Installation Manual - manual gasflare FAI 2.

The Bilgeri EnvironTec GmbH reserves the right to make changes at any time, in order to adapt the
operating manual to the current state of technology.

Copying and distributing this operating manual, or excerpts thereof also its translations, requires the

EnvironTec written approval from Bilgeri EnvironTec GmbH.

Ali trademarks mentioned in this operating manual and its respective proprietors are acknowledged.
Bilgeri EnvironTec GmbH does not lay any claims to the rights of these trademarks.

The scope of delivery and delivery execution may deviate from the illustration on the title page.

Manual Gas Flare

FAI

Article number of this installation number: FAI_ENG_v2014-02.

Bilgeri EnvlronTec GmbH

Schilfweg 1
A- 6972 Fussach
Telefon: +43 (0) 55 78 7 70 OS
Fax: +43 (0) SS 78 7 70 05-300
E-Mail:info@environtec.at
Internet: www.environtec.at

© 2013
Status: 2013, translation of the originial
Ali rights reserved
Installation Manual
Pnnted in Austna.
 lnstallat1on Manual - manual gasflare FAI 3 lnstallat,on Manual - manual gasflare FAI 4

Contents: 9.3 Operat,on ....................................................................................... ... ............................ 32

1. GENERAL .............................................................................................................................. ... 5 9.4 Takmg out of operat10n ................................................................ .................................. 34
1.1 To the operating personnel .•......... ..•... .. .................................. ........................................•. s 10.Malfunct,ons and removal malfunct10ns .. .................................................................................. 35
1.2 Supportlng documents ..................................................................................................... 5 10.1 Behav,our in case of malfunct,ons ................................................................................... 35
1.3 Safekeeplng thls manual ...................................................................................................s 10.2 Troubleshootmg .................. ........................................................................................... 35
1.4 To understand thlS manual bette, ..................................................................................... 5 11.Maintenance ................................... ........................................................................................ 37
2. Safety.................................................................................................................................... 6 11.1 Safety dunng maintenance .............................................•.........•.... ................................. 37
2.1 Correct use ......................................................................................................................6 11.2 Record ........................ ..................••.......................•....•.•......•.•...........••......•................... 37
2.2 l mproper use .. .........................................................................................•.•.••..•.•..........• 7 11.3 lnspekt10ns- und Wartungsplan ....................................................................................... 38
2.3 Operatlng personnel quahficabon ...................................................................................... 7 11.4 Torques ................................................................................................................ ......... 39
2.4 Warnlng, mandatory and information sIgns on the devtce .................. ............. ...... .......... 8 11.5 lnspect,on and maintenance work ................................................................................... 39
2.5 Basic safety Instructions ...................................................................................................9 11 6 Restart .... ... ....... .... .. ................ ................. ...................................... ............................... 44
2.6 Due diligence of operator .................................................................................. ............. 10 11.7 Spare and weanng parts .. ...... .......................... ....... .... ........ ... .. .. ......... .... ...... ........ ... ..... . 44
2.7 Product liab,hty .............................................................................................................. 11 12.Appendix ..... ....... ............................................. ....................................................................... 45
3. Aufbau und Funkbon ............................................................................................................... 12 12.1 Checklist for mItIal start-up ............................. ............... ................................................. 45
3.1 General lnformation ......... ............................................................................................... 12 12.2 Proof of repair work and leak tests ......... .................................................. ....................... 46
3.2 Assembly ..................................... .................... ..... Fehler! Textmarke nlcht definlert. 12.3 Annex ............................................... •........•. .••.• .....•............................................•.. ........ 47
3.3 Func:t10nal pnnaple of the gas Hare ................................. ... ........................................... 13
3.4 Gas tiare, standard commponetns ................................................................................. 13
3.4.l Hauptkompooenten, mechamsch •.•...•.••..•.............. Fehlerl Textmarke nlcht definlert.
3.4.2 Mam components, e!ectric, contrai.. ................................................... ........ .............. 16
3.5 Gas tiare, add-on equlpment and options ............ ............................................................ 18
4. Transportabon and storage .................................................................................................... 19
4.1 Transport. ........................ ............................................................................................ 19
4.2 Storage ............................. ......... ........ ............................................................ ... ............ 19
5. Ueferumrang ..................................................................... Fehler! Te xtmarke nichtdefiniert.
5.1 Gas flare FAJ .................................................................................................................. 20
5.2 accessones ..... .... ........................................................................................................... 20
6. JdentiflC1!tlOl1 plate ............................................................................................ ...................... 21
6.1 l dentificatlOn plate gas Rare FAl ...................................................................................... 21
7. technlcal data .. ... ................ .............................................. .... ............................. ~····•··· ........... 22
7.1 Gas Rare general informatlOll .......................................................................................... 22
7.2 Gas nare by mode! size ...................................................................................................22
7.3 Accessories .................................................................................................................. .. 22
8. l nsta llatlOll ................ .............................................................................................................. 23
8.1 Place ofuse ............ •......................................••..............................................•............•.• 23
8.2 Installation and setup ............................................................................•........................ 24
8.3 Alter mstallatlOn and before initial start up....................................................................... 28
9. Start up and operat,on............................................................................................................. 30
9.1 Initial start up ................................................................................................................ 30
9.2 Start-up ............................ ........ ..................................................................................... 31
Installation Manual - manual gasflare FAI s Installation Manual - manual gasflare FAI 6

2. SAFETY

1. GENERAL
1.1 To the operating personnel
This operating ma nuai informs about the safety, assembly, function, ope ration and maintenance of the
gas tiare. If properly following the instruction, a long, trouble free and safe operation is guaranteed.
The Bilgeri EnvironTec GmbH gas tiares are designed and constructed taking into conslderation the
highest safety requirements, and upon carefully choosing other matching standards to follow, as well
as other technical specifications. It meets the current state of technology and guarantees the highest
measure of safety. However, in operating conditions this safety can only be achieved if all necessary
measures are followed. It is subject to the due diligence of the operator to plan and execute these
measures and to contrai its execution.

