What are the specific steps for lighting a perpetual torch and what precautions should be taken? A beginner seeking advice.
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What are the specific steps for lighting a perpetual torch and what precautions should be taken? A beginner seeking advice.
5. High-altitude igniter 5.1 High-altitude igniter system The high-altitude igniter system is a set of electrical control equipment designed and manufactured by Xuzhou Fuel Control Technology Co., Ltd., capable of enabling automatic ignition at high altitudes. The high-altitude igniter system boasts advantages such as fast ignition speed, no electrical erosion, no carbon buildup, resistance to harsh environments, and high reliability. 5.1.1 Composition of the high-altitude igniter system: The composition of the high-altitude igniter system is shown in Figure (1), and it consists of an igniter control box, ignition electrodes, and high-voltage cables leading to the ignition electrodes. Figure (1) High-altitude igniter control box: The electrical components required for high-energy electric ignition are mainly installed in this control box. Since the control box is installed in an explosion-hazardous area, it is an explosion-proof control box with an explosion protection rating of dIICT4. Ignition electrode: The ignition electrode consists of two stainless steel plates. During ignition, the location of discharge moves between the plates, reducing the occurrence of electrical erosion and **extending the lifespan of the plates. Cable: A cable is used to connect the high-altitude igniter control box and the ignition electrode; for the negative pole, a regular single-core cable is utilized. The connection between the cable and the electrode uses a special junction box. When laying cables along the tower, they should be run in conduits. 5.2 Commissioning of the high-altitude igniter system
5.2.1 Pre-operational inspections
After all equipment has been installed, the following inspections and tests must be carried out prior to putting it into operation:
Check whether the cabinet has suffered any mechanical damage or paint peeling; repairs should be made as necessary. Manually operate the transfer switch and buttons; the movements should be smooth. Check whether all components are intact and undamaged. Check whether the grounding device of the control cabinet is reliable and whether there are clear markings. Check whether all electrical components and connection terminals are loose. Measure the insulation resistance using a megohmmeter, and conduct voltage withstanding tests in accordance with relevant regulations. Check whether all insulated parts are intact; if any damage is found, they should be repaired or replaced immediately. Only after all the above inspections are passed can the power-on test be conducted. 5.2.2 Power-on test 1) Turn the power switch on the panel to the on position; the power indicator light will turn on. 2) Press the ignition button on the control box panel, and observe whether sparks occur at the electrodes and whether the “popping” sound of electrical discharge can be heard. If nothing is detected, the power supply should be turned off, and one minute must pass before checking again. 3) After confirming that ignition is normal, an ignition signal is sent from the control room to observe whether the ignition functions properly. This ignition system requires regular maintenance and cleaning. After operating for a certain period, it should be inspected periodically to ensure its reliability. 5.2.3 Venting test 1) Verify that the condensate in the fuel pipeline of the high-altitude ignition device has been drained, and close the drain valve after confirmation. 2) Confirm that the pneumatic ball valve on the fuel pipeline of the high-altitude ignition device is closed ； Open the bypass shut-off valve of the pneumatic ball valve, open the main valve of the fuel gas pipeline, and check whether the pipeline is unobstructed. 5.3 Ignition of the high-altitude ignition device 5.3.1 Manual ignition method After the preparatory work is completed, the permanent light is ignited manually. The manual ignition method should be used when the torch system is put into operation for the first time, or after maintenance of the high-altitude ignition device is completed. 1) Turn the “Programmed/Local” knob on the programming cabinet to “Local”, and turn the “Manual/Automatic” knob to “Manual”. 2) Close the main fuel gas valve. 3) Open the pneumatic ball valve on the pipeline of the lamp to be kept lit and the ignition tube. 4) Open the main fuel gas valve, and at the same time press the corresponding “Start Igniter” on the programmable control cabinet. 5) Once the flame of the pilot light is established (indicated by the corresponding fire indicator light turning on, or by seeing that the temperature of the thermocouple associated with the pilot light exceeds 100°C in the central control panel), close the pneumatic ball valve of the ignition tube corresponding to that pilot light. 5.3.2 Manual remote ignition method 1) Confirm that the pilot light is extinguished. 2) Confirm that the bypass valve next to the cut-off valve on the permanent light pipeline is closed. 3) Confirm that the “Programmed/Local” knob on the programmable control cabinet is set to “Programmed”. 4) Remotely operate from the control room to open the pneumatic ball valves for the permanent light and the ignition tube. 5) Press the ignition button on the central control screen to light the permanent lamp. 6) Confirm whether the pilot light has been ignited by using a thermocouple installed on the pilot light. 7) Remote-operate from the control room to close the pneumatic ball valve of the ignition tube corresponding to that constant-lit lamp. 5.3.3 Automatic ignition mode: When the programmable control cabinet is in the “Programmed” or “Automatic” mode, and the flow switch or pressure transmitter detects that the flow rate or pressure is above the set value, the PLC will automatically initiate the pilot light ignition procedure to light the unlit pilot light. If no flame is detected one minute after the system issues the ignition command, a fault alarm will appear on the central control interface. Upon the alarm being triggered, the on-site operators were asked to troubleshoot the valves and igniters at the site. After troubleshooting, you can click the button to cancel the fault alarm on the central control interface in order to dismiss the alarm. ※Note: For the manual remote ignition of the high-altitude ignition device, make sure to first open the pneumatic ball valve on the fuel pipeline of the high-altitude igniter before pressing the manual ignition button. ※Note: The high-altitude ignition device requires regular maintenance and cleaning. After operating for a period of time, it should be inspected periodically to ensure the reliability of the ignition system. ※Note: It is essential to ensure that the power is turned off and that there is no residual voltage before attempting to service the high-altitude ignition device. Be careful to avoid electric shock from high voltage, which could result in injuries or deaths. ※Note: Do not ignite twice or more in a consecutive minute.
