MAIN OFFICE

Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega,

Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
BOGOTÁ – COLOMBIA
www.technodrill.com.co BOGOTÁ – NEIVA – CUMARAL

FLARE TANK
MODEL No. FT 20 – 120

S/N TNJ-19-601

OPERATIONS MANUAL
Rev. September 30, 2018

CONTENT
Page

1. INTRODUCTION 2

2. GENERAL DESCRIPTION 2
a. Dimensions for Transportation 2
b. Main Components 2

3. SAFETY PRECAUTIONS 3

4. HANDLING OF FLARE STACK 4

a. Required Personnel and Equipment 4
b. Laying of Flare Stack over Gasbuster 4
c. Hoisting of Flare Stack 5
d. Dismounting of Flare Stack – For mobilization inside locations 6
e. Preparation of Flare Tank for Transportation Outside location 7

5. IGNITING PROCESS 8
a. Required Personnel and Equipment 8
b. Electric Ignition 8
c. Manual Ignition 10

6. INSPECTION AND PREVENTIVE MAINTENANCE OF THE FLARE TANK 10

5CT-1745/5CT- 1762 Neiva – Cumaral CO17.00314 7-1-1108/10D-0055 Tenjo

 1. INTRODUCTION

This Operations Manual includes general description of the Flare Tank, safety precautions, handling of the Flare
Stack, ignition systems and recommendations for preventive maintenance.

2. GENERAL DESCRIPTION

Name: Flare Tank

Model: FT 20 - 120
Serial Number: TNJ-19-601
Date of Manufacture: September 2019
Manufacturing Drawing: TD-0386, Rev. 3

DIMENSIONS FOR TRANSPORTATION

Maximum Skid Length: 30ft (9,15 mt)

Maximum Width (at Hammer Unions): 8ft-4” (2,54 mt)
Maximum Height (with Flare Stack dismounted): 9ft (2,75 mt)
Weight: 7500 Kg approx.

MAIN COMPONENTS

1. Skid Frame: 30ft long x 7ft-10” wide.

2. Containment Tank: 20ft long x 7ft-10” wide x 4ft-6” high. Capacity 682ft3 (121 bbl)

3. Gasbuster: 3ft-4” Diameter x 7ft Long, Capacity 61ft3 (10 bbl).

4. Flare Stack, 25ft high from floor, composed by:

a. Two 10” and 16” diameter tubes.
b. One shroud with cover lid at the top with opening and closing system.
c. One flame arrestor inside the shroud.

5. Hoisting System of the Flare Stack that includes:

a. One Electric Winch Brand WARN, 12 VDC, 3/8”∅ Cable. Capacity 8000 Lb (3629 Kg)
b. One 4”∅ balancing post with a 6”∅ Pulley. Capacity 4409 Lb (2000 Kg).
c. One Manual Winch Brand PROWINCH, 1/4” ∅ Cable. Capacity 551 Lb (250 Kg)
d. One 4”∅ Pulley. Capacity 1102 Lb (500 Kg) for manual winch.

6. Ignition System composed of power line and propane line:

 Power Line (See parts from bottom up in Fig. 5, page 9):

a. Source outlet socket 110 VAC and plug.
b. Electric Push-button 110 VAC with 3x14 AWG 150ft cable for remote control.
c. Metallic box 2” x 4”, 5800 USA, installed near the bottom end of flare stack, with 110-volt socket.
d. 1/2” conduit pipe with 110-VAC cable.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 e. Nema type 4X weatherproof box containing one electric ignition transformer Honeywell
Q652b1006, 120 VAC (+10%-15%) 60 Hz, maximum output voltage of 14.0 kV at 21 kHz. Power
consumption of 40 watts nominal.
f. 2-ft ignition (high voltage) cable.
g. 2” x 4” metallic weatherproof box with interconnection of ignition cable to ignition electrodes.
h. Two Ignition Electrodes.

 Propane Line (See parts from bottom up in Fig. 5, page 9):

a. Two 100-lb propane cylinders (empty, to be filled up at rig site).
b. Flame Regulator 0 to 30 PSI (0-2.1 Bar) brand IMETAN Series G100 installed after the propane
valve.
c. Flame arrestor element brand SUPERFLASH with check valve, installed following the regulator.
d. 150-ft 3/8” gas hose, Parker 7132 LP for remote location of propane cylinders.
e. Rigid Line of 1/2" galvanized steel propane line installed in containment tank
f. 2-foot 3/8” gas hose (metallic).
g. Rigid Line of 1/2" galvanized steel pipe to propane pilot nozzle, installed in flare stack.
h. Propane nozzle installed at crown of flare stack.

