INSTALLATION PROCEDURE

FOR THE FLARE IGNITION

EQUIPMENT

Client : GPS Singapore

Purchaser : PTCS

Location : Vietnam

Flareon Project # : 12-7391-FO726

Date : 2012

For Parts and Service please contact:

FLAREON INC
Kuala Lumpur, Malaysia
Email: info@flareoninc.com

This Flare Equipment must be installed by qualified personnel in accordance with the local
applicable Electrical Code and this Installation Manual.

Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 1 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 TABLE OF CONTENTS

A) INSTALLATION OF THE FLARE IGNITION EQUIPMENT

B) INSTALLATION OF ADDITIONAL FLARE EQUIPMENT

REFERENCE DRAWINGS / DOCUMENTATION

FI726–FTGA–MDW–0100 FLARE TIP GENERAL

ARRANGEMENT

FI726–PID–PDW–0100 PIPING AND INSTRUMENTATION

DIAGRAM (P&ID)

FI726–CPW–EDW–0100 CONTROL PANEL WIRING

DIAGRAM

ALL APPLICABLE PACKING LISTS

ALL RECOMMENDED MI CABLE INSTALLATION PROCEDURES

Installation of the Flare Tip and Flare Ignition Equipment at the

discretion of the Onsite Installation Team, and the following is the
suggested Flareon procedure only.

Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 2 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
A) INSTALLATION OF FLARE IGNITION EQUIPMENT

1. All Pilots supplied come completely assembled. No further assembly of the

Pilot is required.

2. Remove Pilots from crate and remove all plastic wrap.

3. Open Ignitor Ignition Transformer door on Enclosure to inspect and make

sure nothing has come loose in shipment or is damaged. Close door and
make sure it is tightly secured.

4. Mount the three (3) Flareon Model 2000 Pilots on the Pilot Clips with the
Ubolts / Double Nuts provided in the proper orientation and position as
shown on the GA drawing.

5. The clip on the top of the backside of each Pilot slides into the slotted clip
below the Windshroud on the Flare Tip. Each Pilot weights about 75 kgs
(165 lbs).

6. Lift the Pilot on an angle and insert the Pilot Windshroud through the
oblong hole in the Windshroud on the Flare Tip until the Pilot clip can drop
into the slotted Flare Tip clip.

7. The Pilot will mount either on the left or right hand side of the lower clip.
View alignment of Pilot parallel to Flare Tip to determine the best / proper
location. Secure the Pilots with the Ubolts / Double Nuts provided. Hand
tightens bolting for now.

8. Mount the Pilot Manifold to the Pilots in the proper orientation and position
as shown on the GA drawing.

9. Bolt the Pilots to the Pilot Manifold with the Gasket, Studs and Nuts
provided.

10. If it is found that the Pilot flange will not lineup with Pilot Manifold flange,
the Pilot flange / pipe can be turned tightened slightly to fit with two pipe
wrenches. Care should be taken not to over torque or tighten the Pilot
flange / pipe into the venturi as cracking could occur.

11. Once Pilot Manifold is secured to the Pilots, then the Pilot Ubolts can be
tightened in place.

12. Once the Pilot Manifold is secured then the Pilot fuel gas supply piping can
be fitted and welded into position.

Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 3 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
B) INSTALLATION OF ADDITIONAL FLARE EQUIPMENT

1. After Pilots/ Ignitors are installed, then the Thermocouples can be installed
in the Pilot Thermowells. The Thermocouples should have the Swagelock
fittings preinstalled already.

2. If not, then the SS-200-1-8 fitting slides on the end of the Thermocouple
first. The threaded end of the fitting goes towards the (2) wire leads at the
base of the Thermocouple.

3. The SS-200-7-2 fitting slides on next. The threaded end of the fitting goes
towards the end of the Thermocouple and threads onto the Pilot
Thermowell.

4. When installing the Thermocouples, uncoil about 3 meters of the insert

end. Insert the Thermocouple into the Thermowell and push it in until the
Thermocouple comes to a stop when the end of the Thermocouple hits the
end of the Thermowell. Pull the Thermocouple back about 10 mm then
secure the Thermocouple to the Thermowell with the Swagelock fitting.
Tighten both the fitting to the Thermowell and then to the Thermocouple.

