liquid or natural gas stream. The

end result is to heat the stream to improve separation or to prevent hydrates from

forming. The most common way to accomplish this is by using a burner system to affect

(heat) the inlet stream.

In this burner system a repeating chemical process known as combustion is occurring.

There are three components that are required in specific ratios to create combustion. If

any one of these three components are missing, or removed, then combustion cannot

occur or be sustained.

Oxygen Our atmosphere is composed of 20.9% Oxygen in most normal environments. This

makes oxygen the most available component of the fire triangle. For our applications

Oxygen is normally supplied to the burner by natural draft. The amount of oxygen

available to the burner is critical in relationship to fuel. Therefore, the oxygen supply is

usually regulated by a shutter, or mixing system combining the oxygen with fuel.

Fuel


Fuel Many types of fuels can be used in the fire triangle. The primary fuels we will utilize are

natural gas and propane. Both of these fuels are desirable for our application as little

heat is required for ignition and the combustion process is controllable. In natural gas

applications, the fuel supply is commonly provided from the working processes of the

gas stream being generated at the location. There are times when this gas stream may

be sent from an auxiliary location, or central battery. In some instances propane may be

utilized. This occurs when there is little or no natural gas available for burner operations

or the percentage of impurities in the gas stream such as CO2, H2S, etc. prevent burning

the available gas. It is important to be sure of where the fuel stream is coming from, the

type of fuel being used, and British Thermal Unit (BTU) value.

Heat The final component of the triangle is energy (heat). We are seeking to provide this

component to instigate the process of combustion. This is accomplished by utilizing an

ignition source to generate the necessary heat to complete the chemical reaction. This

component is most safely and conveniently provided by a Platinum Burner Management

System (BMS) ignition device.


CONTROLLED COMBUSTION

We have established a goal of providing energy (heat) as a chemical treating process. It is then critical to

be able to control this heat to insure safe and efficient operation. By providing the necessary ignition,

and regulating the oxygen and fuel combination, we can harness available heat energy provided by the

chemical reaction. This dictates that we must have the power to control initial ignition and the

individual oxygen and fuel components brought together as a combined mixture. This control is

imperative for a safe and sustained reaction.

The ratio of oxygen to fuel for efficient operation can change subject to the BTU content. Without the

proper ratio, the reaction can burn rich or lean. This affects the available heat energy, operation

efficiency, sustainability, and maintenance issues relating to burner operation.

Fuel

Oxygen

Heat Heat

Exhaust


Control By Design

Image of Platinums ignition module, wiring, and pilot installed in a flame arrestor.

It is desired for the combustion chamber to be able to operate without the continuous assistance of

personnel. Therefore, the combustion chamber, and supporting devices are designed to be operated

with minimal field operator assistance. The primary assistance comes from startup operations providing

the initial ignition source and adjustment of valves, regulators and oxygen/fuel mixing devices, and is

not ongoing.


Control By Instruments

Dual Platinum BMS-731 units installed for glycol dehydrator and combustor.

Control of the ongoing heating process is required. Once again, it is desirable to minimize human

contact. By utilizing electrical and pneumatic instrumentation for fuel supply and ignition, we can safely

and efficiently decrease the need for personal attention and adjustment to the components utilized in

burner operation.

It is crucial that field personnel are aware and trained in the operation of the devices utilized on their

field locations. There is a variety of components that may provide similar functions, but with different

operating adjustment parameters. It is our recommendation for affected personnel to review the

operations manuals for any component utilized. This is necessary to insure familiarity and an

understanding of safe work practices related to each piece of equipment and the instrumentation

associated.


TYPES OF BURNER ASSEMBLIES

Sketch of an average fired vessel.

There are many different sizes, shapes, styles, and types of fired production equipment. We are

primarily concerned with the most common types utilized in the oil and gas industry. These are direct

fired and indirect fired.

