Well Test Standards Section 3.29 Burners and Ignition Systems

Level: Function / Product Line:
Well Test
Global
Document Type:
Standard
Title:
Well Test Standards

Section 3.29
BURNERS AND IGNITION SYSTEMS
© February 2017 by Expro - ALL RIGHTS RESERVED

This document may not be reproduced, either wholly or in part, nor may it be used by, or its contents divulged to, any other person
whosoever without written permission of Expro. Furthermore the Master Copy of this document is held and formally controlled within
Insight. Hard copies may be printed but will not be update. Please refer to Insight for the latest revision.
Document Number: INS-002688 Revision: 3
Template No: INS-T-002 Rev 1

INS-002688 Well Test Standards
Rev. 3
Revision List
Revision Reason for Change Issued Owner Reviewer Approver
1 New Insight Template 24/Aug/2015 H.Selim E.Riddell D.Cleland

2 DCR 1635 20/Jan/2017 H.Selim A.Purdie D.Cleland
Amendment from Rev 1 to Rev 2
- Update the information in section 3.29.6.3Super Green Burner - Electric Ignition System
(High Velocity)
- Added new section for Smitvonk 3.29.6.4Super Green Burner - Electric Ignition System
(Smitsvonk System)
Page 2 of 33 Global / Well Test

Well Test Standards INS-002688
Rev. 3
Table of Contents
Section Page
Contents
PURPOSE ..............................................................................................................................4
SCOPE....................................................................................................................................4
RESPONSIBILITIES ..............................................................................................................4
3. EQUIPMENT...............................................................................................................5
3.29 BURNERS ................................................................................................................. 5
3.29.1 Burner Introductions ..................................................................................... 5
3.29.2 Burner Installations ....................................................................................... 6
3.29.3 Pressure Testing .......................................................................................... 6
3.29.3.1 Oil Line (Test Medium; Water)...................................................................... 6
3.29.3.2 Air Line (Test Medium; Air) ........................................................................... 7
3.29.4 Procedures ................................................................................................... 8

3.29.5 Sea Emerald ............................................................................................... 10
3.29.5.1 Sea Emerald Air Requirements .................................................................. 10
3.29.5.2 Sea Emerald Burner – Electric Ignition System (Stackmatch) ................... 11
3.29.5.3 Pilot/Jet/Booster Ring Gas Operation ......................................................... 12
3.29.5.4 Setting up an optional Air Purge System .................................................... 14

3.29.5.5 Troubleshooting .......................................................................................... 14
3.29.6 Supergreen Burner ..................................................................................... 15

3.29.6.1 Supergreen burner Atomiser Protective Ring ............................................. 16
3.29.6.2 Supergreen Burner Air Requirements ........................................................ 16
3.29.6.3 Super Green Burner - Electric Ignition System (High Velocity) .................. 17
3.29.6.4 Super Green Burner - Electric Ignition System (Smitsvonk System) .......... 20
3.29.7 Super Sea Burner ....................................................................................... 29

3.29.7.1 Super Sea Burner Air Requirements .......................................................... 30
3.29.7.2 Super Sea Burner - Electric Ignition System (High Velocity) ...................... 30
3.29.7.3 Installation .................................................................................................. 31
3.29.7.4 Start Up ...................................................................................................... 31

3.29.7.5 Shut Down .................................................................................................. 31
3.29.8 Vulcan Burner ............................................................................................. 32

3.29.8.1 Vulcan Burner Air Requirements ................................................................ 32
3.29.8.2 Vulcan Burner – Electric Ignition System (High Velocity) ........................... 32
3.29.9 Burner Performances ................................................................................. 33
Global / Well Test Page 3 of 33

Rev. 3
PURPOSE
The purpose of this Well Test Standard (WTS) manual is to set out the framework for achieving the
highest operational and engineering standard when designing, selecting equipment, training and
selection of personnel and conducting well test operations in a well test environment.
The following verbal forms shall be used when reading this document.
Shall Used to indicate requirements strictly to be followed and which no deviation is permitted,
unless accepted and dispensed / conceded by the Well Test Product Line
Should Used to indicate that several possibilities exist, without mentioning or excluding others, or
that a certain action is preferred but not necessarily required
May Used to indicate a course of action permissible within the limits of this document
SCOPE
This WTS manual applies to those tasked with the design, selection and operation of well test systems.
This practice is tailored specifically to Expro surface Welltest operations which are generally for
temporary deployments. Compliance with the WTS shall be mandatory.
RESPONSIBILITIES
The process of designing, selection of equipment, well test crew training and selection, operation of well
test equipment is the responsibility of the Regional Operations departments.
Well Test Product Line is responsible for the maintenance of the WTS and ensuring that it is updated
where necessary in line with current best practice.

Rev. 3
3. EQUIPMENT
3.29 BURNERS
3.29.1 Burner Introductions

In order to dispose of oil and gas during well testing operations it is a commonly accepted practice
to flare the produced well fluids.
For offshore installations the burner head is installed on the end of a suspended burner boom to
minimise heat radiation on the rig structure.
To burn the oil efficiently it is required to be atomised prior to being ignited by an ignition source. The
oil is atomised by compressed air being introduced to the burner head to act as an accelerant to
shear the oil. The compressed air needs to be supplied in the correct volume and pressure to ensure
efficient atomisation. The oil kinematic viscosity will also affect the atomisation and should be known
and addressed at the well test planning stage, a typical required viscosity of the oil for efficient
atomisation is < 40cP (Sea Emerald requirements are approx. 18cP).
A non-return valve (check valve) should be installed on the oil line pipe work on the burner assembly
as per API RP 14C flow line segment statement ‘A.1, d.2 – flow line segment is protected by FSV in
final flow line segment’.
Figure 3.29.1 Supergreen Burner
Figure 3.29.2 Sea Emerald Burner

