OPERATIONAL PROCEDURE

FOR FLARE IGNITION EQUIPMENT

INSTRUMENT CONTROL PANEL

Client : GPS Singapore

Purchaser : PTCS

Location : Vietnam

Flareon Project # : 12-7391-FO726

Date : 2012

For Parts and Service please contact:

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

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

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

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

A) PRESSURE SETTING ON AIR LINE AND FUEL GAS LINES

B) MANUAL OPERATION (PILOTS NOT LIT)

C) AUTOMATIC OPERATION (PILOTS NOT LIT)

D) MANUAL OPERATION FUEL GAS SUPPLY (PILOTS LIT)

E) AUTOMATIC OPERATION (PILOTS LIT)

F) MANUAL OPERATION ON PROPANE BACK UP SUPPLY

G) AUTOMATIC OPERATION ON PROPANE BACK UP SUPPLY

H) MANUAL OPERATION OF FLAME FRONT GENERATOR (FFG)

I) MANUAL OPERATION OF FFG ON PROPANE BACK UP SUPPLY

J) SECURITY / SAFTEY

REFERENCE DRAWINGS / DOCUMENTATION

FI726–FTGA–MDW–0100 FLARE TIP GENERAL ARRANGEMENT

FI726–PID–PDW–0100 PIPING AND INSTRUMENTATION

DIAGRAM (P&ID)

FI726–CBD–EDW–0100 ELECTRICAL WIRING DIAGRAM

ALL APPLICABLE PACKING LISTS

Operation of the Flare Tip and Flare Ignition Equipment at the discretion of the Onsite
Operational Team, and the following is the suggested Flareon procedure only.

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 2 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 A) PRESSURE SETTING ON AIR LINE

1. OPEN Ball Valve BV01, BV11 and Needle Valve NV01. OPEN Ball BV02.

2. Adjust Pressure Regulator Valve PCV01 such that the Pressure Gauge PI01 is about 20
PSI.

3. Record the Pressure Gauge reading of PI01.

4. CLOSE Ball Valve BV01.

PRESSURE SETTING ON FUEL GAS SUPPLY LINE

5. Ensure BV05, BV07 and BV09 are CLOSED.

6. OPEN Ball Valve BV03; ensure Needle Valve NV03 is OPEN and OPEN BV04.

7. Adjust Pressure Regulator Valve PCV02 such that the Pressure Gauge PI02 is about 10
PSI.

8. Record the Pressure Gauge reading of PI02.

9. CLOSE Ball Valve’s BV03 and BV04.

PRESSURE SETTING ON BACK UP FUEL GAS SUPPLY LINE

10. Ensure BV04 is CLOSED. OPEN all relevant Ball Valves on the Propane Gas Backup
Manifold.

11. Ensure Needle Valves NV04, NV05 and NV07 and Ball Valves BV07 and BV09 are
OPEN.

12. OPEN Ball Valves BV06 and BV08.

13. Adjust Pressure Regulator Valve PCV03 such that the Pressure Gauge PI04 is about 8
PSI.

14. Adjust Pressure Regulator Valve PCV04 such that the Pressure Gauge PI05 is about 6
PSI.

15. Record the Pressure Gauge reading of PI04 and PI05.

16. CLOSE Ball Valves BV06, BV07, BV08, and BV09 and CLOSE all relevant Ball Valves
on the Propane Gas Backup Manifold.
Flareon Inc. 2-C Pusat Teknologi Sunsuria, Jalan Teknologi,
Taman Sans Selangor 1, Kota Damansara, PJU 5 3 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 B) MANUAL OPERATION MODE (PILOTS NOT LIT)

1. The below steps are performed to ensure the ignitors are arcing in manual mode. We
recommend this to be performed during startup.

2. Wire the Igniter’s to respective Terminals on Terminal Bar 1 (TB1) of the Ignition Control
Panel.

3. Ensure that BV02 is CLOSED.

4. Ensure that the Pilot Fuel Gas and Back Up Fuel Gas Supply gas is switched OFF (Ball
Valves BV03, BV04, BV07 and BV09 are CLOSED).