Emulsion Inlet Gas Outlet

Oil Outlet

Water Outlet


Direct Fired Units

Sketch of a direct fired heater already labeled.

In the operation of a direct fired device, the area of heat generated energy is directly in contact with the

product to be affected. The heat contact is made in a fluid section. Examples of these types of

production equipment would be emulsion heater treaters, heated separators, tank heaters, and glycol

dehydration regen units.

In a direct fired unit, the generated heat energy from the combustion chamber radiates from the

firetube directly to the process stream to be affected, such as the inlet emulsion, or glycol to be

recycled. Routine maintenance and inspections are recommended as extra precaution. This is due to

the nature of the process fluid usually being flammable, and the direct proximity of the heat source.

Water, Oil and Gas Emulsion

Clean Oil


Indirect Fired Units

Sketch of an indirect fired heater already labeled.

In the operation of an indirect fired device, the area of heat generated energy is now providing heat

energy to a media fluid. This media fluid, is heated, and transmits the heat energy to the process

stream. This can be a gas or fluid stream. Examples of these types of production equipment would be

water baths on gas production units, salt bath heaters, or line heaters.

An indirect fired unit is an example of heat exchange in which heat is applied to one media, and then

this heat is transferred to the process stream to gain the desired results.

It is important to know whether the equipment being used is direct or indirect fired. This will assist in

having a full understanding of safe, correct, and efficient operation.

Gas or Emulsion Inlet

Heated Outlet

Fluid Media


BURNER CATEGORIES

The majority of fired equipment contains a fuel train, combustion chamber, the firetube, and stack. We

will discuss the additional components which make up the fuel train and combustion chamber later.

There are many different varieties of burner assemblies. The two most common are liquid fueled and

gas fueled. For our purposes we are only concerned with gas fueled, and more specifically gas fueled

natural draft burners.

Liquid Fueled Burners These are burners that use oil, crude oil, diesel, gasoline, kerosene, etc. for

burner fuel. The units are not typically practical in our area of operational

requirements due to the availability and ease of operation of natural gas

burners. In addition there is a requirement for forced oxygen supply and less

stability resulting in more intensive equipment for operation.

Gas Fueled Burners There are two types of gas fueled burners usually found in petroleum industry

production applications. These are forced draft and natural draft.

Forced Draft Burners Forced draft burners require a blower or fan to force oxygen through the air

intake to be combined with fuel.

The above image is of a forced draft burner on a horizontal heater.


Natural Draft Burners

Platinum BMS-731 units installed on multi-well production units.

This is the area of focus for us. Natural draft burners utilize oxygen supplied by the draft created due to

the heat inside the firetube. The oxygen is drafted into the firetube through a flame arrestor

(sometimes called burner front). The most commonly used fuel is natural gas produced on the site of

the burner systems. There is a broad spectrum of usable natural gas from 850 BTU/scf to 1400 BTU/scf.

The difference in supply gas BTU values will affect the heating capability of the burner. Propane may

also be used as fuel for a natural draft burner. Propane has a higher heating value of 2512BTU/scf.

When using propane, or high BTU natural gas, it may be necessary to reduce the fuel gas pressure up to

40% , or reduce the orifice size up to 40% due to the higher heating value of propane. While not

common, it is not out of the question to find landfill gases, or waste gases being burned in the

petrochemical industry. The btu values of such gases can vary greatly, and may require using supplied

propane to maintain a stable flame. It is essential to have a gas analysis to confirm heating value and

combustibility to use landfill or waste gas as a supply.