Rev. 3
The compressed air supply manifold on the burner head assembly shall have a non-return valve (check
valve) installed to prevent any oil from the burner head flowing back to the air compressors. The above
pictures show typical installations.
Expro have four types of burner head in their current inventory:
Flow rate Capacity:
• Sea Emerald Burner – up to 4,000 Bbls/d per cluster/head

• Supergreen Burner – up to 4,000 Bbls/d per head
• Super Sea Burner – up to 4,000 Bbls/d per head
• Vulcan Burner – up to 4,000 Bbls/d per head
Note: The maximum water cut for all burners is limited to 20% of flow rate. Exceeding this
amount shall affect the combustion performance of the burners.
3.29.2 Burner Installations

1. Ensure that access and egress on the boom is clear of all restrictions and that the boom is in a secure
position.
2. Ensure that the set down area of the boom platform is level.
3. Secure tag lines to atomising head assembly and lower assembly into position on boom, ensuring
that sufficient clearance is available for the tie-in pipe work. (DO NOT DISCONNECT FROM
CRANE).
4. Secure assembly to boom by welding in selected areas or inserting pins into burner base plate.
5. Release crane, remove tag lines and remove all lifting apparatus from the burner. Clear tools from
boom.
6. Commence rigging up flow lines to the appropriate service inlets and connect up the ignition system.
7. Ensure a non-return valve (check valve) is installed in the air supply manifold.
Note: The Internal Diameter of the Oil and Air Pipe work should not be reduced at any place in the
hook up.
3.29.3 Pressure Testing
3.29.3.1 Oil Line (Test Medium; Water)

1. Remove Supergreen burner heads and Sea Emerald burner nozzles.
2. Flush through oil line until all debris and air has been expelled from the system.
3. Install Supergreen burner heads complete with end caps – Open ball valves on ends caps.
4. Make preparatory arrangements for pressure testing in accordance with installation Regulations.
5. Flush through oil line until all air has been expelled from the system.
6. Supergreen - Close ball valves on end caps.
7. Sea Emerald – Insert Blanks into nozzles.
8. Super Sea and Vulcan – Close burner head isolation valves.
9. Apply test pressure (Maximum 1440 psig (Sea Emerald may be 1000psig design)) and monitor
pressure for 15 minutes. (Not including the Sea Emerald Burner, see separate air check valve test
procedure below.)
10. This will pressure test the integrity of the burner head assembly and the compressed air supply check
valve.
11. Vent all pressure from system to 0 psi.
12. Remove Supergreen burner end caps, remove Sea Emerald blank nozzles and install burner
nozzles.
13. Close burner head oil line isolation valves.
14. Apply test pressure (Maximum 1440 psig (1000psig for Sea Emerald)) and monitor pressure for 15
minutes.

Rev. 3
15. Vent all pressure from system to 0 psig.
Note: Before pressure testing Supergreen burner using the test cab, the following external
inspection shall be made with particular attention:
A. Remove housing caps/protection sleeves and visually inspect the atomising heads.
B. Visually inspect the external threads, sealing faces and groove for signs of wear, tear, erosion, and
pitting or corrosion damage. Inspect internal thread of Test Cap (End Cap) (Attention should be paid
to the 5.87-6 TPI external stub acme threads (chipping, Rolling, edges removed, deformation, pitting,
corrosion))
C. Inspect seal O-ring grooves for pitting and corrosion that may produce a leak path when pressure is
applied.
D. Inspect Elastomer seals (for sign of deterioration, extrusion, cutting or perishing).
All damage should be reported to the Supervisor or his delegate who may then follow the Hold Process.
3.29.3.2 Air Line (Test Medium; Air)
3.29.3.2.1 Sea Emerald only – Testing the Air check valve only
This will pressure test the integrity of the burner head assembly and the compressed air supply
check valve to 750 psig.
1. Remove Sea Emerald burner nozzles.

2. Open burner head isolation valves.
4. Make preparatory arrangements for pressure testing in accordance with installation
Regulations and Pressure Testing WTS 2.0 INS-002660.
5. To test the Air check valve on the Sea Emerald burner, Insert New Blank nozzle part number
C118519 (SAP# XC118519) into nozzle housing. As detailed in TB 212 and shown below.
Figure 3.29.3 SE Blank Nozzle
6. Apply test pressure through oil line (Maximum Air side 750 psig MAWP) and monitor pressure
for 15 minutes.
7. This will pressure test the integrity of the compressed air supply check valve on Sea Emerald
burner.
3.29.3.2.2 Super Green, Super Sea and Vulcan burners – Testing the Air check valve only

Rev. 3
This will pressure test the integrity of the burner head assembly and the compressed air supply
check valve.
1. Super Green & Super Sea - Remove Burner End Caps.