3. SAFETY PRECAUTIONS

 General:
 Carry out safety talks before starting the handling of the flare stack and flame ignition with the operators
involved to coordinate activities in a safe and controlled manner.
 When handling the Flare Stack and flame igniter, it is recommended to do it in presence of the Rig
Manager and at least three (3) experienced operators using corresponding safety equipment as
recommended by the rig HSE coordinator.
 Check operability of 8” gate valve and 4” ball valve before operating the Flare Tank.
 Verify correct connection of four (4) hammer union inlets, installed on side of containment tank, with
mud and gas lines coming from the well or equipment, incorrect connection with these lines may
generate flames out of control or explosion.
 4”, 8” and 10” lines installed in the tank for flow of mud and gas from the well are rated for pressures
up to 150 PSI (10.3 Bars), do not exceed this pressure.

 Precautions when handling the Flare Stack:

 Make sure all connections and elements used in the handling of the Flare Stack are safe and nearby
areas clear of personnel not involved in the activity; never locate yourself under or in front of a moving
load or near pulley cables.
 Operation of electric and manual winches must be coordinated between winch operators previous to the
lifting or lowering of the flare stack.
 For safety precautions when operating the electric winch at flare stack handling see the manual of the
electric winch Warn included in Flare Tank dossier.

 Ignition safety precautions:

 It is recommended that it be operated by a certified electrician.
 Protect electric cables from being damaged and contact with water.
 Propane pilot flame must remain on while gas is flowing up the flare stack.
 Keep the propane closed if there is no flame either at the flare stack or at the propane line nozzle.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 4. HANDLING OF FLARE STACK

REQUIRED PERSONNEL AND EQUIPMENT

1. Team Supervisor.
2. Crane or forklift loader with operator.
3. Two-strand sling (Flare stack weight 500 kg approx.).
4. One operator for the electric winch.
5. One operator for the manual winch.
6. Tool box with hand tools.

LAYING OF FLARE STACK OVER THE GASBUSTER

Following instructions apply when de Flare Tank arrives at the rig site for the first time.

1. Install the saddle supports provided as it corresponds, one over the gasbuster and the other one on the
vertical tube installed near the pulley of the manual winch, and fix them with pins provided (See Fig. 1)

2. Go to the flare stack sitting on the side of the gasbuster and unclamp it.

3. Using the crane and a two-strand sling lift the Flare Stack horizontally and carefully raise it over to the
Gasbuster.

Figure 1. Mounting Flare Stack over Gasbuster and Balancing Pole.

4 Locate the Flare Stack over the saddle supports previously installed while aligning the eye pads of the
main hinge over the Gasbuster, make sure the 8” gate valve is fully closed to prevent the flare stack from
hitting the screw of the valve handle when laying down. Install the hinge pivot with safety pin provided.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 5 Using the crane and handhelp, lift the balancing pole from the grating floor hooking it from the lifting
padeye, raise it up with the pulley end upwards while locating the other end down to align with the hinge
eye pads on the grating floor, insert the hinge pivot with safety pin provided.

6 Connect the electric winch to a 12-VDC, 900-amp vehicle battery.

WARNING: The electric winch operates only on 12 VDC. Ensure the winch wires have good electric contact
with the source battery as weak connections can cause voltage drop and lead to malfunction or damage
of the winch. To prevent the battery from being discharged, it is recommended to keep it installed on a
turned-on engine during winch operation.

Figure 2. Flare Tank with stack raised in operative position.

7. Operate the electric winch to unwind the cable and pull it over the pulley on the balancing pole, unwind
the cable until you are able to hook it into the eye pad near the shroud on top of the 10” stack. Wind the
cable back as to pull and leave it slightly tightened.

8. From the manual winch, install the steel cable over the nearby pulley and hook it to the pulling padeye
near the top of the 16” stack. Leave the cable of the manual winch loosened.

HOISTING OF FLARE STACK

1. Ensure the 10" and 16" flanges in the Gasbuster have the fleximetal gaskets installed in concentric
position. It is recommended to keep these gaskets glued with Locktite to the flanges so they remain
concentric and bolt holes aligned to facilitate installation.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 CAUTION: Before hoisting the stack coordinate with the operator of the manual winch to unwind it
simultaneously, so it never exhorts any tension over the stack until it gets near the vertical position, to
avoid damage to any of the components while hoisting.

2. Start hoisting the flare stack by pulling with the electric winch, initially applying a slight tension on the
cable, carefully pull the stack up from the supports and continue hoisting slowly and uniformly. During
this hoisting time the manual winch must be controlled to keep its cable loosen.

3. When approaching the vertical position, near a 10° angle, hold the stack with the manual winch to allow
it sitting slowly in full vertical position and until the flange faces make full contact.

4. Once the hoisting has been finished, install and tighten the bolts on the flanges, leave the winch cables
installed and slightly tightened.