The most common type of burner found in the field in petrochemical applications is the gas fired natural

draft burner. These burners are used for convenience and ease of operations. When properly sized and

maintained gas fired natural draft burners will perform reliably. Key components are the fuel gas train,

flame arrestor, burner mixer, burner nozzle, pilot mixer, pilot nozzle, burner management or ignition

device, firetube, and stack. There are additional components that may be found on some installations

such as secondary air adjustment, turbulators, shutters, combustion air controllers, but we will discuss

these later. The burner should be sized according to the expected flow conditions of the location. It is


always preferential to have a gas analysis and Btu content of the gas supply to be used. Note it is a

common practice to move equipment from location to location as wells deplete. This can create a

situation in which improperly sized equipment designed for a completely different set of conditions is on

the site. This can result in poor heating capacity, unsatisfactory equipment performance, or even safety

concerns.

All natural draft burners operate on a gas fuel supply, and are not designed for liquid fuels. The fuel gas

supply will flow from the source. This could actually be the equipment that the burner is situated on.

An example would be a heat treater, or gas production unit. The gas supply flows through a scrubber to

remove liquids, possibly a filter and/or a Y strainer to remove impurities, then to a pressure reducing

regulator to maintain between 5 to 15 pounds average pressure, and then a fuel gas supply valve to

allow for gas flow when required, and to shut gas flow off when not needed. A pilot gas supply is usually

taken from the fuel gas scrubber as well; however this usually operates from ounces, possibly up to 8

pounds (average 2-5 lbs.). In addition there can be relief valves, isolation valves, and gauges in the fuel

gas train. The supply gas then goes into the combustion chamber to be mixed with oxygen which, is

drafted into the firetube via the flame arrestor.

There are a variety of brands of manufacture of all of the components in the fuel gas train and burner

components in the combustion chamber.

It is critical to have an understanding of correct burner adjustment procedures specific to the

components being utilized to insure safe, reliable, and efficient burner performance. Proper burner

tuning is essential to minimize heat release rate and allow for maximum combustion efficiency.

There are several variables to be considered to allow for optimum burner adjustment:

BTU content

Confirm no impurities such as CO2 in gas supply stream

Process volume through vessel

Desired temperature for separation, prevention of hydrates

Fuel gas pressure

Unobstructed flame arrestor

Firetube free of sooting, hot spots, paraffin buildup

Orifice sizing


Liquid in gas stream/plugging or freezing

Primary air

Requirement for secondary air

Correct stack height

Atmospheric conditions and elevation

Correct operation of the burner will prevent excess cycling or excessive heat transfer. Both of these

situations cause inefficient or wasted gas consumption.

Thermal efficiency can be reviewed in some cases using a thermal heat gun. A complete analysis should

be performed using a flue gas analyzer.

Flue Gas Analyzer


TYPES OF OILFIELD EQUIPMENT WITH BURNER ASSEMBLIES

Heater Treater

A vessel that heats an emulsion and removes water

and gas from the oil to raise it to a quality acceptable

for a pipeline or other means of transport. A heater

treater is a combination of a heater, free-water

knockout, and oil and gas separator.

Electrostatic Treater

A vessel that receives emulsion flows and resolves

the emulsion to oil, water, and usually gas, by using

heat, chemicals, and a high-voltage electric field.

This field, produced by grids placed perpendicular to

the flow of fluids in the treater, aids in breaking the

emulsion. The electrostatic treater is also called the

Chemelectric or electrochemical treater.

Heated Separator

An item of production equipment used to separate

liquid components of the well stream from the

gaseous elements. Separators are vertical or

horizontal and are cylindrical or spherical in shape.

Separation is accomplished principally by gravity, the

heavier liquids falling to the bottom and the gas

rising to the top. In this vessel a firetube or heating

element has been added to prevent freezing or assist

with emulsion separation.


Glycol Dehydrator

A unit used to remove minute water particles from

natural gas if dehydration has not been attained

using separators. A glycol dehydrator unit is

composed of an absorber, reboiler, and supporting

components.