2. All Burners - Open burner head isolation valves.
4. Super Green, Super Sea and Vulcan- Install Burner End Caps/Test Caps and close End
Cap/Test Cap ball valves.
5. Make preparatory arrangements for pressure testing in accordance with installation Regulations
and Pressure Testing Well Test Operational Guideline – WTOG 2.0.
6. Apply test pressure through oil line (with consideration of the Maximum Allowable Working
pressure of the burner) and monitor pressure for 15 minutes.
Note: Supergreen pressure test cap shall be removed after the pressure test and not to be used
to isolate any of the heads, if any of the burner heads require being isolated due to change in
flow rate this shall be done from the actuated/isolation valve, burner heads that don’t have
isolation valves then they should be the selected first.
3.29.4 Procedures
3.29.4.1.1 Pre Flow Test Procedures
On completion of the pressure test program the following preparatory tests shall be conducted.
1. Start all compressors for five minute warm up period (see compressor operating procedures).
2. Ensure all Air isolation valves on burner are open (If installed).
3. Ensure a non-return valve (check valve) is installed correctly in the air supply manifold.
4. Put single compressor on load and supply air to burner.
5. Record air delivery pressure at receiver/distribution manifold and engine revs/min.
6. Put second compressor on load and supply air to burner.
7. Continue repeating Step’s 4 and 5 until all information has been recorded.
8. Put third compressor on load and supply air to burner.
9. Repeat Step 4 and continue until all compressors have been checked
Assuming that all compressors are running "On Load" and at maximum revs/min, water should be
pumped through the oil line whilst monitoring the pressure at the air receiver/distribution manifold
and the compressor revs/min. The pump rate should be increased until a pressure increase is
observed at the air receiver/distribution manifold or a reduction in the compressor revs/min is noticed.
Both of these indicate closure of the airline non return valve and the maximum pump rate offers an
approximation of the optimum flow rate obtainable whilst maintaining a clean burn.

Rev. 3
3.29.4.1.2 Start Up Procedure
1. Check piping connections and hook-up and select number of burner heads to be used.
Note: Heads without isolation valves to be selected first.
Sea Emerald – For anticipated maximum oil rates less than 4000 bbl/day it is advisable to
flow through 1 head as this ensures that the atomising air obtains maximum benefit.
Super Sea – For anticipated maximum oil rates less than 4000 bbl/day it is advisable to flow
through 1 head as this ensures that the atomising air obtains maximum benefit.
Supergreen – For anticipated maximum oil rates less than 4000 bbl/day it is advisable to
flow through 1 head as this ensures that the atomising air obtains maximum benefit.
Vulcan – For anticipated maximum oil rates less than 4000 bbl/day it is advisable to flow
through 1 head as this ensures that the atomising air obtains maximum benefit.
2. Check prevailing wind direction and select downwind burner suitable for operations.
3. Operate ignition system and ignite propane pilot light.
4. Start air compressors and supply compressed air to the selected burner head assembly on
the downwind burner boom.
5. Open water supply to heat radiation screens and boom water screen at a low rate until
good combustion has been established.
6. Check that all valves downstream of the choke are lined up to direct flow to the selected
burner boom, open oil diverter manifold valve directing flow to appropriate oil burner, open
air diverter valve on air distribution manifold to selected burner.
7. Ensure pilot flame is alight.
8. Open well to burner head at choke manifold.
3.29.4.1.3 Operating Procedure
1. Once burner is alight observe flame stability. During the entire period of burning, routine
observations of the burn stability and potential fall-out should be made and documented on
the Equipment Report Form 2-QMS-WT-FRM-001-038 – INS-002058.
2. Adjust air flow to achieve smokeless burn, if excessive black smoke is visible, increase air
output via the compressors.
3. Open or close in burner heads from the isolation valves as required for the flow rate.
4. If required, start water injection pump and adjust flow for optimum burn.
5. Measure and record all flow data on burner performance data sheet.
6. Immediately prior to final flaring operations being completed, pump out contents of
gauge/surge tank to flare.
3.29.4.1.4 Shut down Procedure
1. Once the flow period is near completion pump out all surge/gauge tanks contents of stored
oil to the burner heads.
2. Close in well at choke manifold or down hole test valve.
3. Continue running the air compressors until all the pipework inventory of oil has been bled
to 0 psig and burnt off.
4. Close all burner head oil line isolation valves.
5. Shut down air compressors.
6. Extinguish the pilot light.

Rev. 3
3.29.5 Sea Emerald

The Sea Emerald well test burner is designed to perform free of smoke and hydrocarbon fallout
during crude oil disposal. The Sea Emerald was developed specifically for simple, effective operation
over the wide range of conditions expected during well tests.
The atomizer is used in the Sea Emerald to produce the small droplets necessary to ensure complete
combustion of the liquid droplets. The atomizer uses multiple tips to discharge droplets at high
velocities in a unique array, creating the turbulence that maximizes air ingestion, the process is
necessary for efficient combustion.
The Sea Emerald burner cluster/head creates a back pressure of 200psig at a rate of 4,000Bbls/d.
The below diagram is a typical set up of a Sea Emerald cluster/head, the oil enters nozzle N1 and
the air enters nozzle N2.
Figure 3.29.4 Sea Emerald Cluster
3.29.5.1 Sea Emerald Air Requirements

 High Atomizing Air to Crude Oil Ratio is required.
 Air requirement can be calculated by: (BOPD x 0.375SCFM)*1440 = Air requirement
Scf/d (see also air requirement spread sheet CFT 2940- INS-003863).
Figure 3.29.5 Sea Emerald

Burner Air Requirement

Rev. 3
3.29.5.2 Sea Emerald Burner – Electric Ignition System (Stackmatch)