5. Disconnect the electric winch from the battery.

6. Install the 2-ft metallic gas hose to the propane line near the bottom of the Flare Stack.

After the hoisting process has been completed the Flare Tank is ready to be operated (See Fig. 2). For ignition
see Numeral 5 “Ignition Process” below.

DISMOUNTING OF FLARE STACK – For mobilization inside locations

Instructions that apply to dismount the Flare Stack when relocating the Flare Tank within location (See Fig. 3).

1. Disconnect the propane line near the bottom of the stack at upper connector of the 2-ft metallic gas hose.

2. Disconnect the electrical line by unplugging the 150ft cable from the socket near the bottom of the stack.

3. Loosen and remove all bolts from the 10" and 16" flanges, at the same time make sure that the gate valve
is fully closed to prevent the flare stack from hitting the screw of the valve handle when laying down.

4. Connect the electric winch to 12 VDC battery.

5. The operator of the manual winch must ensure the winch is engaged to wind up the cable as to be able
to pull the Flare Stack down.

CAUTION: Before pulling down the Flare Stack the operator of the manual winch must coordinate with
the operator of the electric winch to keep the lowering movement controlled to prevent the stack from
falling down rapidly, it may cause an accident or damage the equipment.

6. Start pulling the stack slowly with the manual winch while the operator of the electric winch simultaneously
unwinds maintaining sufficient tension in the cable to allow the stack be moved in a controlled and safe
manner until it looses its equilibrium point at an approximate 5° angle, at this point the stack will continue
falling by gravity and the lowering movement must be controlled with the electric winch, no more pulling
is required with the manual winch.

7. Once the tension on the manual winch cable is fully released keep winding it to prevent tangling.

8. Keep unwinding the electric winch slowly and uniformly until the flare stack lays completely horizontal
over the two saddle supports.
PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 9. Install the two safety clamps on the saddle supports on the Gasbuster around the 16" pipe. You may leave
the winch cables installed (See Figure 3).

Figure 3. Flare Stack dismounted for mobilization of tank inside location.

10. Uninstall the 150-ft gas hose and 150-ft electric cable. Relocate the two propane cylinders in the small
platform of the skid, clamp and lock them to the tank wall. You may leave the winch cables installed in
the eye pads while moving inside the camp.

For transportation outside location, where oversized load restrictions apply, the flare stack must be completely
dismounted from the Gasbuster down to the saddle supports on the grating floor according to following
instructions.

PREPARATION OF FLARE TANK FOR TRANSPORTATION OUTSIDE LOCATION

Having completed all previous steps proceed as follows:

1. Remove the 2-foot metallic gas hose from the propane line.

2. Unhook and fully wind back the cables of the down winches.

3. Remove the safety pin and pivot from the Flare Stack hinge.

4. Using the crane and the two-strand cable lower the Flare Stack and set it down onto the two saddle
supports located on the grating next to the Gasbuster (See Figure 4).

5. Install the safety clamps around the 16" pipe to secure the stack over the saddles.

CAUTION: When handling and setting the Flare Stack on the saddle supports be careful not to affect the
propane line or the components of the electrical connections.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 Figure 4. Flare Stack dismounted for transportation on roads with restriction to oversized loads.

6. Remove the saddle support located on top of the Gasbuster as it exceeds the maximum height allowed
for transportation on inter-municipal roads.

7. For the same reason, lower the second saddle support located on the grating floor, near the manual winch
pulley, by removing the two pins and letting it slide down slowly to the stop.

8. Using the crane and with a helper, lift the balancing pole to loosen and remove the pivot from the hinge,
remove the pole and secure it horizontally over the serrated grating on the gasbuster side.

5. IGNITION PROCESS

Follow this procedure to ignite the propane flame at the nozzle inside the shroud on top of the flare stack. The
ignition system components are described in Numeral 2, sub numeral 6 above.

REQUIRED PERSONNEL AND EQUIPMENT

1. Team Supervisor.
2. Electrician to operate the ignition system.
3. Operator for the propane line.
4. One help hand
5. One full charge 12 VDC vehicle battery

ELECTRIC IGNITION

Set up push button and propane tanks 150-ft away from flare tank for remote control as shown in scheme of
Figure 5, page 9, and proceed as follows:

1. Install propane line and ignition sytem:

a. Connect the 2-ft metallic gas hose to the propane line at the bottom of the stack, near the flanges.
b. Connect the 150-ft gas hose from tank to propane bottles.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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 c. Connect 150-ft electric cable from 110 VAC source or wall socket to the 110 VAC socket installed
at the lower end of the 16” stack.

CAUTION: Locate the propane cylinders at remote control area away from the Flare Tank. Install a
rigid protector on floor over the 150-ft gas hose and 110 VAC electric cable to prevent damage from
trampling and vehicles passing.

Figure 5. Schematic diagram of ignition system and remote control.