1.2 Supporting documents 2.1 Correct use

See Annex The gas tiares of type FA! are conceptualized for burning of explosive gases of the Group IIA
temperature class Tl (methane with C02 biogas plants or water treatment plants).

1.3 Safekeeping this manual

f1ibdiHfüi
Danger of explosion!
The manual (including supporting documents) is always kept in legible condition, available
completely at the operating location!
The FA! type gas tiare is only permitted for using outside of the Ex zones.

1.4 To understand this manual better • From the customer sicle it must be made sure that unintentional operation in and explosive
atmosphere is safely prevented. See operator Ex-protection zone plan.
Conventions • The operation of the manual gasflare must be carried out under the supervision of the operating
staffs! When uncontrolled tlame extinction (eg by a gust of wind), butterfly valve must be closed

f1iM:Hfüi
This danger symbol refers to an imminent threatening, serious, danger, which leads with certainty to
immediately in order to prevent the further gas flow. Ther starting procedure must be
performed again.
If automatic option is chosen, the gasflare is monitored automatically and the procedure

-
serious injuries or even to death, if the danger is not avolded. discribed above is not applicable.

The burning of explosive gas/air mixtures in the gas tiare in not permitted!

Any other use is considered as unauthorized and is thus explicitly prohibited.

This danger symbol refers to a possible danger, wh1ch can lead to serious injuries or even to death, if
the danger is not avolded. The operator of the gas tiare is responsible for all damages caused if not operating the unit properlyl

Proper use lncludes:

!AVORSICHT ! • Following all notes in this operating manual
This danger symbol refers to a potentially, dangerous situation, which can lead to medium or light
injuries or property damages, if it is not avolded. • following the mandatory, prohibition and warning signs on the system

• Complying with the inspection and maintenance lntervals.

IMM3€1
This symbol refers to supportlng information.

Cross-references
Cross references are presented in italics.
Installation Manual - manual gasflare FAI 7 Installation Manual - manual gasflare FAI 8

2.2 Improper use 2.4 Waming, mandatory and information signs on the device

If not usmg as lnstructed (improper use), for example: The following signs can be found on the gas flare (OIN 4844):

• 1f not usmg m accordance with the conformity statement.

• incorrect mstallatJOn m the system Unauthorized access is prohibited !

• if the gas flare, including contrai cabinet are not ready for operation, or were mod1fied

• by taking the safety devices out of operation

• by unauthorized access ta the sw1tch cabinet and wmng Fire, open light and smoking is prohibited !

• by using other types of gasses

.•• the system may be destroyed.

Warnmg of explosive atmosphere
This results m the operatar being exposed ta incalculable increased danger potential, for example by:

• hot parts
Warning hot surface
• explosion

• electrocut1on

• uncontrolled gas leak Warning of dangerous electrical current

• creat1ng an explosive atrnosphere

• poisoning with health damag1ng gas components, etc.

Observe operating manual
The system must 1mmediately be shut-down if there are any changes!

2.3 Operating personnel qualification

Only trained and mstructed personnel is allowed ta operate the gas flare. The completJOn of the
instruction should be documented in writing.

Only a qualified electrical engineer is allowed ta work on the electncal equipment!

Installation Manual - manual gasflare FAI
2.5 Basic safety instructions
The safety instructions are for purposes rK avoiding persona! injury and darnaging the gas flare and our
environment. Ali operatars are obligated ta read and always follow these safety instructions.
General Information
Please follow the safety rules, the relevant accident prevention rules for biogas plants and those for pits
and channels, the national implementation of directive 99/92/EC, and other rules of technology.
In addition ta the Operating Manual, the generally valid and local regulations on accident prevention,
health and safety and the regulations on environmental protection must be readily available and
followed.
People under the influence of alcohol, drugs or prescription medicine, may not transport, setup, start
up, operate or repair the gas flare system.
The minimum age of operating personnel 1s 18 years.
Make sure that the operating personnel 1s instructed on ail applicable questions conceming work safety
and environmental protection, and that they understand and follow the operating manual, particularly
the safety instructions contained therein.
Please follow ail warning and information labels attached ta the gas flare. Also ensure that such signs
are not removed and always remain legible. (See above).
Defects ta the gas flare must be removed immediately. The manufacturer must be notilied immediately
in the event of malfunction. Do not make any changes or reconstruction yourself.
When exchanging defective components, use only original components with the same electrical and
mechanical data. Otherwise, this will not maintain safety and function.
Ali safety equipment, fasteners and electrical connections and lines must be checked regularly for proper
condition.
Unrestricted access ta the gas flare by people or animais must be prevented with suitable means (e.g.
safety fence).
6i5Htifüi
Danger of electrlc shockl
Electrical work is may only be performed by qualified electrical engineers. An electrical engineer is
someone, who based on professional education, knowledge and experiences, as well as knowledge of
the relevant regulations of the assigned work, is able ta recognize potential dangers and take appropriate
safety measures.
• When working on starter electrodes, it is mandatary ta operate the emergency shut-off switch,
or safely interrupt the power supply. Please also stop the gas supply by closing the manual tlap.
• Before working in the switch cabinet, rnake sure ta shut-off the power supply, and secure it
from unintentionally switching back on, and attach the respective waning sign.
9 Installation Manual - manual gasflare FAI 10
tiiSHiHfüi
Wamlng of risk of explosion and flammable atmospherel
Installation and repair work on systems protected frorn explosion is completed by personnel
appropriately trained who follow the 99/92/EC directive and the safety and maintenance instructions of
this operating manual.
tîib#iHfüi
Rlsk of bums!
caution! Methane flames are invisible
• Shut-off the system before working on the burner or ignition electrodes.
• Make sure that all parts are completely cooled off.
Rre Hazard!
The safety distance ta prevent damage by lire impact on buildings and surfaces of stationary traffic
should be 5 m •provided not otherwise stated in relevant local fire protection provisions.
• the Sm surrounding area around the gas nare must be kept free of any growth (bushes, trees).
Within this safety distance, fire, open light, smoking and storing of flammable or ignitable
materials is prohibited.
In justilied exceptional cases these distances may be reduced, if other measures for avoiding fire impact
are ensured for the surrounding area.
2.6 Due diligence of operator
As the operatar, you must especially make sure that
• the gas tiare is only used as instructed.
• The gas nare is only operated when functioning properly, and especially that the function of the
safety equipment is checked regularly. If there is damage or destruction, or a riskfree operation
of the gas tiare cannot be guaranteed for other reasons, then the system must immediately be
taken out of operation and may under no circumstance be put back into operation.
• The necessary persona! protective equipment is available and is used by the operating,
maintenarice and repair personnel.
• The instruction manual is always in legible condition and available completely at the operating
location.
• Only adequately qualified and authorized personnel may operate, maintain and repair the
system. The personnel is regularly instructed in all questions coriceming work safety and
environmental protection, understands the operating manual and especially the safety
instructions contained therein.
Ali safety and waming signs attached ta the gas tiare are not removed and remain legible.
EnvironTec GmbH will not assume any responsibility for damages or operating malfunctionsthat have
been created by improper use or gross negligence.
Installation Manual - manual gasflare FAI 11 lnstallatKJn Manual - manual gasflare FAI 12