The Stackmatch pilot system with remote ignition provides an exceptional stable pilot and with
gas jets which are directed to each nozzle.
This arrangement initiates oil spray ignition quickly during start-up and provides a stable ignition
source during shutdown.
The pilot gas supply, which is always propane, is separate from the gas jet supply. Gas usage
for the pilot is low, 4 SCFH per pilot or about 1.1 lb/hr/pilot.
Figure 3.29.6 Gas Jets Gas Consumption
Stainless tubing, 1/4" diameter is acceptable. The remote ignition panel lights it. To allow
uninterrupted gas flow, while switching bottles, two bottles are rigged up with regulators, gauges
and flexible hoses that tie into a tee with valves.
The gas jet supply is also propane. Two regulator/gauge assemblies are used for uninterrupted
gas flow while changing bottles. There are three jets on a pilot and propane gas usage is
approximately 8.6 lb/hr/pilot with the 1/32". Orifice at 15 psi. A 1/2". Stainless line is used to
supply the three heads. The dual source supply option from the separator should include a
regulator located at the separator.
The igniter assembly has three major parts. For igniting the pilot, there is an internal sparking
device connected to a remote control panel. This pilot is the ignition source for the three gas
jets. The gas jets are directed by the pilot toward the nozzle. The igniter lights the pilot, the pilot
lights the gas jet, and the gas jet lights the oil discharging from the nozzle.
The pilot and igniter assembly slips through the tube in the centre of the head and is secured
with one set screw. The gas jets are directed past the pilot toward the nozzles, the round knob
on the gas jet rests against the pilot body. There are three connections at the burner:
• Pilot gas - 1/4 in. FNPT

• Gas jets - 1/4 in. MNPT
• Electrical - 1/2 or 3/4 in. conduit.
Control Panel
Pilot & Igniter Assembly
Red Lead to Plasma Generator

Brown Lead to ground at pilot
Power
110 or 220 V
Green Lead to Ground
Figure 3.29.7 Stackmatch pilot & igniter

Rev. 3
3.29.5.3 Pilot/Jet/Booster Ring Gas Operation
3.29.5.3.1 Pilot Gas
Light pilots well in advance of burn periods.
1. Rig two bottles with regulators, gauges and flexible hoses that tie into a tee with valves to
allow uninterrupted gas flow while switching bottles.
Figure 3.29.8 Stackmatch pilot gas
2. Open propane to pilot.

3. Activate ignition switch to light pilot
4. Once pilot alight open gas jet supply
Note: Pilots are an important part of the burner system and require regular maintenance.
Exposure to salt water, heat, and electricity on a regular basis causes an extreme
operating condition.
Propane supplies should be kept out of the line of sight of the flame.
3.29.5.3.2 Jet Gas
1. Tap off separator gas for a dual source as an option.

2. Use two regulator/gauge assemblies using a regulator located at the separator with the
propane for uninterrupted gas flow while changing bottles. There are three jets on a pilot and
propane gas usage will be approximately 8.6lb/hr/pilot with the 1/32" orifice at 15psi. Use a
½" stainless line to supply the three heads. As the liquid level in the bottle drops and cools,
the vapour pressure in the propane tank lowers.
3. During operation, bottles may have to be switched before they empty due to low pressure.
They may be reconnected and emptied after a while.
Note: The use of separator gas for the pilot supply source is forbidden, separator gas
can be used for the jet/booster ring supply only.

Rev. 3
3.29.5.3.3 Booster Ring Gas
Addition of ‘Gas Booster Rings’, SAP # 100068592, to each cluster of the Sea Emerald
nozzles is mandatory. The Gas Booster Rings use produced gas from the separator to
provide a much stronger pilot for igniting liquid hydrocarbons at the burner. Produced gas
supply to the booster rings should be taken from a regulator installed downstream of the
Daniels Senior orifice meter and upstream of the gas backpressure control valve. A minimum
1" line is recommended for this supply to the burner. Pressure in this line of 35 psi should be
sufficient. During start-up it may be necessary to flow to the calibration tanks until separator
gas is available or alternatively provide a plentiful source of clean fuel gas until such time as
produced gas is available. Gas Booster Rings are fitted with three Gas Booster Jets (SAP #
100068843) per Ring.
Booster Ring installed:
Figure 3.29.9 Gas Booster Ring

Rev. 3
3.29.5.4 Setting up an optional Air Purge System

This should not be required for normal operation but if moisture or salt build-up becomes a
problem, this is an inexpensive solution.
The sketch below shows an optional air purge setup. By pressurizing the termination box and
flowing air through the conduit, moisture concerns are eliminated, electrical conductors are kept
within temperature limits, and salt free air is supplied for pilot combustion.
Clean or replace filter if pilot has adequate pressure

but fails to stay lit or appears to be weak.
Air Supply
Wiring from Always use a backup here when installing the tubing
Control Panel fitting to prevent damage to the mating part.
Figure 3.29.10 Air Purge System

3.29.5.5 Troubleshooting
There are four items to check if the pilot fails to operate properly.
1. Check for adequate pressure at the inlet.

2. Check that the filter and orifice are clear to allow the proper gas flow.
3. Check for restricted air passages in the pilot.
4. Ensure proper orientation of Jets directed to atomizer as below. (Head shown below with
optional booster ring.)
Note: When operating properly, the pilot flame should be visible, extending 1/2" or so
from the ports. After a short period of operation, the centre section of the pilot should
glow red hot.
Figure 3.29.11 7” Booster Ring

Rev. 3
3.29.6 Supergreen Burner

The Super Green produces a more effective flame pattern which allows complete combustion of the
crude oil, giving a smokeless and fallout free burn. The oil path through the burner is via a 2" mixing
chamber (atomisation occurs out with the chamber) which allows passage of solids without danger
of blockage and subsequent performance problems. This also reduces operating back pressures,
which results in a significant safety advantage by reducing the well test system operating pressure
and decreasing the risk of hydrocarbon back-flow into the atomising air system.
The super green burner design concept although extremely effective is very simple thus
guaranteeing continuous trouble free operation. Its simplicity also reduces the need for maintenance
operations on the burner boom which contributes significantly to Expro’s safety advantage.
The Supergreen burner head creates a back pressure of 50psig at a flow rate of 4,000Bbls/d.
Figure 3.29.12 Supergreen Atomiser head

