International Headquarters

2809 Longhorn Blvd.

Austin, Texas 78758 U.S.A.
Tel: 512-836-9473 i Fax: 512-836-3025
Web: www.flareindustries.com

Document Title: FACTORY ACCEPTANCE TEST PROCEDURE

Customer Ref. No.: 06-405 Punj Lloyd

Document No.: 06405-P01-0100, ESI, Mdl. 255

Functional Test for ESI Control System with (3) Model 255 Energex Pilots with
Description:
back-up FFG
Equipment Required: Multi-Meter
Ladder Logic Diagrams
Enclosure Layout Drawings
Fuel Supply, Air Supply
230 VAC Power Source

System F.A.T. Approvals:

NAME DATE TITLE / COMPANY SIGNATURES

Project Manager, Flare Ind., Inc.

QA Manager, Flare Ind., Inc.

Service Manager, Flare Ind., Inc

Controls Designer, Flare Ind.,
Inc.
Customer Representative or
Third Party Inspector

0 05/29/2008 ISSUED FOR TEST CN

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

Page 1 of 8
 STEP DESCRIPTION NOTES RESULTS

1.0 SYSTEM SETUP

1.0.1 Ensure that all circuit breakers and
fuses within the panel that provide
power to the circuits are in the OPEN
position
1.0.2 Verify that no power is present at the
panel using a multi-meter.
1.0.3 Ensure that the MAIN POWER OFF/ON
selector switch (1SS90001) is in the
OFF position.
1.0.4 Ensure that PILOT #1, PILOT #2, and
PILOT #3 MAN/OFF/AUTO selector
switches are in the OFF position.
Pilot #1 – (1SS90101)
Pilot #2 – (1SS90102)
Pilot #3 – (1SS90103)
Ensure that FFG BACKUP IGNITION
MAN/OFF/AUTO selector switch
(1SS90301) is in OFF position.
1.0.6 Ensure valves line up in accordance
with piping instruction and are in closed
position prior to beginning test.

Note: For testing purposes, blind the

purge gas line outlet of the valve train.
1.0.7 Connect field wiring in accordance with
electrical diagrams.
2.0 SYSTEM VERIFICATION
2.0.1 Visually inspect MAIN IGINITION
control panel wiring and mechanical
connections for; fraying, discoloration,
corrosion, physical integrity, and proper
identification.