2.7 Product liability 3. COMPONENTS AND USE

Llablllty exduslons 3.1 General information

For persona! injury, property damage, environmental and/or operating damages caused by not
followrng, or not completely follow,ng the operat,ng manual, Bllgeri EnvironTec GmbH will not assume
fiability. Unauthonzed contact with the system will result in termrnation of the warranty. Brlgen
EnvironTec GmbH will not assume liability or warranty, if another spare part rs used instead of the
ongrnal spare part recommended in the operating manual or in the spare part lrst, and the use of non·
original spare parts has led to persona! rnJury, material damages and/or failure of the system.
Warranty and liabilrty claims for persona! inJury, property and environmental damages are excluded if
the damage or injury is attributable to one or more of the followrng causes:
• Improper transportation, assembly, start-up, operatron or repair of gas flare
• Not observing the instructions in the operatrng manual regarding assembly, start-up, operation
and maintenance.
• Unauthorized contact or structural changes of the gas tiare
When operating biogas or water treatment plants it may be necessary under certain circumstances to
safely burn excess gas, for example during start· up, maintenance, in cases of consumer accidents or ln
case of failure of gas flow (CHP [Cogeneration Unit], etc.).
The FA! gas flare 1s a safety device that functions manualy (optronal: fully automatic). It is manufactured
completely from stainless steel and equipped with high quality components and instruments.
Safety Features
With the respective dimensionrng of the flow cross-sections, blowrng out or return of the flame 1s
prevented. If the flame should return anyway, it is stopped by the deflagration protection. Damage to
other systems parts its thus excluded.
The entire electrical equipment was configured according to DIN VDE 0116, and meets the highest
safety engineering standards.

• Poor monitoring of parts that are subject to wear or agrng 3.2 Structure

• Improperly completed reparrs The gas tiare can be obtarned rn varrous srzes. See 7.2 Gas llare by mode! sae.

• Improper use of the gas flare

IMMMI
The descnptions and rnstructJons rn th1s operatrng and maintenance manual refer to the standard
designs. Therefore, not ail details and condrtrons have been mentioned. If missing informatron, please
contact Env1ronTec GmbH immediately.

For details about our warranty please refer trJ our general terms and conditions, or your agreement
documentation.
Installation Manual - manual gasflare FAI 13 Installation Manual - manual gasflare FAI 14

3.3 Functional principle of the gas flare

Deftagratlon·protectlon
Manual operatlon

To start the flare, first the butterfly valve must be opened and the ON button must be pressed
lmmediately after. Pressing the on button will sparc the flare and the flare starts buming. After the flare
starts buming, stop pressing on the ON button.
To stop the flare, close the butterlfy valve.

Automatlc operatlon (Option)

The start/stop command is issued by an external signal (e.g. gas storage fill level). The
monitoring/autornatic functions described for the hand operation will take place as described above.

Automatlc operatlon / pressure contrai (Option)

As an option the flare may be equipped with an additional pressure control. If exceeding the pressure
previously defined on the pressure controller ( =max. controller), the flare starts automatically (as in
normal autornatic operation) . If the pressure falls below the specified shut-off pressure ( =min. pressure
controller), the flare is automat1cally shut off (time delayed).
The funct1ons of the hand and automatic operation will proœed as described above.
3.4 Gas flare standard components
3.4.1 Principal mecanical components
Butterfty valve
Fig. 3: Deffé1gralion prolEdion in the instalfatbn positkJn!+ f1ame Hier in detal
Prevents the effective creation of pipe deflagrations (accelerates deflagration in the piping, which is
moving in the pipe axle direction with a flame extension speed below the sound of speed).
A statically dry flame protector made of spiralled bound metal bands with flame extinguishing gaps is
used. The flame is extinguished by heat output in the boundary layer "s" to the larger surface of the
gap, in relation to the gap width D and lowering the temperature below the ignition temperature of the
product.
As an option, the deflagration protection may be equipped with a temperature gauge on the "hot'' side.
Burner head / combustion chamber

Fg. 2: butœrfly KWe Fig. 4: Lw buner hei1d in the ambustial chamber

By default one (or more) diffusion burner heads are used. There 1s a mixture of fuel and oxidant (air)
The manual vavle ls used for manually opening and closing the gas supply lines for repairs or when in the combustion chamber. The mtxing is essentially completed by diffusion and leads to the formation
taking out of operation as an additional shut-off valve. lt is equipped with a hand lever and an opening of a diffusion flame.
regulator. Below the burner head, there is a air dise to regulate the air flow.

The burner heads are replaceable and are manufactured from temperature resistant stainless steel.