Rev. 3
3.29.6.1 Supergreen burner Atomiser Protective Ring

Supergreen burner atomiser head has 5.875-6 TPI external stub acme thread, unprotected
thread could face a severe damage and degraded extensively, therefore this thread shall be
protected using a protective ring part number C211085 as detailed in TB249 and shown below
Figure 3.29.13 Supergreen Protective Ring
3.29.6.2 Supergreen Burner Air Requirements

• High Atomizing Air to Crude Oil Ratio is required.
• Air requirement can be calculated by: SG2 x 178.039m3/m3 (see also air requirement
spreadsheet CFT 2941– INS-03864).
Figure 3.29.14 Supergreen Air Requirements

Rev. 3
3.29.6.3 Super Green Burner - Electric Ignition System (High Velocity)

Lodge system -The system has been designed and tested specifically for use in conjunction with the
supergreen crude oil burner. It has been tested under severe critical conditions and has a proven
operational record.
3.29.6.3.1 Ignition and control unit
High energy Ignition Unit
The unit consists of a transformer, half wave rectifier, resistor-capacitor network and a sealed spark gap,
all contained within a study case.
A limiting resistors controls the capacitor charging rate. Bleed resistors are fitted to discharge to leak. The
unit can then be safely serviced following the removal of five bolts, which must be released before the lid of
the unit can be taken off. The electrical components within the unit are siliconised after assembly to
prevent any internal flash-over, and the lid of the case is seated on a soft strip to prevent the entry of
moisture.
Figure 3.29.15 High energy Ignition Unit
High energy Igniter
A wire conductor runs axially through a tubular body, from which it is electrically insulated by magnesium
oxide. At the firing end, an annular semi-conducting high energy sparking surface is disposed about a
centre electrode, which is electrically insulated from the earth electrode by ceramic. The terminal end
contains a contact button, which is electrically insulated from the outer sleeve by ceramic. Both the firing
end and the terminal end are glass sealed to prevent the ingress of moisture.
Figure 3.29.16 High energy Igniter

Rev. 3
High-energy cable
The high energy cable comprises an inner conductor and a sealed ¼” ID. Toplock flexible conduit which
may be Viton covered if required. HE/F/90 and HE/M/90 fittings mate the cable with the igniter and terminal
of the high energy ignition unit respectively.
Figure 3.29.17 High energy cable
The complete assembly provide the correct low-resistance earth return to the ignition unit
3.29.6.3.2 Flame Tube
For the flame tube details please refer to drawing number 116317
Figure 3.29.18 Lodge ignition flame tube details

Rev. 3
3.29.6.3.3 Installation
Figure 3.29.19 Supergreen Electric Ignition System (High Velocity) Schematic
1. Ensure that the unit is set on the correct power supply i.e. either 110 V or 230 V
2. Secure flame tube body (item 1) approximately 4" in front of burner/atomising head assembly.
3. Connect high energy igniter “spark plug2 (item 2) and High energy cable (item 4) ensuring that a good
earth is obtained.
4. Connect the gas supply to the gas pilot connection.
5. Install and secure Lodge box enclosure (item 11) approximately 20 ft behind atomising head assembly.
6. Position cable reel (item 9) in a dry area (off the boom) and connect cable (item 8) to Lodge box by
connecting items 6 & 7.
7. Run remote ignition switch to off boom location.
8. Unwind cable (item 8A) and connect to correct AC voltage power supply.
3.29.6.3.4 Start-Up
1. Open propane supply and adjust pressure to suit.

2. Ignite the pilot by pressing and holding the ignition switch. If ignition is not immediate adjust the pilot gas
supply and re try ignition.
3. Adjust the pilot gas pressure in order to achieve the optimum pilot flame.
4. Once the pilot is a light stop the power supply to the igniters to prevent it burning out.
3.29.6.3.5 Shut Down
1. Close the main propane supply. Once the main propane supply is closed, the pilot flame will become
extinguish

Rev. 3
3.29.6.4 Super Green Burner - Electric Ignition System (Smitsvonk System)

Pilot burner
Main principle of the burner is to create a combustible mixture of air and gas which is
ignited by three integrated spark plugs. Through the gas connection, gas flows to the
main gas tube and to the nozzle. The small bore in the nozzle increases the velocity
of the gas in this nozzle. Directly after the nozzle a vacuum is created caused by the
velocity of the gas. Environmental air is aspirated into the burner and is mixed with
the gas. The spark plugs ignite the major part of this mixture and flows to the
stabiliser and through the centre of the stabilizer. The remaining part flows with lower
speed through the holes and sleeves of the outer ring of the stabiliser. A flame
appears directly after the centre of the stabiliser. Small flames surround the “centre”-
flame and have a stabilising effect to the “centre”-flame.
The pilot burners are mounted vertical. To prevent water storage, caused by
condensation or rain, in the lowest part of burner, this part is provided with drain
holes.
Ignition and control unit.