Page 2 of 8
STEP DESCRIPTION
2.0.2 Supply electrical power to the panel.
Verify power at Circuit Breaker
(1CB90001) located within the panel.
2.0.3 Turn on Circuit Breaker (1CB90001).
2.0.4 Place the MAIN POWER OFF/ON
selector switch (1SS90001) in the ON
position.
Press and hold the LAMP TEST Push
Button (1PB90201).
2.0.5 Ensure that the temperature controller
set points are at 250oF.
NOTES RESULTS
Verify the following:
PILOT #1 ON Status
• TBA-190230B and TBA-190230C
- open
• TBA-190230A and TBA-190230C
- closed
PILOT #1 RE-IGNITION FAILURE Status
• TBA-190231B and TBA-190231C
- open
• TBA-190231A and TBA-190231C
- closed
PILOT #2 ON Status
• TBA-190232B and TBA-190232C
- open
• TBA-190232A and TBA-190232C
- closed
PILOT #2 RE-IGNITION FAILURE Status
• TBA-190233B and TBA-190233C
- open
• TBA-190233A and TBA-190233C
- closed
PILOT #3 ON Status
• TBA-190234B and TBA-
190234C - open
• TBA-190234A and TBA-
190234C - closed
PILOT #3 RE-IGNITION FAILURE Status
• TBA-190235B and TBA-190235C
- open
• TBA-190235A and TBA-190235C
- closed
SYSTEM COMMON FAILURE ALARM
• TBA-190236B and TBA-190236C
- open
• TBA-190236A and TBA-190236C
- closed
FFG IGNITION FAILURE ALARM Status
• TBA-190330B and TBA-190330C
- open
• TBA-190330A and TBA-190330C
- closed
Verify 230VAC present at MAIN POWER
OFF/ON selector switch (1SS90001)
Verify the following:
POWER ON light (1LT90201) is on.
Verify all indicator lights on front of control
panel illuminate. Release push button.
Page 3 of 8
 STEP DESCRIPTION
3.0 SYSTEM MANUAL OPERATION
3.0.1 Place the PILOT #1 MAN/OFF/AUTO
selector switch (1SS90101) in the MAN
position and press and hold the PILOT
#1 MANUAL SPARK push button
(1PB90101)
3.0.2 Place the PILOT #2 MAN/OFF/AUTO
selector switch (1SS90102) in the MAN
position and press and hold the PILOT
#2 MANUAL SPARK push button
(1PB90102)
3.0.3 Place the PILOT #3 MAN/OFF/AUTO
selector switch (1SS90103) in the MAN
position and press and hold the PILOT
#3 MANUAL SPARK push button
(1PB90103)
3.0.4 Open ball valves (BV-400 and BV-402)
on the pilot gas valve train.
3.0.5 Allow sufficient time for the fuel to
completely fill the pilot line up to the
pilot heads.
3.0.6 Momentarily press (3 seconds) the
PILOT #1 MANUAL SPARK push
button (1PB90101)
3.0.7 Watch for visual indication of flame at
the pilot head.
3.0.8 Momentarily press (3 seconds) the
PILOT #2 MANUAL SPARK push
button (1SS90102)
3.0.9 Watch for visual indication of flame at
the pilot head.
3.0.10 Momentarily press (3 seconds) the
PILOT #3 MANUAL SPARK push
button (1SS90103)
3.0.11 Watch for visual indication of flame at
the pilot head.
NOTES RESULTS
This will energize PILOT #1 Exciter and
produce a spark. After verifying spark,
release push button.
This will energize PILOT #2 Exciter and
produce a spark. After verifying spark,
release push button.
. This will energize PILOT #3 Exciter and
produce a spark. After verifying spark,
release push button.
This will allow fuel to reach the pilot
heads.
This will briefly energize PILOT #1 Exciter
to produce a spark in the pilot head and
light the pilot.
Visual proof may exist prior to the control
panel acknowledging the presence of
flame due to the inherent delay of the
thermocouple as it heats up past the
temperature controller set point (250° F).
This will briefly energize PILOT #2 Exciter
to produce a spark in the pilot head and
light the pilot.
Visual proof may exist prior to the control
panel acknowledging the presence of
flame due to the inherent delay of the
thermocouple as it heats up past the
temperature controller set point (250° F).
This will briefly energize PILOT #3 Exciter
to produce a spark in the pilot head and
light the pilot.
Visual proof may exist prior to the control
panel acknowledging the presence of
flame due to the inherent delay of the
thermocouple as it heats up past the
temperature controller set point (250° F).
Page 4 of 8
 STEP DESCRIPTION
3.0.11 Close pilot gas ball valves on the pilot
gas valve train.
4.0 SYSTEM AUTOMATIC OPERATION
4.0.1 Open ball valves (BV-400 and BV-402)
on the pilot gas valve train.
4.0.2 Allow sufficient time for the fuel to
completely fill the pilot line up to the
pilot heads.
4.0.3 Place the PILOT #1 MAN/OFF/AUTO
selector switch (1SS90101) in AUTO.
4.0.4 Place the PILOT #2 MAN/OFF/AUTO
selector switch (1SS90102) in AUTO.