Flare base, plplng and combustion chamber

Installation Manual - manual gasflare FAI 15 Installation Manual - manual gasflare FAI 16

3.4.2 Main components, electric, control

Ignition electrodes

F,g. 7: Ignit,on electrodes m mstallation condlàon, v,ew from the bottom

Fig. 5: OveraH v.av of the /lare base, pPhg and axnbustbn chamber
The entire gas flare is manufactured from stainless steel. The base and frame, as well as no gaswetted
parts are from matenal 1.4301,the entIre gas piping and the combustion chamber of material 1.4571.
The combustion gas is ignited directly above the burner head by means of two high voltage ignition
electrodes. An electric arc is generated between the ignition electrodes, which under normal
circumstances will immediately Ignited the gas mixture.
Control / swltch cabinet (option)

Anchoring

Fig. 8: Swi/d1 cabinet· view of the door wlth lghts and SWitches

1 Swltch: Manual-OFF-Automatic 5 Dlsplay (optional)

2 Signal lamp motor valve open(optiona/) 6 Emergency stop button
3 Slngnal lamp operating (opt;onalj 7 Inspection tag
4 Slngal lamp errer or reset button
Fig. 6: view of the andlorhg
The most important control elements (SPS control module Omron, flame detector, ignition
The gas flare is anchored using a heavy load anchor system on the foundation anchored by the customer transformer, mode selector••• ) of the flare are stored m the flare switch cabinet and are
sîde. mterconnected / wired accordingly.
Installation Manual - manual gasflare FAI 17 Installation Manual - manual gasflare FAI 18

3.5 Gas tiare, add-on equipment and options

The switch cabinet is delivered in the series production made from plastic (protection type IP
54), including switch cabinet heating, emergency stop button (formerly emergency off button)
Display on the tiare switch cabinet
and signal lamps. As an option the delivery may be made in a stainless steel design. As an option an
autornatic burner contrai could be chosen.

The power supply needed is 230 V, 50 Hz. The respective operating conditions of the gas flare are
displayed by means of pilot lights on the switch cabinet.

Communication (only available if automatic option is taken)

The flare contrai can be directly incorporated in the control/visualization of the respective operating
plant (biogas plant, digester gas, or similar). The following signais are planned for this purpose:

Central Control Gas Flare Gas Rare - Central Control

• external on or off (for "on" signal the • Automatic valve open - without limit
flare signal "on" is withdrawn, it will position monitoringVâlvula automâtica
stop) abierta - sin control de limite de posicién
• Fault acknowledgement • Operating message
• Malfunction Ftg. 10: Display on the switr:h cabinet
1. Dlsplay
Grounding connectlon
Optionally, a LCD display may be integrated in the flare switch cabinet. Depending on customer request
/need displays about the current flare status, combustion temperature or other parameters may be
implemented.

Electrical heatlng of the fittlngs

Generally, biogas is 100% humidity saturating. To prevent iœ format10n or freezing of the valves, an
electrical support heater with thermostat may be used, and the fitt1ngs can be insulated additionally.
For this purpose the valves and applicable piping sections are covered by a heating cable. The
temperature contrai occurs via a thermostat in a manner that the fittings are always kept at > O °C.
The heated system parts are then also insulated.

Fig. 9: Grounding connection of the gas nare (with identification label}

In the standard production the gas flare is equipped with a grounding connection to a gas flare base.
From the customer side, the connection must be completed according to the local or national
regulations.
Installation Manual - manual gasflare FAI 19 Installation Manual - manual gasflare FAI 20

4. TRANSPORTATION AND STORAGE S. SCOPE OF DELIVERY

The gas flare is available in the following mode! sizes:
4.1 Transport
• Gas flare FA! 50
The gas flare is packaged by Env,ronTec GmbH ex works in a manner that it can be transported
smoothly. • Gas flare FA! 100

The gas flare ,s t,ed down fiat on palettes. Small parts or valves > DN 150 are packed on the pallet • Gas flare FA! 150
separately.
• Gas flare FA! 300
The items are packaged tn a manner that the gas flare can be accommodated and transported on site
ustng a fork lift. • Gas flare FA! 500

4.2 Storage • Gas flare FA! 600

When storing the gas flare must be protected from dirt, dust and moisture. Each mode! size is working with an operating pressure from 2,5· 20mbar, but therefore the flow is
chang1ng by pressure.

!AVORSICHT ! 5.1 Gas flare FAI

Rlsk of damaglng the gas tiare! Element IQuantity

Gas flare, complete with ail standard components
If not storing the gas flare properly penetrattng moisture or small animais may cause damage. See 3.4 Gas flare, standard components.
Befestigungsmaterial:
• If stonng on site for an extended penod it must be made sure that the electrical components 1 set
3 x heavy-load anchors for flare base fastening
of the gas flare do not get in contact with the ground or possible puddles.
Installation manual
• The switch cabinet may also be protected from water.

• Open pipe ends or valves must be protected from water penetrattng, or small animais, by 5.2 Accessories
means of protect,ve flaps intended for this purpose.
See 3.5 Gas nare, add-on equipment and options.
Installation Manual - manual gasflare FAI 21 Installation Manual - manual gasflare FAI 22

6. IDENTIFICATION PLATE 7. TECHNICAL DATA

6.1 Identification plate gas tiare FAI 7.1 Gas tiare general information
Gas primary pressure (mbar) 12,S - 20
Das Typenschild der Gasfackel is placed on the gas flare.
Heating value (kWh/ Nm 3 ) = flow rate x 6,5
Medium* Biogas (65% CH4, 34% C02, 1% H25)

Methane content (%) 45-70

Operating and contrai voltage 24 VDC (only if automatic mode is

hoosen)
Power supply 230 VAC, 50 Hz, others on request

*The percentages listed are assumed biogas compositions common for biogas or digester gas plants.

7.2 Gas tiare by model size (standard)

Gas MaxAowrate Max Flow rate
rlJFlametube lnlet at2,Smbar at20mbar
Model slze
mm ON Nm•/h Nm•/h
Rg. 11: 111e identKication plaœ ofthe gas 11are FAI 50 DM350 40 50 80
FAI 100 DM 350 50 70 140
When calling our customer service m case of malfunctions and for ordering spare parts, please
provide us with the identification plate, the serial number and year built. FAI 150 DM450 65 150 230
FAI 300 DM450 80 160 300
FAI 500 DM636 100 250 530
Other identification plates are found on the components. FAI 600 DM636 125 500 600
FAI 50 Auto DM350 40 40 80
FAI lO0Auto DM350 50 60 130
FAI 150Auto DM450 65 130 210
FAI 300Auto DM450 80 140 300
FAI SO0Auto DM636 100 230 510
FAI 600Auto DM636 125 410 600

The information about the type specifications can be found in the prospectus sheet "Biogas Flare FA!".