5. Locate the Thermocouple / Power Junction Boxes as per CPW-EDW-

0100, Page 10.

MOUNTING of JB-01 (Thermocouple) and JB-02 (Power)

6. Locate the junction box bracket at the base of the Flare Tip and mount
these Junction Boxes away from possible heat exposure. Carefully mount
the junction boxes onto this bracket ensuring that they are equally spaced
and squarely mounted.

7. Now the Thermocouples can be tied into the Thermocouple Junction Box
JB-01. The Swagelock fittings thread into the Conduit fittings on the
bottom side of the Thermocouple Junction Box. Tighten both the fitting to
the Junction Box and then to the Thermocouple. Make sure the fittings in
Junction Box are tight as well.

8. Take excess coil of the Thermocouples and tuck up beside the Junction
Box underneath the platform. If this is not possible coil them out of traffic
on the Maintenance Platform so they are not stepped on later and
damaged. Secure with SS tie wraps.

9. Terminate the (6) Thermocouples to the Terminal Block in the Junction

Box as per the Control Panel Wiring Diagram.

Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 4 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 10. Now the three (3) ½” SS Power Flex Hoses can be tied into the Power
Supply Junction Box (JB-02) The ½” Flex Hoses thread into the Conduit
fittings on the bottom side of the IDE Enclosure and the Power Supply
Junction Box. Tighten both and make sure the fittings in both the IDE and
Junction Box are tight as well.

11. Take excess coil of the Flex Hoses and tuck up beside the JB underneath
the platform. If not possible coil out of traffic on the Maintenance Platform
so they are not stepped on later and damaged. Secure with SS tie wraps.

12. Each Flex Hose has (3) lengths of 14 AWG Hi Temp Wire (Black / Yellow /
Red) in them. Insert wire through Flex hoses and terminate to the Terminal
Blocks in the IDE and Junction Box as per the Control Panel Wiring
Diagram. Black is hot, Yellow is neutral, Green is ground.

MOUNTING of JB-03 (Thermocouple) and JB-04 (Power)

13. Locate the Thermocouple / Power Junction Boxes as per CPW-EDW-

0100, Page 8. Junction Box JB-03 & JB-04 are to be installed on a
Junction Box Mounting Bracket located at the base of the Flare Boom.

14. Carefully mount the junction boxes onto this bracket ensuring that they
are equally spaced and squarely mounted.

15. Locate the MI Power and Thermocouple Cables. Each comes complete
with threaded fittings to tie-in to the Junction Boxes. Cable Tray for
installation is not provided and to be supplied by others.

16. Now the MI Thermocouple Cable can be tied into the Thermocouple
Junction Box (JB-03). The MI Cable comes with threaded fittings that
thread into the Conduit fittings on the bottom side of the Thermocouple
Junction Boxes. Tighten MI Cable to the Conduit fittings and make sure
Conduit fittings in Junction Box are tight as well.

17. Take excess coil of the MI Thermocouple Cable and tuck up beside the
Junction Box out of traffic at the base of the Flare Boom so they are not
stepped on later and damaged. Secure with SS tie wraps

18. Now the MI Power Cable can be tied into the Power Supply Junction Box
(JB-04). The MI Cable comes with threaded fittings that insert into the
bottom side of the Junction Boxes and are secured with the Nut and
Washer provided.

19. Take excess coil of the MI Power Cable and tuck up beside the Junction
Box out of traffic at the base of the Flare Boom so they are not stepped on
later and damaged. Secure with SS tie wraps.
Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,
Taman Sans Selangor 1, Kota Damansara, PJU 5 5 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 20. Terminate the MI Thermocouple Cable to the Terminal Blocks in the
Junction Boxes as per the Control Panel Wiring Diagram.

21. Terminate the MI Power Cable to the Terminal Blocks in the Junction
Boxes as per the Control Panel Wiring Diagram.

22. Connect the incoming Instrument Cable and Power Cable to JB-03 and
JB-04 with the Cable Glands provided.

23. Terminate the Instrument and Power Cable to the Terminal Blocks in the
Junction Boxes as per the Control Panel Wiring Diagram.

After final checks are made to all applicable Reference Drawings, the
Flare Equipment is ready for Startup, Commissioning and Operation.

Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 6 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
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Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,

Taman Sans Selangor 1, Kota Damansara, PJU 5 7 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727