Amine Unit

An Amine Unit is a combination of a contactor

tower, surge drum, regenerator, condenser, and

accumulator assembled together with associated

instrumentation for the removal of the acid gases

CO2, H2S, plus additional contaminants from a

natural gas stream. The sour gas is absorbed by

Amine in the contactor tower. Hydrocarbon is

separated from the solution in the surge drum. The

acid gases are stripped from the rich amine in the

regenerator. The now lean amine is circulated

back to the contactor, while the acid gas and

condensed liquids are sent to the condenser for

cooling and then collected in the accumulator. This

process can be found in both field and plant

operations.


Line Heater

A container or vessel enclosing an arrangement of

tubes and a firebox in which an emulsion is heated

before further treating, or in which natural gas is

heated in the field to prevent the formation of

hydrates.

Gas Production Unit

A unit that is a combination of a line heater, and a

separator together on one skid or possibly

enclosed housing. These units can also be referred

to as stack packs and T-packs. More elaborate

units can have multiple combinations housed

together and may include dehydration equipment

as well.


Combustor

A device used to incinerate waste gas emissions

VOCs (Volatile Organic Compounds), and BTEX

(Benzene, Toluene, Ethyl Benzene, Xylenes)

resulting from the production process. It

eliminates and vaporizes these hazardous

emissions by maintaining a certain temperature

at the flash point. Maximum destruction

efficiency is paramount.

Combination Unit

These units may be the combination of a gas

production unit and a dehydration system

combined on the same skid and enclosed.


Multi-well Unit

These units are essentially two or more gas

production units on the same skid and are usually

enclosed. They are designed for use on multiple well

pad locations.

Tank Heater

These are firetubes designed to be mounted in the

door of storage tanks. The units are found primarily

in colder climates.

Flare

A device designed to ignite vent gas and other

emissions. The flare does not have the destruction

efficiency of an incinerator.


THE FIRETUBE

Sketch of firetube and components.

The firetube is an integral part of the burner assembly. As discussed earlier, it allows for control by

design. Without the firetube there would be no requirement for a burner assembly. While we are

discussing fired vessels, it is important to note that fired vessels fall into a category of heated vessels.

Not all heated vessels use an actual fire. We distinguish the equipment in our conversation as fired

vessels, because they do in fact have a fire contained within the combustion chamber and firetube. The

firetube itself houses the flame, a barrier from the process fluids or media, and provides for heat

exchange. The heat produced in the firetube is communicated to the media or process fluids, thereby

raising their temperature.

Wildlife Protector

Stack Arrestor

Turbulators

Flame Arrestor Firetube Return

Bend Flange

Main

Pilot Burner and Igniter Ignition Module

Main Burner


When properly adjusted, the flame in the firetube should not reach further than the beginning of the

first bend of the firetube. It is an important consideration that the flame from the burner does not

contact the firetube wall. Prolonged contact with the firetube wall can weaken the firetube causing

hot spots or weak areas in the firetube that are subject to failure. If a firetube fails, the results could

be catastrophic. A potential for explosion or fire would be possible if for example crude oil came in

contact with the flame from the burner. A serious threat would be posed to safety, the environment,

additional equipment, and revenue in the case of such an event.


Heat Flow in the Firetube

Once stabilized, the temperature of heat in the firetube is generally about the same as the temperature

of the fluid surrounding the firetube. This is possible even when the temperature of combustion is far

greater inside the firetube. This is due to the fact that heat exchanges from the firetube into the fluid

faster than it moves from the combustion gas. Liquid is more dense than flue gas, allowing heat to

move faster.

Note in the illustration the heat flows from the hot gas through the firetube to become flue gas. Heat

moves in the firetube from the inside to the outside. The metal firetube then absorbs and transfers heat

to the liquid.

Example of firetube heat transfer.

Heat Transfer

Heat raises temperature of process.

Heat transfers through firetube shell.

Heat transfers from hot flue gas to firetube.


Example of firetube concerns.

Example of carbon in the firetube.

Example of a hotspot in the firetube.

Example of sooting inside of the firetube.