7.3 Accessories
Descrintion Data Comrnents
Switch cabinet Stainless steel
Display for flare status LCD 2-lines In the switch cabinet door
Installation Manual - manual gasflare FAI 23

8.2 Installation and setup

8. INSTALLATION

f•i3@.fü;• Pii34ihfüi
Danger of persona! injury, property and environmental damage!
Danger of persona! lnjury, property and envlronmental damage!
Electrical and gas pressure engineering connect1on conditions must coincide with the information in
Please follow the safety instructions in Chapter 2. Safety. Chapter ''fechrncal Data".

8.1 Place of use Electrical connection

The electrlcal connection may only be completed by instructed and qualified spec1alized engineering
comparnes.

To reduce the probability of electrical corrosion, the entire electrical installation of the system should
Danger of explosion!
be designed in a network configuration TN-C-5 or TN-5.
The gas flare is not permitted to be used in Ex zones.
For operating the gas tiare a wiring provlded by the customer is necessary.
• When positioning the gas tiare, please observe the ex zone plan of the biogas or digester
system!
Potential equallzation
Requirements
The customer s1de (operator) must ensure potential equalizat1on
• The gas tiare may only be setup outside.

• Addit10nal roofing 1s not permitted.

• No w1res (power etc.) may be run in the v1cinity of the bumer head or above it.

• Fire protection distances to buildings, areas of stat10nary traffic and bushes and trees must be
maintained. For this purpose see the warning signs in Chapter 2.

• The manual shut-off tlap must always be easily accessible without using any aids.

• To avoid risks of mechanical damage (e.g. with start-up), the traffic areas should be a safe
distance away from the gas tiare.

• The structure of the foundation (Static) for the gas tiare may only be implemented according
to the respective foundation drawings. F,g. 12: Groundilg aJf1l1ec/ion a the gas ffare
• When preparing the installation make sure that possible concrete fixtures (lines, etc.) are not The standard release of the gas tiare is equipped with a labelled grounding connection.
damaged.
lightenlng protection

The customer (operator) must prov1de lightmng protection.

IMMMI Gas connection
Make sure that for the gas tiare location the gas line cannot freeze, 1.e. no condensation may form
and the gas line must have a slope adjusted for the terrain. The electrical connect1on or gas pipe connectlon may only be completed by instructed and qualified
specialized engineering companies.
Installation Manual - manual gasftare FAI 25 Installation Manual - manual gasftare FAI 26

Assembly Attached gas flare

• Unload flare from truck / container, remove transport locks, place crane hook.

• Place a strap or steel cable and fasten it to the flare as showed in Figure 13.

fig. 13: S1rap lixalion

• Lift the flare until it 1s completely ln vertical position

Fig. 15: Attached gas ffate

1
Knmhoken ,
cranehaol< • Verticalty set gas flare on concrete foundation.

!AVORSICHT!
Danger of persona! lnjury and property damage!

There is risk of inJury and damage to the gas flare, because of bpping before the gas flare is correctty
attached to the concrete foundabon, and is secured with guy ropes.

• Unhook crane hook only after fixing the anchor of the lift belt.

Fig. 14: Flare/illing

• Place the flare on the foundation. Fig. 16: View ofanchor.;

• Attach gas flare with fix anchor M 16 (1) on the concrete foundat1on (2)
Installation Manual - manual gasflare FAI 27 Installationsanleitung - manuelle Gasfackel FAI 28

8.3 After installation and before initial start up

Settings

Electrode distances

Fig. 17: lnsert inst11Jction !br dn:p-in

anchor.

Follow the insert instruction for drop-in anchor.

• Drill hole

• Clean hole bore

• Insert anchor

• Set anchor

• Set torque

Connect gas flare

F,g. 19: Eleclrode distances

• Check the electrode distances {A and B), and if necessary readjust.
o A = max. 8 mm / min. 5 mm
o B = Electrodes must be placed inside the pipe B.

Air supply

• Check distance of air regulating dise (factory setting: 10mm)

Fig. 18: Connect gas fiare

• Attach fiange piece (2) and manual folcl (1).

EE
- - -- -- 1E
• Connect manual gas fiap with gas pipe.
._..1.1--__.11--- -s'
EE

F,g 20: Ar regulatIng dise

 Installation Manual - manual gasflare FAI 30

Other necessary activlties before Initial start up

9. START UP AND OPERATION
The following activities must be completed:

• Check the function of the condensate drain cock, and empty condensate. See also 11.5
f•iM=Hfüi
Danger of persona! lnjury, property and envlronmental damage!
• Inspection and mamtenance work.
P/ease lbllow the salèty instructions in Chapter 2. Salèty.
• Ali fastenlng parts used for the installation of the gas flare at the place of utilization must be
checked, and if necessary tightened. Please observe the tightening torque of the respective
fastenlng element. See 11.4 Torques. The flare body must be firmly anchored and tightened 9,1 Initial start up
using three steel ropes.
Before putting the gas flare ,nto operation the first time,
• Make sure that ail safety equipment such as protective covers, emergency switch/button
(formerly emergency shut-off), main switch etc. are available, correctly installed, and are • make sure you are well familiar with it:
functioning.
• the equipment and operating elements, see under operation
• Check the gas flare for visible damage and immediately remove the defects noted. The gas • the measures in case of an emergency.
flare may only be operated if in perfect condition!
• Make sure that ail control activities have been completed before initial start up. See 8.3. Alter
• Check the marked protective area to make sure that it ts free of installation and before initial start up.

• people or vehicles and • Complete the check list. See 12.2 Check list for initial start up .

• dangerous materials and substances, Logs

• no objects (e.g. curtains, flags, birds' nests, etc) could blow or walk from the buildings or • Document the first inspection of the gas seal and initial start up. See 12.J Proof of repair work
building parts into the protective area. and /eak tests.

• Remove ail objects and other materials not needed for operation from the work area.