5. Turn switch One (SW-1) to ON position. Ensure that the GREEN (PL-7) POWER ON
Lamp is illuminated.

6. Turn Switch 2 (SW-2) to HAND position.

7. Press ‘LAMP TEST’ (PB-1) to ensure all lamps illuminate.

8. Press Push Button for Ignitor One (PB-2) ‘MANUAL IGNITION #1’ for a fraction of a
second, Confirm Arc at IDE -01 Pilot 1.

9. Press Push Button for Ignitor Two (PB-3) ‘MANUAL IGNITION #2’ for a fraction of a
second, Confirm Arc at IDE -02 Pilot 2.

10. Press Push Button for Ignitor Three (PB-4) ‘MANUAL IGNITION #3’ for fraction of a
second, Confirm Arc at IDE -03 Pilot 3.

11. Press Push Button PB-6 ‘Manual FFG’ for fraction of a second, Confirm Arc at sight Port
BZ 01.

12. Turn Switch Two (SW-2) to OFF position.

13. Turn Switch One (SW-1) to OFF Position.

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 4 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 C) AUTOMATIC OPERATION (PILOTS NOT LIT)

1. Ensure Switch One (SW-1) is in the ON position and POWER ON lamp (PL-7) is
illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-04, BV-05, BV-06, BV-07, BV-08, BV-09 and BV-
11 are CLOSED and open Ball Valve BV03

3. Confirm Red ‘LOW FUEL GAS’ Lamp (PL-9) is OFF

4. Turn Switch Two (SW-2) to AUTO Position

5. There is a one minute delay (This is to allow Pilot fuel gas to reach the pilots under
normal operation conditions)

6. Automatic operation Begins and Ignitor #1 (IDE-01) Starts arcing for 0.1 Sec every 60
Secs.

7. Confirm Green Pilot #1 Flame On Lamp (PL-1) is OFF & Red Pilot #1 Flame Off Lamp
(PL-4) is ON and ‘Pilot #1Failure’ Alarm contact is OPEN. (943-XI-930A)

8. Ignitor #2 (IDE-02) starts arcing after an interval of 20 secs from Igniter #1 and Arcs for
0.1 sec every 60 secs.

9. Confirm Green Pilot #2 Flame On Lamp (PL-2) is OFF & Red Pilot #2 Flame Off Lamp
(PL-5) is ON and ‘Pilot #2 Failure’ Alarm contact is OPEN. (943-XI-930B)

10. Ignitor #3 (IDE-03) starts arcing after an interval of 20 secs from Igniter #2 and arcs for
0.1 sec every 60 secs.

11. Confirm Green Pilot #3 Flame On Lamp (PL-3) is OFF & Red Pilot #3 Flame Off Lamp
(PL-6) is ON and ‘Pilot #3 Failure’ Alarm contact is OPEN. (943-XI-930C)

12. Confirm Common Pilot Failure Alarm contact is OPEN. (943-VA-930)

13. This sequence will continue for 5 minutes. Because of the lack of pilot fuel gas, all 3
pilots will fail to ignite resulting in all 3 pilots’ failure alarms and the common pilot failure
alarm becoming active.

14. Confirm Red ‘AUTO IGNITION FAIL’ Lamp (PL-8) is ON.

15. Confirm ‘AUTO IGNITION FAILURE’ Alarm contact is OPEN (943-XI-930)

16. Turn SW-2 to the OFF position and press PB-5 Reset. Ensure Red ‘AUTO IGNITION
FAIL’ Lamp (PL-8) is OFF

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 5 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 D) MANUAL OPERATION FUEL GAS SUPPLY (PILOTS LIT)

1. Ensure Switch One (SW-1) is in the ON position and the Green lamp (PL-7) ‘POWER
ON’ is illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08, BV-09
and BV-11 are CLOSED.

3. Turn Switch Two (SW-2) to HAND Position.

4. OPEN Ball Valve BV-03 and Ball Valve BV-04.

5. Confirm Red Fuel Gas Lamp (PL-9) is OFF.

6. Allow sufficient time for the gas to reach the pilots.

7. Press Manual Igniter #1 Push Button (PB-2) for fraction of a second. Confirm Pilot #1is
Lit.

8. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #2 Flame Off Lamp
(PL-4) is OFF.