Be very cautious of hot spots developing on the firetube, as well as scale or paraffin buildup on the

outside of the firetube. This paraffin buildup will prevent heat transfer to the liquid, but will cause the

metal to superheat and development of hot spots or weak points in the firetube.

When liquid hydrocarbon is present, it will not completely burn. This results in coke forming inside the

firetube. This coke will insulate the firetube and prevent well dispersed heat transfer. This will decrease

the bath temperature, and increase the stack temperature. Thereby efficiency is decreased.

Sooting inside firetube. Hot spot in firetube. Scale or paraffin buildup on outside of firetube.


There are 4 different types of return bend designs for firetubes. It is worth noting that the square miter

is the least expensive of the firetube designs, however it is the weakest. The longer the firetube leg,

larger the diameter, and the more temperature cycling, the more susceptible to stress cracking the

firetube becomes. It is also useful to note the firetube miter design for cleaning purposes and whether

the firetube is a horizontal or vertical configuration.

The Firetube Stack

The stack is designed to incite oxygen flow or draft into the firetube via the flame arrestor. Due to this

draft hot gases are expelled from the firetube via the stack. The design size and capacity of the

combustion chamber and firetube dictate the height of the stack. The hot gases will rise ultimately to

be dispersed outside the stack area. This creates a void in the firetube causing a lower pressure area

around the burner. This allows the cooler oxygen to flow (draft) into the firetube and react in the

combustion chamber. This process is integral to the ongoing chemical reaction of combustion taking

place in the combustion chamber. The height of the stack, which may be between 10 and 25 long, is

also designed to insure adequate stack drafting. Stack temperature can be monitored to prevent

excessive heat loss or extreme fuel gas pressures to the main burner. Improper drafting can cause main

and pilot burner flameouts, inefficient fuel consumption, poor combustion, and soot buildup.

Square Miter Firetube Return Bend Designs

4 Miter Square Miter

Smooth Return


Flash Arrestor/Stack Head

Flash arrestor/stack heads installed on production equipment.

Not all fired vessels come equipped from the manufacturer with these devices. They are important

considerations for safe and efficient operations. Flash and stack arrestors are designed to be mounted

at the top of the firetube stack to prevent sparks, flashes, or any burning material from escaping the

stack. Any escaping burning debris could ignite any combustibles that could be around or near the

burner or stack assembly. Sparks are basically burning carbon remnants. An inefficient burner will

generate the burning carbon. This carbon becomes attached to the firetube walls which can decrease

drafting efficiency. This carbon can also crack, fall off, and re-ignite, potentially igniting any

combustible material in proximity. The flash/stack arrestor can prevent these from escaping, but the

burning carbon will cause soot buildup on the inside of the firetube, which leads to additional problems.

The flash arrestor and stack arrestor are mounted on the stack head if the vessel is so equipped. These

devices consist of an arresting element to prevent short duration sparks or flashes. These devices are

designed of sufficient size to not add to backpressure on the stack which would prevent proper drafting.

The stack head is utilized to minimize the possibility of pilot or main burner flame blowouts due to down

drafts, or wind issues. Stack arrestor size must be at least as large as flame arrestor. Accurate sizing

requires BTU requirement, firetube diameter, length, and stack height.

NOTE Not all fired production equipment is supplied with stack heads, stack arrestors, flash arrestors. Installation of these devices is usually determined by the producer, purchased from equipment manufacturer, and determined by state and federal land regulations.


Turbulators

Sketch of firetube and components.

A firetube turbulator is a component installed in the second leg of the firetube past the return bend.

The purpose of the turbulator is increase heat transfer on the back side of the firetube. The turbulator

directs flue gas outward towards the wall of the firetube. This increases heat retention and heat

transfer from the firetube, lowers stack temperatures, decreases pressure loss, increases efficiency,

while decreasing operating expense.

Wildlife Protector

Stack Arrestor

Turbulators

Flame Arrestor Firetube Return Bend Flange

Main Burner

Pilot Burner and Igniter Ignition Module


THE COMBUSTION CHAMBER

Sketch of combustion chamber and components.