• Check and make sure that the electrical connection was made according to the valid provisions.
The cable feed through must be tightly screwed in and water tight.

• Make sure that ail components for ensurlng the potential equalization are correctly attached as
specified in DIN or the EC guidelines, and were checked by the electrical engineer.

• Check and make sure that the gas connection was made according to the valid provisions.

• Make sure that an adequate quality of gas is available. The quantity, quality and pressure is
prevalent for proper operation.

IMM@i
The minimum gas quantity required to start up the gas flare can be obtained from the technical data
of the gas flare according to data table 7.2 or the "project specific data sheet" in the Annex.
 9.2 Start-up 9.3 Operation

Only alter you are convmced that the gas flare 1s ready for operation, can you put the gas flare mto Standard:
operation .
Alter the flare started when pressing the ignition button ON, the button can be released. The flare wlll
• Before connect1ng the supply voltage, check that... burn as long there is gas. If closing the butterfly valve, the tiare will stop burning.

o the selector switch is off OPTION: Automatic:

o the manual tlap is open
Alter the ON request from the superior contrai or fill level contact on the gas storage has been issued,
o the distance of the ignition electrodes is between 5 and B mm
the operating cycle of the tiare system will start (opttonally the tiare can also be operated with help
o the ignition electrodes are correctly positioned from pressure switches).
o there 1s enough gas in adequate quahty available

• Turn the power supply on, i.e. turn on fuse. If necessary unlock emergency stop switch
(previously emergency button).

• Make sure that the PLC contrai is set to "Run" (Optional).

• If the reset button/light is on (may be possible) • push to reset (confirm) (Optional).

• Check if...

the message from the tlame indicator is 1n queue (check by using a lighter).
o the function of the malfunction confirmation button
o the function of the interfaces.
Fig. 21: Gis' tiare FA/, switd1 cabinet
Conduct a test operatton:

• Set the selector switch to MANUAL The automat,c valve shoulcl open and alter about two
seconds ignition will start. VALVE OPEN lights up (optional). Swilth cabinet Iock 5 Sigoal lamp error or reset button
• If the flare burns and the contrai light is on OPERATION, then one can assume that the 2 Mode selector switch 6 Display
confirmatton ON of the gas flap works properly and the tiare systems works. OPERATION only 3 SiÇ11ill lamp motor valve apen 7 Eme<gency stop switch (prl!VIOUSly
lights up tf the tlame monitoring detects a flame. Alter a few seconds the ignition stops 4 SiÇ11i!l lamp operatlon emergency button)
(optional).
• Slowly close the manual flap unttl no more gas escapes. As soon as the tlame is ext1nguished, Ignition process
the automattc flap must close immediately and alter a few seconds the tiare makes aoother
attempt at start1ng. This will s1mulate oon-combustible or too httle gas. First, the pneumattc or electncally operated gas flap is opened. At the same time the ignition
transformer is activated, a ignition spark (electric arc) is generated above the tiare burner and the
(If the flare malfunctions then ail possible faults must be examtned and removed. See 10.2 contmuous combustion of the gas is imbated.
Troubleshoottng).
• Turn the gas tiare to AUTOMATIC to contrai operation externally (optional). Here, the tlame is contmuously monitored by a UV flame sensor. If a flame is detected, the ignitton is
shut off alter a t1me delay of 10 seconds.

If oo flame is detected over an ignition pertod of about 10 seconds, the ignition will stop and the
automattc value wtll close momentarily.

If based on poor gas quality the tlame stalls, the tlame will attempt to ignite. If alter five starting
attempts a burning flame is still oot detected, the flare will switch to malfunction.

If a flame is detected even though the flap 1s not opened, then the flare will switch to malfunction.
Installation Manual - manual gasflare FAI 33

Pressure control (optional, only with automatlc)
Via two pressure switches the turn-on and shut-off point for the nare is defined. Here the turn-on Signal
for the Hare is generated by the pressure switch, and the ignition process runs automatically as
described above. The pressure contrai functions via the contrai, if the selection switch is turned to
AUTOMATIC.
9.4 Taking out of operation
If the gas flare must be taken out of operation because or for example greater maintenance work, then
only trained qualified employees who have read the operating manual and have the respective
authorization can complete this work.

• Complete the following steps:

Furthermore, the flare can be activated via an external starting signal or the manual contrai.

Operating mode ON/MANUAL (optlonal)

• Stop pressing the ignition buttin, Mode selector switch to "0"

In this switch position, the ignition of the gas nare occurs the same way as in AUTOMATIC OPERATION. • Engage the emergency stop switch
As a result, dunng start-up drive the gas can be manually burned off.
• Interrupt power supply (turn off fuse) and secure fram restarting.
Operating mode OFF (optional)
• Close butterfly valve
In the OFF position of the switch attached to the switch cabinet, the burn off and ignition is not possible.

Air regulation:

To contrai the combustion air supply, there is one airregulating dise placed below the burner.

An adjustment of the airregulating dise is necessary if the flame burns unstable. That means:
• If the name is strang and blows out based on the high name speed, or burns far above the
combustion chamber, then the airregulating dise must be closed.

• If the flame burns far below, directly on the burner, and if the combustion is instable, then
more air is needed and the airregulating dise must be opened.

To adjust airregulating dise, proceed as follows:

• Turn the selection switch to FLARE OFF.

• Loosen counter nuts and slightly move airregulating dise

• Tighten the counter nuts again.

EMERGENCY STOP procedure

• Press the Emergency Stop switch to interrupt the supply voltage. The emergency stop switch
catches and with a slight turn can be deactivated again.

Wintermode

See Electrical heating of the valve route on page 22.