9. Confirm ‘Pilot #1Failure’ Alarm contact is CLOSED. (943-XI-930A)

10. Press Manual Igniter #2 Push Button (PB-3) for fraction of a second. Confirm Pilot #2 is
Lit.

11. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

12. Confirm ‘Pilot #2 Failure’ Alarm contact is CLOSED. (943-XI-930B)

13. Press Manual Igniter #3 Push Button (PB-4) for fraction of a second. Confirm Pilot #3 is
Lit.

14. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

15. Confirm ‘Pilot #3Failure’ Alarm contact is CLOSED. (943-XI-930C)

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 6 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 E) AUTOMATIC OPERATION FUEL GAS SUPPLY

1. Ensure Switch One (SW-1) is in the ON position and the Green (PL-7) ‘POWER ON’
lamp is illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08, BV-09
and BV-11 are CLOSED.

3. OPEN Ball Valve BV-03 and Ball Valve BV-04

4. Turn Switch Two (SW-2) to AUTO Position.

5. Confirm Red ‘LOW FUEL GAS’ Lamp (PL-9) is OFF.

6. There is a one minute delay (This is to allow Pilot fuel gas to reach the pilots)

7. Automatic operation Begins and Ignitor #1 (IDE-01) Starts arcing for 0.1 Sec every 60
Secs. Confirm Pilot #1 is Lit.

8. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #1 Flame Off Lamp
(PL-4) is OFF.

9. Confirm ‘Pilot #1Failure’ Alarm contact is CLOSED. (943-XI-930A)

10. Ignitor #2 (IDE-02) starts arcing after an interval of 20 secs from Igniter #1 and Arcs for
0.1 sec every 60 secs. Confirm Pilot #2 is Lit.

11. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

12. Confirm ‘Pilot #2Failure’ Alarm contact is CLOSED. (943-XI-930B).

13. Ignitor #3 (IDE-03) starts arcing after an interval of 20 secs from Igniter #2 and arcs for
0.1 sec every 60 secs. Confirm Pilot #3 is Lit.

14. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

15. Confirm ‘Pilot #3Failure’ Alarm contact is CLOSED. (943-XI-930C).

16. Confirm Common Pilot Failure Alarm (XA1750D) is not triggered.

17. Confirm Red ‘AUTO IGNITION FAIL’ Lamp (PL-8) is OFF.

18. Confirm ‘AUTO IGNITION FAILURE’ Alarm contact is CLOSED (943-XI-930)

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 7 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 F) MANUAL OPERATION ON PROPANE GAS BACKUP SUPPLY

1. Ensure Switch One (SW-1) is in the ON position and POWER ON lamp (PL-7) is
illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08, BV-09
and BV-11 are CLOSED.

3. Turn Switch Two (SW-2) to HAND Position.

4. OPEN respective valves on the Propane Gas backup Manifold.

5. OPEN Ball Valve BV-08 and Ball Valve BV-09.

6. Allow sufficient time for the propane gas to reach the pilots.

7. Press Manual Igniter #1 Push Button (PB-2) for fraction of a second. Confirm Pilot #1is
Lit.

8. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #2 Flame Off Lamp
(PL-4) is OFF.

9. Confirm ‘Pilot #1Failure’ Alarm contact is CLOSED. (943-XI-930A)

10. Press Manual Igniter #2 Push Button (PB-3) for fraction of a second. Confirm Pilot #2 is
Lit.

11. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

12. Confirm ‘Pilot #2Failure’ Alarm contact is CLOSED. (943-XI-930B)

13. Press Manual Igniter #3 Push Button (PB-4) for fraction of a second. Confirm Pilot #3 is
Lit.

14. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

15. Confirm ‘Pilot #3Failure’ Alarm contact is CLOSED. (943-XI-930C)

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 8 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 G) AUTOMATIC OPERATION ON PROPANE GAS BACKUP SUPPLY

1. Ensure Switch One (SW-1) is in the ON position and the Green (PL-7) ‘POWER ON’
lamp is illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08, BV-09
and BV-11 are CLOSED.

3. OPEN respective valves on the Propane Gas backup Manifold

4. OPEN Ball Valves BV-08 and Ball Valve BV-09

5. Turn Switch Two (SW-2) to AUTO Position.

6. There is a one minute delay (This is to allow Pilot fuel gas to reach the pilots)

7. Automatic operation Begins and Ignitor #1 (IDE-01) Starts arcing for 0.1 Sec every 60
Secs. Confirm Pilot #1 is Lit.

8. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #1 Flame Off Lamp
(PL-4) is OFF.