The ignition unit has been installed in a Cast Aluminium housing, protection grade
IP66.
The ignition units start the ignition sequence, a sequence for the set time (5 sec.), by
pressing and releasing the Start push button 20S3. The ignition units will produce
sparks for the set time with a frequency of 3 Hz.
Figure 3.29.20 working principle of the electronic ignition unit
The ignition unit is suitable for a supply voltage of 90-264 Vac. The drawing shows that the AC supply
is connected to the primary winding of the transformer 20V8.
The secondary voltage of 24Vdc is connected to the ignition unit ICB1 and transformed to 2000V.
This voltage is connected to capacitor C1 which will charge up to a voltage of about 2000V.
This capacitor is periodically discharged across the sparkplugs by means of an integrated high power
switching circuit.
The high current during a short discharge time results in a flame-shaped spark on the spark plug,
that is unaffected by filthiness, humidity and other disturbances. After the capacitor has been
discharged, it will be charged again. An integrated Pulse Unit, which determines the discharge time

Rev. 3
and the spark frequency, drives the switching circuit. In this case the ignition unit generates 3 sparks
per second for the set time.
A resistor module has been installed to ensure that the capacitor C1 will be discharged when the
power supply is switched off and that there are no high voltages at the output terminals.
Notes: Ignition cable and sparkplug should always be connected to the ignition unit. The
thyristor/diode can be damaged when the unit is working without a connected cable and
sparkplug
3.29.6.4.1 Technical Details
Pilot burner
Smitsvonk® heavy duty, high energy straight pilot burner with flame deflection cap.
Type HD60PF19-1200-FC
Fuel Propane 90 Vol% C3H8
Length 1200 mm
Gas pressure 0,2 - 0,8 Barg
Gas consumption 0,7 - 1,6 nm3/hr
Capacity 19 - 30 kW
Gas connection 1/2" BSP
Combustion air None, self-aspirating
Ignition By three integrated sparkplugs located below the high
heat radiation zone
Materials 310 SST for 2" pipe, Flame deflection cap and ventury
316 SST connection part
Ignition unit
Smitsvonk® explosion proof high energy ignition unit for four ignition burners.
Type 4 E-LIGHT-EJB51-HDS-PH-AC
Power supply 90-264 Vac
Spark tension 4 x 2 kV
Spark energy 4 x 2 Joule
Spark frequency 3 Hz
Power consumption 160 VA Panel heater included: 40 VA
Max. distance to Conductor Ø 4mm² : 100 meter
sparkplug Conductor Ø 1.5mm² : 30 meter
Number of ignition units 4 pieces E-light
Enclosure EJB51
Explosion proof ATEX 2G Ex d IIB T5 (Zone 1)
Aluminium enclosure IP66
Dimensions 366 x 566 x 269 mm
Min./max. temperature -20° to 55° C

Rev. 3
Signal lamps and push x on/off switch

buttons 1 x yellow lamp system on
1 x pushbutton start ignition
Ignition cable
Smitsvonk® high temperature ignition cable
consisting of: 31 meter ignition cable
31 meter mass cable
10 meter protection hose
Coupling piece
20 meter protection hose
1 plug M30 for connection to pilot burner.
Type SKSLANG014/10 + SEKB000304/301 + PLUG-M30 L31
Length 31 meter
Quantity 16 pcs
Power supply cable
Power cable for off shore, oil & gas, ships and marine industries according NEK606
Type / P/N. 3G 2.5mm² 0.6/1KV / 104888
Conductors Conductors : 3 x 2,5 mm² (blue - brown - yellow/green)
Min/max temperature -40° to 90° C
Outside diameter 15 mm Outer sheath: SHF2 - black.
Max. bend radius 6 x outer diameter
L:ength 30 meter
Quantity 4 pcs
Please pay attention to the following.
General
 If any obscurity arises please contact the service department of Smitsvonk.

 It is recommendable to mount the materials as soon as possible. Do not store the products without
the packaging for a long time in order to decrease the chances of damage.
Pilot Burner
 Be certain that there is a good support of the burner. Use the mounting flange or suspension
brackets.
 During the operation conditions temperature can rise till about 500° C or even higher. Rising of
temperature makes materials expand. During mounting you have to take full account of this. There
must be some clear space for the burner head to expand after mounting, see Figure 3.29.17.
Hindering of this free movement can lead to damages or malfunctioning of the burner.
 Do not expose the pilot burner to external load.
 Do not turn the hexagon nut at the gas connection, see Figure 3.29.18

Rev. 3
Ignition unit
 The ignition unit has to be mounted on a stable background.

 Take care of sufficient earthing of the ignition unit
 When mounting the ignition unit outside, be sure that there is sufficient protection against the
weather conditions.
 Don’t place the unit to close to heat sources.
Figure 3.29.21 Oil Burner Pilot

Rev. 3
Figure 3.29.22 Gas Flare Pilot
Figure 3.29.23

Rev. 3
Connections pilot burner
The following connections are applicable for the pilot burner.
(Heat resistant) ignition cables
These ignition cables with stainless steel protection hose have been provided with connectors that match
the connection pieces at the end of the pilot burner. Connect the cables to the pilots and tighten the lock
nuts. Check the sealing ring (No. 11) of the connector to prevent water will flow into the cable assembly.
Ignition unit
 The low-tension electronic ignition unit shall be mounted in a vertical position with the cable glands
down (see figure 3.29-21 below). When the cover of the unit is mounted properly, no special
measures need to be taken to prevent the ingress of dust or humidity into the box.
 Refer to the manufacturer drawings (ignition unit) for electrical connections.

Rev. 3
Figure 3.29-24
Figure 3.29-25 Oil and Gas ignition panel

Rev. 3
3.29.6.4.3 Preparation
Before starting up, check the following points:
Check if the flare system is free of oxygen and purged.

Before starting up the system, one must be ensured that the pilot gas supply lines are free from dirt or rust
particles.
Mechanical
 Check if the gas supply connection is mounted correctly.

 Check if the burner is mounted correctly.
 Check if the gas pressure is present.
 Check if the gas valves are open.
Electrical
 Check if the power is present.