The combustion chamber is the front end portion of the firetube adjoined with the flame arrestor. This

is where oxygen from outside the firetube is combined with the supplied pilot and main burner gas for

ignition and sustained combustion. The combustion chamber consists of piping coming in to the

chamber from the fuel gas train, the pilot orifice, mixer and nozzle, the main mixer, and burner nozzle,

in addition to burner ignition components. It is recommended the burner nozzle extend from the flame

cell into the firetube 4.

Inspection Port

Hood

Flame Arrestor

Pilot Gas Fuel Gas

Burner Nipple Burner Mixer

Burner Nozzle

Pilot Nozzle Pilot Nipple Pilot Mixer

High Voltage Cable

Ground Cable

Ten-Conductor Cable

Ignition Module

Igniter Rod

Air Flow

Air Flow

Flange


Flame arrestor orientation and installation.


The Flame Arrestor

Sketch of flame arrestor and components.

The purpose of the flame arrestor is to insure that combustion stays in the combustion chamber. In

case of an explosion, the flame arrestor cools the vapors from inside the combustion chamber to

prevent a potential ignition on the outside of the arrestor. The flame arrestor is the shell that holds the

flame cell. The flame cell is a tortuous path of passages that serves as heat exchanger. This path arrests

all flames providing safety and protection. The flame cell is sized to deliver an excess air level of 15

percent considering the lowest draft amount available for ignition and sustained reaction. This also

serves to dissipate the heat generated internally in the combustion chamber to below ignition

temperature on the outside of the flame arrestor. The flame arrestor flame cell or element is

engineered with sufficient mass to endure being positioned near the burning flame inside the

combustion chamber.

It is important to know that there are two different types of combustions that occur within a

combustion chamber near the flame arrestor. These two types of combustions are deflagration and

detonation. The controlled burning that takes place at the burner tip is known as deflagration. A

substantial flame velocity fed by high internal pressures with extreme gas turbulence is known as

detonation.

Inspection Port

Burner Mixer Gas Inlet

Flame Arrestor Housing Firetube Flange

Burner Nozzle

Pilot Nozzle Pilot Mixer

Burner Mixer

Flame Arrestor


The flame arrestor element is designed to withstand explosions (detonations) in the firetube or prevent

flashes from passing through the element that could potentially ignite outside the flame arrestor. To do

so the wrap density of the flame arrestor must be sufficiently tight utilizing alternating wraps of flat and

corrugated metal. The flame arrestor housing is engineered with the same considerations in mind. In

addition, considerations are made in regards to the design being able to withstand adverse hot and cold

weather conditions. Most modern flame arrestors are made of aluminum or stainless steel in offshore

applications. In the past arrestors were made of carbon steel, and many of these are still in service.

Gaskets used between all jointed components of the flame cell are critical. These gaskets must be in

good shape and provide a seal to prevent fugitive combustible material from exiting the flame arrestor

area.

It is recommended to service flame arrestors and the combustion chamber on a regular basis to be

determined by the equipment usage. It is important to inspect these components for damage, plugging,

debris, wear, holes, leaks, etc..


Benefits of Flame Arrestors

Flame arrestor disassembled.

Flame arrestors have not always been used, and it is possible to find vessels in the field that still do not

have flame arrestors on them. These have what was called a burner front. These can be dangerous as

an open flame may be exposed. These units should be replaced for safety and to be compliant with

regulations in most areas.

The flame arrestor itself provides many benefits:

Ease of inspection and cleaning.

Corrosion resistant.

Explosion resistant retaining band which when maintained allows for a long service life.

Designed to prevent debris and other materials from entering the firetube.

Provides a measure of dampening of burner noise.

Decreases potential for downdrafts or wind to blow out the burner or pilot flame.