9. Confirm ‘Pilot #1 Failure’ Alarm contact is CLOSED. (943-XI-930A)

10. Ignitor #2 (IDE-02) starts arcing after an interval of 20 secs from Igniter #1 and Arcs for
0.1 sec every 60 secs. Confirm Pilot #2 is Lit.

11. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

12. Confirm ‘Pilot #2 Failure’ Alarm contact is CLOSED. (943-XI-930A)

13. Ignitor #3 (IDE-03) starts arcing after an interval of 20 secs from Igniter #2 and arcs for
0.1 sec every 60 secs. Confirm Pilot #3 is Lit.

14. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

15. Confirm ‘Pilot #3 Failure’ Alarm contact is CLOSED. (943-XI-930C)

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 9 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 H) MANUAL OPERATION ON FLAME FRONT GENERATOR (FFG) Line (Pilots Lit)

1. Ensure Switch One (SW-1) is in the ON position and the Green lamp (PL-7) ‘POWER
ON’ is illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08 & BV-09
are CLOSED.

3. Turn Switch Two (SW-2) to HAND Position.

4. OPEN Ball Valves BV-01 & BV-02, BV-03, BV-04, BV-05 and BV-11.

5. Confirm Red ‘LOW FUEL GAS’ Lamp (PL-9) is OFF.

6.

7. Allow sufficient time for the gas to reach the FFG ignitors and the pilots.

8. Press Manual FFG Push Button (PB-6) for fraction of a second. Confirm Pilot #1 is Lit.

9. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #1 Flame Off Lamp
(PL-4) is OFF.

10. Confirm ‘Pilot #1Failure’ Alarm contact is CLOSED. (943-XI-930A)

11. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

12. Confirm ‘Pilot #2 Failure’ Alarm contact is CLOSED. (943-XI-930B)

13. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

14. Confirm ‘Pilot #3 Failure’ Alarm contact is CLOSED. (943-XI-930C)

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 10 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 I) MANUAL OPERATION ON (FFG) on PROPANE BACK UP FUEL (Pilots Lit)

1. Ensure Switch One (SW-1) is in the ON position and POWER ON lamp (PL-7) is
illuminated.

2. Ensure Ball Valves BV-01, BV-02, BV-03, BV-04, BV-05, BV-06, BV-07, BV-08 & BV-09
are CLOSED.

3. Turn Switch Two (SW-2) to HAND Position.

4. OPEN respective valves on the Propane Gas backup Manifold.

5. OPEN Ball Valves BV-01, BV-02, BV-05, BV-06, BV-07, BV-08, BV-09 and BV-11.

6. Allow sufficient time for the gas to reach the FFG ignitors and the pilots.

7. Press Manual FFG Push Button (PB-6) for fraction of a second. Confirm Pilot #1 is Lit.

8. Confirm Green Pilot #1 Flame On Lamp (PL-1) is ON & Red Pilot #1 Flame Off Lamp
(PL-4) is OFF.

9. Confirm Pilot #1 Alarm Contact (XA1750A) is not triggered.

10. Confirm Green Pilot #2 Flame On Lamp (PL-2) is ON & Red Pilot #2 Flame Off Lamp
(PL-5) is OFF.

11. Confirm Pilot #2 Alarm Contact (XA1750B) is not triggered.

12. Confirm Green Pilot #3 Flame On Lamp (PL-3) is ON & Red Pilot #3 Flame Off Lamp
(PL-6) is OFF.

13. Confirm Pilot #3 Alarm Contact (XA1750C) is not triggered.

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 11 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727
 J) Security / Safety

1. In Manual FFG mode ensure the manual FFG push button (PB-6) is pressed only for a
fraction of second ( 0.5 sec ) and release immediately.

2. In Manual mode ensure that PB-2, 3 or 4 is pressed only for a fraction of second ( 0.5
sec ) and release immediately.

3. Only ever attempt to manually ignite 1 pilot at a time. Never depress more than one
‘MANUAL IGNITION’ pushbutton at a time.

4. Do not open the control panel enclosure unless the power supply to the control panel is
completely isolated.

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

Taman Sans Selangor 1, Kota Damansara, PJU 5 12 Telephone: +603 6151 0036
47810, Petaling Jaya, Selangor Darul Ehsan Malaysia Telefax: +603 6151 6727