IMM%i
Communication

The flare contrai is designed to be directly incorporated in the control and visualization of the respective
operating system (only if automatic option is choosen).
Installation Manual - manual gasflare FAI 35

Troubleshooting table
10.MALFUNCTIONS AND REMOVAL MALFUNCTIONS
Malfunctlon

f iM=Hfüi
1
Power supply 1s
General malfunctlons
Fuse was triggered Check flare on site
Power cable is defect Loosen emergency off switch, check
Danger of persona! injury, property and environmental damage! interrupted or ready
Emergency stop switch was fuse
message 1s not seen
pressed Check power supply
Please fbl/ow the safety instructions m C/iapter 2. Safety. Contact manufacturer and follows
SPS is defect
test instructions,
Malfunction contrai Switch is not in "Automatic" mode
10.1 Behaviour in case of malfunctions Check fiare
Tighten flange connection, replace
Loose fiange, defect seals, seals, check valves.
• In case of malfunction of the electrical system or contrai units always contact EnvironTec System is no longer
mechanical load Oleck, if mechanical forces are
GmbH or the blogas plant manufacturer. technically sealed
Other exterior effects working (e.g. by setting
the terrain severe weather etc.1
You can reach us on business day from 8 am to 5 pm at +43 (0) 55 78 7 70 05 (outside of these hours
leave a message on voicemail , fax or email). See contact information on page
Ramefault
Not enough gas, poor gas quality.
2 of this document.
Gas feed is interrupted Test gas
UV sen50r is dirty or defective, Check gas supply
• in case of fire, 1mmediately contact the lire department, Tel: 112!
Flame monitoring (UV wiring error Clean UV sen50r, check flame
sen50r, fiame detector) Defect high voltage line to the ig- monitoring
For malfunctions that last more than 24 hours, suitable measures must be mitiated such as reducing
the feed quantities, 50 that the gas product10n is reduced, and it 1s no longer necessary to use the gas does not detect a fiame nition electrodes or corroded Check ignition
alter ignition process plug. Ignition electrodes - check
fiare m contmuous operation.
Distance between the electrodes distances and if necessary correct
(between 0.5 and 0.8 cm) Check ignition transformer
Ali spare parts (except for valves) can be obtained withm one day by couner service. See 11.7
Ianition transformer is defective
Spare parts.
After fifth successful Very poor gas quality
Test gas.
ignition process, the Gas pressure is tel0 high or too
Check gas supply
•MM@I fiame stalls and burns low
for less than 30 seconds Fame monitorioo is defect
Even though the flap is
Check fiame monitoring

Please inform us at any time about your system malfunct1ons. We depend on the expenences you make Flame monitoring is defective, Check fiame monitoring
closed, the fiame is
with the system, 50 that we can always make improvements. fiap does not close Check wmng
detected
Electrodes or cable or plug are
No ignition Check ignition
defective
10.2 Troubleshooting

A maJQrity of the malfunctions that occur can usually be attributed to a small error in the system of
your system. Stay cairn and think about the situation. Sorne malfunctions can easily be localized and
removed if thinking about the problem logically.
For this purpose use the following list of malfunction messages.
Fault acknowledgement (only if automatic option 1s choosen)
A malfunction is identified when the indicator light on the tiare cabinet is lit and displays the message
"Malfunction".

For malfunctions that cannot easily be removed, please contact EnvironTec GmbH, or the manufacturer With the acknowledgment key on the switch cabinet (longer than 2 s), or the remote acknowledgement
of the system in which the gas fiare is installed. key (see communication), the occurring disturbance can be reset at any time.
 Installat1011 Manual - manual gasflare FAI 38

11.MAINTENANCE 11.3 Inspection and maintenance plan

The maintenance measures include inspection, maintenance and repair. Check (for) / Operatlng resource /
lntervals Components
Actlvltv comments
AH safety equipment, must be checked If necessary, repair (have
11.1 Safety during maintenance Daily fasteners and electrical regularly for proper done ). Replace defect parts
connections and lines condition /have done\
fiiMiHfüi Weekly
(depending Condensate discharge
Empty the condensate
container
See under inspection and
maintenance work
on case\
Danger of persona! injury, property and envlronmental damage!
Monthlv Manual ooeration Funct1on
Fame monitoring Function
Pfease fol/ow the safèty instructions in Chapter 2. Saœty. Semi-
annually
Waming of rlsk of explosion and flammable atmospherel Maonet/Enoinevalve Function dirtvinn
With help from foaming
For maintenance work on the gas nare make sure that there is no potential explosive atmosphere while material, ex. leakage
working! detection spray for gas lines
Visual check for leak
Only alter turning off the affected system part can you work on the gas lines and the accumulated gas Piping connections or a suitable gas detection
tightness
can be released and the system rinsed (inerting). Annually devlce, a qualified persan
Smoking is prohibited ! will check for leaks
Record the results in a IOQ
Distances of the See 11.5 Inspection and
Ignition electrodes
electrodes maintenance work
• ALWAYS use the relevant, required personal safety equipment (gas warnlng device, safety toe- Check for corrosion, dirt
cap shoes, safety gloves, hat, etc.)! and possible
Flame overvoltage The check is performed by
As needed discoloration of the
protection (flame grid) an authorised persan
• Ali Ignition sources (e.g. open flame, hot heat sources, not spark-free tools, not explosion steel, which denotes
protected electrical equiprnent, cell phones) MUST be kept away from the explosion area (ex deflanration
zones)! Switch cabinet and ail
Every 3 See 11.5 Inspection and
electronic and electrical Clamps are stuck
years. maintenance work
• ONLY use spark free tools (also applies to boring machines, drills, core drills, chisels, etc.)! comoonents
Work that can generate weid, burn and sparks may NEVER be clone ln the vicmity of the explosion
zones!
*e.g. leak detector in the canister with frost protection according to DIN DVGW No. 8801 E 582 plus
Before working on the electncal equipment frost protection or in a spray can.
• Press and engage the emergency stop swltch.

• Set mode selector switch to 0

• Interrupt power supply (turn off fuse) and secure from restarting.

• Close manual flap.

• Lock all work areas of the system, and make sure that no animais, chiklren or unauthorized
people are in the work area .