5.2.1 Pre-operational inspections
After all equipment has been installed, the following inspections and tests must be carried out prior to putting it into operation:
Check whether the cabinet has suffered any mechanical damage or paint peeling; repairs should be made as necessary. Manually operate the transfer switch and buttons; the movements should be smooth. Check whether all components are intact and undamaged. Check whether the grounding device of the control cabinet is reliable and whether there are clear markings. Check whether all electrical components and connection terminals are loose. Measure the insulation resistance using a megohmmeter, and conduct voltage withstanding tests in accordance with relevant regulations. Check whether all insulated parts are intact; if any damage is found, they should be repaired or replaced immediately. Only after all the above inspections are passed can the power-on test be conducted. 5.2.2 Power-on test 1) Turn the power switch on the panel to the on position; the power indicator light will turn on. 2) Press the ignition button on the control box panel, and observe whether sparks occur at the electrodes and whether the “popping” sound of electrical discharge can be heard. If nothing is detected, the power supply should be turned off, and one minute must pass before checking again. 3) After confirming that ignition is normal, an ignition signal is sent from the control room to observe whether the ignition functions properly. This ignition system requires regular maintenance and cleaning. After operating for a certain period, it should be inspected periodically to ensure its reliability. 5.2.3 Venting test 1) Verify that the condensate in the fuel pipeline of the high-altitude ignition device has been drained, and close the drain valve after confirmation. 2) Confirm that the pneumatic ball valve on the fuel pipeline of the high-altitude ignition device is closed ； Open the bypass shut-off valve of the pneumatic ball valve, open the main valve of the fuel gas pipeline, and check whether the pipeline is unobstructed. 5.3 Ignition of the high-altitude ignition device 5.3.1 Manual ignition method After the preparatory work is completed, the permanent light is ignited manually. The manual ignition method should be used when the torch system is put into operation for the first time, or after maintenance of the high-altitude ignition device is completed. 1) Turn the “Programmed/Local” knob on the programming cabinet to “Local”, and turn the “Manual/Automatic” knob to “Manual”. 2) Close the main fuel gas valve. 3) Open the pneumatic ball valve on the pipeline of the lamp to be kept lit and the ignition tube. 4) Open the main fuel gas valve, and at the same time press the corresponding “Start Igniter” on the programmable control cabinet. 5) Once the flame of the pilot light is established (indicated by the corresponding fire indicator light turning on, or by seeing that the temperature of the thermocouple associated with the pilot light exceeds 100°C in the central control panel), close the pneumatic ball valve of the ignition tube corresponding to that pilot light. 5.3.2 Manual remote ignition method 1) Confirm that the pilot light is extinguished. 2) Confirm that the bypass valve next to the cut-off valve on the permanent light pipeline is closed. 3) Confirm that the “Programmed/Local” knob on the programmable control cabinet is set to “Programmed”. 4) Remotely operate from the control room to open the pneumatic ball valves for the permanent light and the ignition tube. 5) Press the ignition button on the central control screen to light the permanent lamp. 6) Confirm whether the pilot light has been ignited by using a thermocouple installed on the pilot light. 7) Remote-operate from the control room to close the pneumatic ball valve of the ignition tube corresponding to that constant-lit lamp. 5.3.3 Automatic ignition mode: When the programmable control cabinet is in the “Programmed” or “Automatic” mode, and the flow switch or pressure transmitter detects that the flow rate or pressure is above the set value, the PLC will automatically initiate the pilot light ignition procedure to light the unlit pilot light. If no flame is detected one minute after the system issues the ignition command, a fault alarm will appear on the central control interface. Upon the alarm being triggered, the on-site operators were asked to troubleshoot the valves and igniters at the site. After troubleshooting, you can click the button to cancel the fault alarm on the central control interface in order to dismiss the alarm. ※Note: For the manual remote ignition of the high-altitude ignition device, make sure to first open the pneumatic ball valve on the fuel pipeline of the high-altitude igniter before pressing the manual ignition button. ※Note: The high-altitude ignition device requires regular maintenance and cleaning. After operating for a period of time, it should be inspected periodically to ensure the reliability of the ignition system. ※Note: It is essential to ensure that the power is turned off and that there is no residual voltage before attempting to service the high-altitude ignition device. Be careful to avoid electric shock from high voltage, which could result in injuries or deaths. ※Note: Do not ignite twice or more in a consecutive minute.
All newly installed torches come with operation instructions