Total combustion of fuel gas by providing steady oxygen feed to the main and pilot burners.

An important additional component of the flame arrestor is the inspection port. The inspection port is

typically on the front of most modern flame arrestors and may contain a temperature resistant window.

This port is beneficial for inspection of flame, burner components, and can assist in troubleshooting.

NOTE NEVER REMOVE INSPECTION PORT COVER WHILE A FLAME IS PRESENT IN THE COMBUSTION CHAMBER. A HAZARDOUS FLASHBACK CAUSING INJURY COULD RESULT.


Types of Flame Arrestors

There are a variety of flame arrestor types, brands of manufacture, and sizes. We will illustrate some of

the more common below. Examples are of the T-Type, O-Type, Barrel Type, and A-Type.

T-Type flame arrestor on horizontal treater.

O-Type flame arrestor on gas production unit.

Barrel/Box Type flame arrestor on line heater.

A-Type flame arrestor on line heater.

T-Type O-Type Barrel-Type A-Type


Flame Arrestor Operations

The flame arrestor is a valuable safety device. To remain an asset, and not turn into a liability, the flame

arrestor must be in good operation condition with maintenance performed regularly.

Inspect regularly as determined by usage, weekly, monthly, quarterly, semi -annual. Confirm the flame arrestor element is free of plugging, oily residue, sand, soot, corrosion, etc Look for signs of warping or heat damage. Insure firetube is free of sooting, obstructions, or hot spots Check positioning of burner equipment. Check gas flow through main and pilot burners. Check and test thermostats. Inspect gaskets, and observe sealing surfaces and seams for integrity. Always use new gaskets when performing maintenance or repairs. Clean flanges before re-assembly during maintenance. Flame arrestor and firetube joint seal must be airtight. All seams on firetube must be free of pinholes or cracks. Make sure sight glass cover is clean with no cracks. Be sure inspection cover is in place and sealed. Make sure there are no additional ignition sources near flame arrestor. Remove any flammable materials from the area around flame arrestor. Inspections of fuel gas supply and fuel gas train should be conducted at this time. Inspect and clean any additional flame or stack arrestors at this time.

CONSULT API RP 12N FOR OPERATION, MAINTENANCE, AND TESTING OF FLAME ARRESTORS


Standard Flameco Nomenclature

STANDARD A TYPE F/A SIZES

A Type (Flameco O Type)

MM Btu/Hr. Standard Model # Mixer Style 0.05 SB 12-6-1 Mixer Head 0.10 SB 12-6-1 Mixer Head 0.25 SB 12-8-1-1/2 Mixer Head 0.40 SB 16-8-2 Mixer Head 0.50 SB 16-8-2 Mixer Head 0.75 SB 20-10-3SS Single Stage 1.00 SB 24-12-3SS Single Stage 1.25 SB 26/18-14/3CI Compound 1.50 SB 28/18-14/3CI Compound 1.75 SB 32/18-20/4SS Compound 2.00 SB 34/18-20/4SS Compound

Box Type Flame Arrestor

2.50 SB 30-20B-4CI Compound 3.00 SB 32-20B-5CI Compound 3.50 SB 36-24B-5CI Compound 4.00 SB 38-24B-5CI Compound 4.50 SB 40-24B-5CI Compound 5.00 SB 30-18B-4CI Two Compound 6.00 SB 32-20B-5CI Two Compound 7.00 SB 36-24B-5CI Two Compound

NOTE: Low noise burner applications use the same arrestor, mixer and nozzle combinations, but use a larger orifice.

Firetube Count Compound Mixer Burner Size Box Type Firetube Size Body Length (12 is Standard) Element Diameter Single Burner MB-MultiBurner

SB 12 / 16 6B 1CI (TWO) -


MAIN & PILOT BURNER ASSEMBLIES

Sketch of flame arrestor with burner components.