11.2Record

The inspection and maintenance work, as well as sealing checks completed must be
documented without fail. See 12.3 Proof of repa1r work and leak tests.
Installationsanleitung - manuelle Gasfackel FAI 39 Installat10nsanleitung - manuelle Gasfackel FAI 40

11,4 Torques • Open discharge drain and drain condensate container

Infonnat10n in Nm

To hold screws by tightemng us1ng the specified tension, they may only be tightened up to the maximum
permitted t19htening torque. If exceeding the tlghtemng torque, the screw may stretch out and the
tension force is lost.
Screw MS MlO M12 M16
Quallty A2/A4-70
drv u = 0.14 17.7 34.8 59.9 148
Lubricated* u = 0.10 13 28 45 105
Quallty 8.8 zinc plated drv u = 0.14 25.4 49.5 85. 2 211

*lubricated with OKS white ail-round or comparable lubncating agent.

11.5 Inspection and maintenance work

Interval: see inspection and mamtenance plan

Drain condensate water

Explosion hazard because of gas escaping !

When opening the condensate water discharge drain, gas may escape

• Before opening the discharge drain, set the selection switch to FLARE OFF

Rg. 22: Condensate Kffie" discmtge drain

The discharge drain is located at the lowest pomt of the flare piping.

• Turn the select1on switch to FLARE OFF.

• Place collect1ng tray beneath the drain.

Installationsanleitung - manuelle Gasfackel FAI 41 Installatfonsanleitung - manuelle Gasfackel FAI 42

Ignition electrodes and flame sensor Check Ignition electrode distance

f•iMiHfüi
Danger of surge

See the safèty precautions in 2 Safèty

See also 11.5 Inspection and mamœnanœ work - Before working on the electnœl equipment

Clean Ignition electrodes

Fig. 23: Gis tiare FA/, ignitkn electrodes

F1g. 23: gas tiare FA/, ched< lgnitbn eectro1e distanœ
• Turn the selection switch to FLARE OFF.
If the distance of the ignition electrode is incorrect, then there is either not ignitfon spark or the ignition
• Carefully loosen the electrode bracket
spark is too weak to ignlte the gasses.
• Remove existing deposits with a wire brush.
• Turn the selection switch ID FLARE OFF.
• Tighten electrode hokler. Caution! Ceramic can easily break.
• Carefully loosen the electrode container

• Check Electrode distance according to informatfon in the illustration above. If necessary reset.

• Tighten electrode .holder. Caution! Ceramic can easily break.

Check fla me sensor for functlon and cleanliness ( optional)

Ag. 24: Rame sensor (W Sensor) with heat protedlon 591

1 Heat protedlon 591 2 W Sensor

• Remove sensor

• Check cleanliness of lense, if necessary clean with cloth and water.

Installation Manual - manual gasflare FAI
Flamearrestor and bumer head
Check and clean flame backlash protection and burner head
For disassembly, maintenance and installation of the flame backlash protection, please see the
respective instructions in the detail documentation (in the Annex under supporting documents).
These must be checked periochcally for functionahty, especrally if the flare is not being operated or only
rarely.
Butterfly valve
• Turn the selection switch on the switch cabinet ta OFF.
• Open and close the latching lever of the manual flap until stop and check Free movement.
• Check for leaks using a leak detection agent.
• Watch for corrosion. For external corrosion, see manufacturer maintenance instructions.
Motor valve/solenoid valve (Optronal)
For disassembly, maintenance and installalJon of the motar valve, please see the respective instructions
ln the detail documentation (in Annex under supportrng documentation)
Switch cabinet, electronic and electric
Fl{l. 25: Test plate an the switr:h cabnet
• Every 3 years check the switch cabinet and inspect ail electronic and electrical components.
• Record the results in a log. Apply inspection sticker.
43 Installationsanleitung - manuelle Gasfackel FAI 44
11.6 Restait
The following points must be followed, after concluding the maintenance work and before restarting
the gas flare:
• Check again ail previously loosened screw connections for a tight fit.
• Make sure that ail prevrously removed protectrve installatron, covers, etc. are installed again
properly.
• Make sure that ail the tcrols, materrals and other equipment used are removed from the work
area. Thereafter clean the work area.
• Make sure that ail safety equipment 1s working properly agarn.
After completing the maintenance, the operator or service personnel must make sure that ail work
ls completed and only then can the system be released for operation.
11.7 Spare and wearing parts
The lifetime of the wearing parts 1s depending of the hours of using the flare, weather conditions and
temperature.
Ali spare and wearing parts can be obtained from EnvironTec GmbH upon request, and be delivered
quickly by courrer service.
To order spare parts for the gas flare, please contact us directly.
Please ta speed up the ordering process, take note of the information of the flare's identification plate
(e.g. The identification plate, senal number, year made).
•MIMI
We recommend keeping a spare part package on hand ta allow immediate repairs.
See contact information on page 2 of this document
Installation Manual - manual gasflare FAI 4S Installation Manual - manual gasflare FAI 46

12.APPENDIX 12.2 Proof of repair work and leak tests

12.1 Checklist for initial start-up .,... Opallllnghoun Workpeib1ned

P91fo.1'Ndby
(stamp, llgnaba9)
Please use this page as your template

Ooerator
Address
Zio / Citv
Phone
Device / Serial Number FAI/50/ 15/ 500-05-08 /Giraud

Guideline for evaluatlng initial operation* Yes Comments:

Are all documents (conformity statement, operating
1 manual) completed, in the country's language and D
accessible?
2 Is it used properly as defined in the operating manual? D
Were an safety and installation specifications of the
3 D
Operating Manual followed/implementecl?
Was the installation completed properly and checked
4 D
(torque, seals, fastenings)?

Is there adequate protection from mechanical hazards,

5 D
through jamming, clip, eut, record, pull-in, hit and friction?

Is there adequate protection from electrical hazards caused

6 by a short circuit, overload, error conditions, touching live D
parts and electro-static charge7
Is there adequate protection from noise, vibrations, heat
7 D
and hazardous materials?
Is a safe, proper operation and hazardous-free operation
8 D
provided (if necessary determine in the test operation)7
Were all ignition sources and flammable materials removed
9 from the fire protection area, or avoided in the area of the D
system7

*Depending on the scope and risk potential of the technical system, a detailed assessment
method may be necessary for the initial start-up.

Responsible for the Responsible for the Responsible for the start up:
assembly: electrical installation:

Signature Signature Signature

lnstalla~on Ma nuai - manual gastlare FAI 47

12.3Annexes