 Check if the ignition cable is mounted correctly.
 Check if the cables aren’t damaged.
 Check the earthing of the ignition unit.
When power supply is switched on and the start sequence is activated the ignition unit will produce a high
tension and high current for a very short period. Via the ignition cable the spark plugs will spark and ignite
the gas/air mixture.
3.29.6.4.4 START OF THE SYSTEM
NOTE: Do NOT switch on the power supply before all connections have been checked and the
boxes have been closed.
Check whether pilot gas and main voltage are available.
 Supply gas to the pilot burners.

 Turn the main switch to the “ON” position.
 TO START THE SYSTEM LOCAL
The ignition unit will start producing the tension and energy for the spark when the start ignition push
button is pressed. After the push button is pressed it can be released. The ignition unit will produce
sparks for the set time (about 5 seconds). As soon as the pilot is ignited, the ignition unit can be switched
off. The enclosure of the ignition unit has one main power switch, one power on lamp and one push
button and no remote control signals to operate the ignition unit.
When the gas pressure is correct, a stable flame with a core and a cone will appear.
As soon as a pilot has been successfully ignited, it should be possible to see the pilot flame. Depending
on the gas pressure and the wind velocity the flame length will vary in the range between 5 and 15 cm.
If the pilot burner is used for the first time or after maintenance, the gas pressure has to be set as
described in the 3.29.6.4.1Technical Details. The pilot burner is self-aspirating. Air will come to the
nozzle via the holes in the lower burner tube, adjustment is not necessary. Check if any obstacle disturbs
the air inlet (air supply). A good flame has a centre flame in the middle of the stabiliser. Small flames
are surrounding the “centre”-flame and have their stabilising effect to the “centre”-flame.
3.29.6.4.5 TROUBLE SHOOTING

Rev. 3
When the system is malfunctioning the following checkpoints can be used in order to find the failure.
The pilot burner has no thermocouple, the flame detection has to be done with other means.
Possible causes pilot burner can be:
Failure Cause Result Action
There is no flame The nozzle or the The burner doesn't Clean the nozzle and the
(Signal). filter are clogged. ignite, there is no flame filter.
signal to the
temperature controller.
There is no flame Gas air ratio is not The burner doesn't Check and adjust the gas
(signal). correct. ignite, there is no flame pressure.
signal to the temperature
controller
There is no flame There is no gas The burner doesn't Check the pipe work for
(signal). present. ignite, there is no flame Leakage. Check if the Pilot
signal to the valves are opened
temperature controller
There is no flame The spark plug is The burner doesn't Replace the spark plug(s).
(signal). worn out. ignite, there is no flame
signal to the
temperature controller.
When the above mentioned points didn’t solve the problems than please contact the manufacturer.
Possible causes for the ignition unit can be:
Failure Cause Result Action
There is no flame Ignition unit doesn't The burner doesn't Check and if necessary
(signal). function. ignite. replace the fuses.
There is no flame Ignition unit doesn't The burner doesn't Check the wiring and
(signal). function. ignite. check if there are no
loose contacts.
There is no flame Ignition unit doesn't The burner doesn't Check if the LED is
(signal). function. ignite. flashing on the PCB
(pulse unit) in the
enclosure.
There is no flame Ignition unit doesn't The burner doesn't Check the ignition,
(signal). function. ignite. ionisation or
thermocouple cables.
There is no flame Ignition unit is defect. The burner doesn't Replace the ignition unit
(signal). ignite. internal.
If applicable

Rev. 3
There is no flame Ignition unit doesn't The burner doesn't Check if the remote start
(signal). function after ignite. signal (24Vdc) is at the
remote start signal terminals. Check if the
remote start relay
switches, if not replace
the relay.
There is no flame Ionisation relay or The burner does Replace the ionisation or
(signal). thermocouple relay ignite but there is no thermocouple relay.
is defect. flame signal to the Ionisation signal should
ionisation or be > 5 mA. Thermocouple
thermocouple relay. signal in mV.
When the above mentioned points didn’t solve the problems than please contact the manufacturer.
For more information please refer to the manufacturer’s Installation, Operating and Maintenance
manual. Smitsvonk IOM Manual
3.29.7 Super Sea Burner

The Super Sea burner allows the oil to flow through the centre of the burner via a swirl vane which
agitates the oil flow, it then passes through a 0.5" nozzle, which allows solids smaller than 0.5" to

Rev. 3
exit with the oil. The oil then enters the mixing chamber which is flowed too by the compressed
air via a vanes swirl boss to assist in the atomisation of the oil.
The Super Sea creates a higher back pressure than the Super Green, approx. 400psig at a flow
rate of 4,000Bbls/d.
The below diagram is of the Super Sea burner arrangement.
Figure 3.29.26 Super Sea Burner Arrangement
3.29.7.1 Super Sea Burner Air Requirements
Figure 3.29.27 Super Sea Air Requirement

3.29.7.2 Super Sea Burner - Electric Ignition System (High Velocity)
The Super Sea burner pilot system is similar to the Supergreen burner pilot system. It
incorporates a flame tube housing a gas pilot jet and a high tension igniter on each burner head.

