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The following list covers those typical problems with Flame Front
generation which are largely responsible for many problems and
unsatisfactory reports of Flame Front generator usage.
Incorrect Mixture:
The pressure requirements for Gas and Air sometimes change due
to variations in gas composition or even due to changes in ambient
temperature and pressure. If problems are experienced using gas
and air pressures which have been previously successful, return to
the original set up procedure of the instructions and find a new
mixture.
Impatience of the Operator:
The flame travel through the flame front line and the time taken to
fill, purge and refill the line during ignition attempts are all time
consuming. Trying to start a flame front too frequently will only lead
to extinguishing of previous attempts before the flame front has
had time to complete its run to the pilot.
Cold Climate:
During severe winter conditions, an ultra-cold flame front line can
quench the flame by cooling the flammable mixture as it flows to
the tip. This may create narrower flammable limits within the line
than those which exist at the ignition panel. Thus a flame may
ignite at the panel but be quenched as it progresses further along
the pipe. Flammable characteristics may also change in the line if
cooling causes dew-point fall out of heavy components.
To resolve this problem,
- increase all settings to provide a greater flow rate and try to
minimize heat transfer;
- if possible, change fuel gas to a composition with minimal dew-
point concerns;
- in the extreme case, heat tracing and insulation of lines may be
needed.
FLARE OPERATIONS
Initial Preparation
5. Check that pilot fuel gas, ignition fuel gas and ignition air are
available upstream of isolating valves or line blanks.
8. Open the isolating block valve for the pilot fuel gas supply
and set the pressure regulator according to the Pilot Burner
manufacturer's instructions. If you do not know the correct
pressure, check it.
Most suppliers use pressures in the range of 5 - 15 psig with
individual pilot gas flows providing a pilot flame in the range
of 50,000 Btu/h - 250,000 Btu/h.
9. Allow sufficient time for the fuel gas to reach the pilot after
displacing the air or purge gas from the pipe line. The
length of time needed will depend on the length and
diameter of the fuel gas line to the top of the flare, as well as
the number and style of pilot being supplied.
As a conservative estimate, estimate 1 second gas travel
time per square inch of pipe internal area for every 1 ft
length of pipe.
[1500 ft of 1" pipe could take up to 20 minutes][1000 ft of 3"
pipe could take up to 2 hours]
Manual Operation of a Flame Front Generator
1. Check that the flame front piping is dry, that all the drain
valves have been closed.
2. Open the isolating block valves on the ignition fuel gas and
air supplies.
5. Carefully note which is the gas train relative to the air train
on the panel.
Set the ignition fuel gas and air pressure regulating valves to
give the manufacturer's recommended setting. If this is not
known use approximately 5 - 10 psig for each, for the initial
trials.
7. Allow sufficient time for the gas and air mixture to fill the
flame front pipe all the way to the pilot. Approximately 10
seconds per 100 feet of pipe run should be adequate for a 1"
pipe.
11. Remember that, after the flame passage along the line, all
that hot flue gas has to be purged out before you get back to
the useable mixture so patience is the order of the day.