2. Open the shroud lid by pulling down the handle installed on the 16” tube near the bottom of the stack.
Keep the lid open to facilitate ignition of the propane flame and later the burning of gases from the well.

3. Fully open the propane valve by turning it counterclockwise, open the flame regulator installed next to
the valve by turning the knob two to three complete turns in clockwise direction.

4. Simultaneously, the electrician must energize the line activating the push-button to generate spark at the
electrodes, near the propane nozzle on top of the flare stack, inside the shroud.

CAUTION: If the pilot does not light at the propane nozzle after a few electrical pulsations, close the
propane valve and restart the process all over again. Ensure the electrical system is working properly and
there is gas in the propane cylinder.

5. While performing the previous step keep watching if flame is ignited at the nozzle, once the propane at
the nozzle ignites regulate the amount of flame by opening or closing the regulator knob. The propane
flame should be at least 1 foot (30cm) high to ensure that gas coming out of the well and flowing thru
the flare stack burns.

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 CAUTION: If at any time the pilot flame turns off while the propane line is open, and before starting to
burn gas through the flare stack, restart the ignition procedure by previously closing the propane cylinder
valve for a few minutes to dissipate the gas that might have accumulated in the shroud while the flame
was off.

6. Once the flame at the propane nozzle stabilizes, the gas or mud from the well or equipment can be allowed
to flow to the Flare Tank to burn as required.

CAUTION: Make sure to keep the propane pilot flame permanently ON for as long as gas from the well is
burning or generated or if the propane line is open.

7. Upon termination of gas flowing from the well, turn off the pilot flame by completely closing the valve of
the propane cylinder in the clockwise direction. Also, close the flame regulator by turning the knob all the
way to the left counterclockwise.

8. Close the shroud lid by lifting up the handle when there is no more gas emission from the well and flame
is off. Keeping the shroud lid closed protects the propane nozzle and electric components on top from rain
and dirt.

MANUAL IGNITION

The Flare Tank ignition system designed by Technodrill includes manual ignition so that, in case of failure in the
electric system, the propane line can be easily lowered down to the floor to be lighted with a regular manual
lighter and raised and relocated back at its original position in the stack.

CAUTION: Before starting manual ignition procedure ensure there is no risk of presence of gas from the well in
the area near de Flare Tank, DO NOT PROCEED with manual ignition if you detect gas presence, IT WILL CAUSE
EXPLOTION.

Proceed as follows:
1. Before removing the propane line from the stack make sure the valve at propane cylinder is fully closed.
2. Loosen the clamp that fixes the propane rigid line to the lower end of the stack.
3. Remove the propane line manually from the stack by pulling it down with a helper.
4. When the propane tube is down open de propane valve and light it up at the nozzle using a regular lighter.
5. Once it is lighted regulate the flame to ensure it doesn´t go off as it is raised up again.
6. Lift up the burning propane tube against the stack and introduce it thru the guide ring at the top of the
stack to its original position, clamp it up again to the stack at the bottom. Ensure the pilot flame remains
lighted while raising the propane tube back in position.
7. Regulate the pilot flame again if required. Shroud lid must be open.
8. Once the pilot flame is stabilized you can initiate flowing of gas from the well to be burnt.

6. INSPECTION AND PREVENTIVE MAINTENANCE OF FLARE TANK

1. Periodically check cables and electric components to ensure they are all in good condition.
2. Periodically check the propane line and hoses to ensure they are in good working conditions and have no
leaks.
3. Inspect operability of winches, gate valve and ball valve previous to each operation.
4. Inspect visually and with magnetic particles all welds in tank and in 4”, 8” and 10” pipe lines at least once a
year and repair as required.
5. Fluid waste in tanks and valves must be cleaned after each well completion.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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6. Uninstall 8” gate valve and 4” ball valve to realize preventive maintenance at least every six (6) uses or every
six (6) months, whichever occurs first. See technical sheets of valves provided in the dossier.
7. Periodically check wall thickness of the three 1/2" (12 mm) wear plates installed inside the Gasbuster to
evaluate its wear rate, particularly if they have been aggressively affected (See Fig. 6). First wall thickness
inspection recommended after ten (10) uses of Flare Tank. Readings of UT wall thickness must be taken from
inside of Gasbuster. Replace wear plates with new plates when they have reached a wall thickness of 1/16"
or less at any place. Gasbuster can be removed from the tank for repairs.
8. For the maintenance of the electric winch, follow manufacturer's instructions in the dossier provided.
9. Inspect visually the tank and other components at least once a year.
10. Change or repair components as required from inspections.
11. Paint tank and components as required. Keep safety signals.

Figure 6. Gasbuster section showing three 1/2” wear plates.

PRINCIPAL OFFICE: Autopista Medellín, Km. 9,5 Vía Bogotá – La Vega, Parque Industrial Morelia, Tel. +57 (1) 865-6012, Tenjo
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