The burner assembly housed inside the flame arrestor/combustion chamber is made up of the following

components:

Fuel gas supply nipple

Main gas primary air mixer

Main gas burner nipple

Main gas burner nozzle

Pilot gas supply nipple or tubing

Pilot gas orifice

Pilot gas mixer

Pilot gas burner tip

Inspection Port

Hood

Flame Arrestor

Pilot Gas Fuel Gas

Burner Nipple Burner Mixer

Burner Nozzle

Pilot Nozzle Pilot Nipple Pilot Mixer

High Voltage Cable

Ground Cable

Ten-Conductor Cable

Ignition Module

Igniter Rod

Air Flow

Air Flow

Flange


Keep in mind when adding a Platinum Burner Management System or Igniter, you will also see the

following components in the combustion chamber and firetube area. These items will be discussed later

at length.

Igniter module

10 conductor wire from BMS panel

Ground wiring

Ionization rod wiring

Ionization Rod and standoff

When installing or performing burner maintenance, make sure and inspect each of these components to

confirm working condition.


The Burner Nozzle

Sticktite Burner Nozzle

Rosebud Burner Nozzles

Slotted Burner Nozzles

The burner nipple, burner tip, pilot nipple, and pilot tip are all non-adjustable and designed according to

manufacturer specifications. They only need to be inspected and cleaned periodically or replaced if

needed.

Many different styles of burner nozzles are available. These diverse nozzles provide specific flame

shapes to meet the firetube application. Single port nozzles that produce long cylindrical flames work

well on equipment with long firetubes. These nozzles may not work as well on firetubes with shorter

firetubes that may require more modest fuel gas supply pressures. Nozzles with smaller ports are more

suited to shorter firetube applications. For example a rosebud style nozzle produces a shorter bushier

flame suited to vertical heat treaters with firetubes typically less than 6 long. Just as with the pilot

nozzle, main burner nozzles have a ring of smaller ports around the main burner port. These ports serve

to keep the flame by continuing to ignite fuel as it is diverted through these ports.


The Mixer

The main burner mixer is designed to mix the oxygen supply and fuel gas for ignition of the main burner.

This component can see fuel gas pressures between 5 psig to 30 psig. An average is more likely to be

between 8 psig and 15 psig. This varies due to the type of equipment, size of burners, and btu value of

the gas.

The mixer for the main burner gas is adjustable with gas flow stem, orifice and usually an air shutter.

This is by design to allow for mixing of primary oxygen and fuel. Flame adjustment is performed utilizing

the fuel flow stem and air shutter and pressure from the fuel gas supply regulator. Most manufacturers

recommend a main burner flame that is mostly blue with flecks or fingers of red and yellow at the flame

tips. The burner pictured above uses primary air, or a single air source being drafted in through the

flame arrestor. This air volume is adjusted using the primary air shutter. In cases where it is difficult to

establish anything but a long yellow potentially smoky flame a secondary air source should be

considered. Note there are other circumstances that can cause similar symptoms such as restrictions of

the orifice, mixer, or burner nozzle. The nozzle pictured above comes equipped with venturi. Many

modest size burners do not have these. The venturi can increase burner efficiency. Much like an orifice

the venturi regulates the flow going to the burner and disperses the gas stream at a lower velocity than

the mixer inlet.

Image of an eclipse mixer with single state venture.

Sketch of parts breakdown of an Eclipse mixer.

Single Stage Venturi Mixer Head Primary Air

Adjustable Orifice

Fuel Gas Inlet


The Pilot

Assembled Platinum pilot assembly.

The pilot assembly is a similar but smaller version of the main burner. The majority of pilot mixers are

non-adjustable however, there are adjustable pilot mixers available that can be used to improve

operations with very rich or very lean gas mixtures. Positioning of the pilot tip is crucial as main burner

ignition cannot be achieved otherwise. Additionally the position of the flame ionization rod used to

ignite the pilot i

Technical Training Manual v2

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Transcript of Technical Training Manual v2