Rev. 3
3.29.7.3 Installation
1. Secure the flame tube body approximately 4" in front of burner/ atomising head assembly.
2. Connect high tension igniter and H.T. cable ensuring that a good earth is obtained.
4. Install and secure Lodge box enclosure approximately 20 ft. behind atomising head
assembly.
5. Position cable reel in a dry area (off the boom) and connect cable to Lodge box enclosure.
7. Unwind cable and connect to correct voltage AC supply.
3.29.7.4 Start Up
2. Ignite the pilot by pressing and holding the ignition switch. If ignition is not immediate adjust
the pilot gas supply and re try ignition.
4. Once the pilot is a light stop the power supply to the igniter to prevent it burning out.
3.29.7.5 Shut Down

1. Close the main propane supply. Once the main propane supply is closed, the pilot flame will
become extinguished.

Rev. 3
3.29.8 Vulcan Burner

The Vulcan Burner is a ‘complete combustion’ type burner that features:
 Reduced smoke
 No fall-out
 Reduced heat radiation
One of the positive features is the presence of four heads, allowing division of the flame into
four independent smaller flames. This increases the amount of air available for combustion,
provided by injection of air into the mixing chamber as well as ambient air.
The Vulcan burner is a two-stage atomisation device, installed on each of the four gun heads,
consisting of:
 A mixing chamber for preparation of the fluid/air mixture

 A static mixer gun producing a fine spray.
The Vulcan burner creates a back pressure of approximately 70psig at a flow rate of
4,000Bbls/d.
The below diagram shows a single Vulcan burner arrangement.
Figure 3.29.28 Vulcan Burner
3.29.8.1 Vulcan Burner Air Requirements

Maximum air requirements for up to 15,000Bbls/day is 600ft3/min at 150psig (17m3/min at 10.2
Bar).
3.29.8.2 Vulcan Burner – Electric Ignition System (High Velocity)

The Vulcan burner pilot system is similar to the Supergreen burner pilot system. It incorporates
a flame tube housing a gas pilot jet and a high tension igniter on each burner head.
1. Secure the flame tube body approximately 4" in front of burner/ atomising head assembly.
2. Connect high tension igniter and H.T. cable ensuring that a good earth is obtained.
4. Install and secure Lodge box enclosure approximately 20 ft behind atomising head
assembly.
5. Position cable-reel in a dry area (off the boom) and connect cable to Lodge box enclosure.
7. Unwind cable and connect to correct voltage AC supply.
3.29.8.2.2 Start-Up

Rev. 3

2. Ignite the pilot by pressing and holding the ignition switch. If ignition is not immediate
adjust the pilot gas supply and re try ignition.
4. Once the pilot is a light stop the power supply to the igniter to prevent it burning out.
3.29.8.2.3 Shut Down
1. Close the main propane supply. Once the main propane supply is closed, the pilot flame
will become extinguished.
3.29.9 Burner Performances

The burner performance should be completed during all oil burning operations to allow for details
to be documented and reviewed based on performance, to provide lessons learnt and a detailed
history of the various burners within the Expro inventory.
This should be completed using the Equipment Report Form 2-QMS-WT-FRM-001-038 section
C5 – INS-002058.

Well Test Standards Section 3.29 Burners and Ignition Systems

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Well Test Standards Section 3.29 Burners and Ignition Systems

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Well Test Standards

© February 2017 by Expro - ALL RIGHTS RESERVED

Document Number: INS-002688 Revision: 3

Template No: INS-T-002 Rev 1

Revision Reason for Change Issued Owner Reviewer Approver

1 New Insight Template 24/Aug/2015 H.Selim E.Riddell D.Cleland

Amendment from Rev 1 to Rev 2

Page 2 of 33 Global / Well Test

3.29.4 Procedures ................................................................................................... 8

3.29.5.4 Setting up an optional Air Purge System .................................................... 14

3.29.6 Supergreen Burner ..................................................................................... 15

3.29.7 Super Sea Burner ....................................................................................... 29

3.29.7.4 Start Up ...................................................................................................... 31

3.29.8 Vulcan Burner ............................................................................................. 32

3.29.9 Burner Performances ................................................................................. 33

Global / Well Test Page 3 of 33

Page 4 of 33 Global / Well Test

3.29.1 Burner Introductions

Figure 3.29.1 Supergreen Burner

Figure 3.29.2 Sea Emerald Burner

Global / Well Test Page 5 of 33

Expro have four types of burner head in their current inventory:

Flow rate Capacity:

• Sea Emerald Burner – up to 4,000 Bbls/d per cluster/head

3.29.2 Burner Installations

3.29.3 Pressure Testing

3.29.3.1 Oil Line (Test Medium; Water)

Page 6 of 33 Global / Well Test

15. Vent all pressure from system to 0 psig.

3.29.3.2 Air Line (Test Medium; Air)

1. Remove Sea Emerald burner nozzles.

Figure 3.29.3 SE Blank Nozzle

Global / Well Test Page 7 of 33

1. Super Green & Super Sea - Remove Burner End Caps.

3.29.4.1.1 Pre Flow Test Procedures

Page 8 of 33 Global / Well Test

3.29.4.1.2 Start Up Procedure

Note: Heads without isolation valves to be selected first.

3.29.4.1.3 Operating Procedure

3.29.4.1.4 Shut down Procedure

Global / Well Test Page 9 of 33

3.29.5 Sea Emerald

Figure 3.29.4 Sea Emerald Cluster

3.29.5.1 Sea Emerald Air Requirements

Figure 3.29.5 Sea Emerald

Page 10 of 33 Global / Well Test

3.29.5.2 Sea Emerald Burner – Electric Ignition System (Stackmatch)

Figure 3.29.6 Gas Jets Gas Consumption

• Pilot gas - 1/4 in. FNPT

Pilot & Igniter Assembly

Red Lead to Plasma Generator

Figure 3.29.7 Stackmatch pilot & igniter

Global / Well Test Page 11 of 33

3.29.5.3 Pilot/Jet/Booster Ring Gas Operation

3.29.5.3.1 Pilot Gas

Light pilots well in advance of burn periods.

Figure 3.29.8 Stackmatch pilot gas

2. Open propane to pilot.

3.29.5.3.2 Jet Gas

1. Tap off separator gas for a dual source as an option.

Page 12 of 33 Global / Well Test

3.29.5.3.3 Booster Ring Gas