4.0.5 Place the PILOT #3 MAN/OFF/AUTO
selector switch (1SS90103) in AUTO.
4.0.6 Watch for visual indication of flame at
the pilot heads.
4.0.7 When PILOT #1 temperature exceeds
250° F, the PILOT #1 ON light
(1LT90202) will illuminate and the
associated customer contacts will
change state.
4.0.8 When PILOT #2 temperature exceeds
250° F, the PILOT #2 ON light
(1LT90204) will illuminate and the
associated customer contacts will
change state.
4.0.9 When PILOT #3 temperature exceeds
250° F, the PILOT #3 ON light
(1LT90206) will illuminate and the
associated customer contacts will
change state.
NOTES RESULTS
This will cause the pilots to extinguish.
This will allow fuel to reach the pilot
heads. Note, open valves right before
getting ready to light pilots to avoid
unnecessary fuel waste.
This will cause PILOT #1 Exciter to
produce a spark and light the pilot.
This will cause PILOT #2 Exciter to
produce a spark and light the pilot.
This will cause PILOT #3 Exciter to
produce a spark and light the pilot.
Visual proof may exist prior to the control
panel acknowledging the presence of
flame due to the inherent delay of the
thermocouple as it heats up past the
temperature controller set point (250° F).
Verify the customer contacts have
changed state and should read:
PILOT #1 ON STATUS
• TBA-190230B and TBA-190230C
– closed
• TBA-190230A and TBA-190230C
- open
Verify the customer contacts have
changed state and should read:
PILOT #2 ON STATUS
• TBA-190232B and TBA-190232C
– closed
• TBA-190232A and TBA-190232C
- open
Verify the customer contacts have
changed state and should read:
PILOT #3 ON STATUS
• TBA-190234B and TBA-190234C
– closed
• TBA-190234A and TBA-190234C
- open
Page 5 of 8
STEP DESCRIPTION
4.0.10 Close pilot gas ball valves on the pilot
gas valve train.
4.0.11 After the temperature drops below
250°F., Verify that all of the PILOT ON
lights (1LT90202, 1LT90204, and
1LT90206) turn off and that the PILOT
ON STATUS customer contacts revert
back to their de-energized state.
4.0.12 The system should attempt to re-light
the pilots. After 5 minutes with no re-
ignition; PILOT #1 RE-IGNITION
FAILURE Light (1LT90203), PILOT #2
RE-IGNITION FAILURE Light
(1LT90205), PILOT #3 RE-IGNITION
FAILURE Light (1LT90207) will
illuminate, and the associated customer
contacts will change state.
4.0.13
Momentarily press (3 seconds) the
MANUAL RESET push button
(1PB90104).
4.0.16 Place PILOT #1, PILOT #2, and PILOT
#3 selector switches back in the OFF
position.
NOTES RESULTS
This will cause the pilots to extinguish
After the delay as the temperature drops
verify the customer contacts have
changed state and should read:
PILOT #1 ON STATUS
• TBA-190230B and TBA-190230C
– open
• TBA-190230A and TBA-190230C
– closed
PILOT #2 ON STATUS
• TBA-190232B and TBA-190232C
– open
• TBA-190232A and TBA-190232C
- closed
PILOT #3 ON STATUS
• TBA-190234B and TBA-190234C
– open
• TBA-190234A and TBA-190234C
- closed
Verify that the associated customer
contacts have changed state and should
read:
PILOT #1 RE-IGNITION FAILURE
• TBA-190231B and TBA-190231C
– open
• TBA-190231A and TBA-190231C
– closed
PILOT #2 RE-IGNITION FAILURE
• TBA-190233B and TBA-190233C
– open
• TBA-190233A and TBA-190233C
– closed
PILOT #3 RE-IGNITION FAILURE
• TBA-190235B and TBA-190235C
– open
• TBA-190235A and TBA-190235C
– closed
Verify the following;
PILOT #1 Exciter will energize to produce
a spark at the pilot.
PILOT #2 Exciter will energize to produce
a spark at the pilot.
PILOT #3 Exciter will energize to produce
a spark at the pilot.
Page 6 of 8
 STEP DESCRIPTION NOTES RESULTS

4.0.17 Testing of the system in Automatic is

complete.

5.0 BACK-UP FFG OPERATION.

5.0.1 Align gas and air to FFG lines.
5.0.2 Open air and gas ball valves (BV100
and BV-200) on the valve train.
5.0.3 Place the FFG BACKUP IGNITION Set pressure regulators (PCV100 and
MAN/OFF/AUTO selector switch in the PCV201) each at 8psi.
MAN position. Place the FFG AIR AND
GAS OFF/ON selector switch in the ON Note: This may take a few tests to set air
position. and gas mix correct for optimal operation.
Open PILOT #1 Ball valve (BV101) and
pilot gas ball valves (BV400 and
BV402).
5.0.4 Quickly press and release FFG Listen for combustion and check for flame
MANUAL SPARK push button on pilot #1.
(1PB90301).
5.0.5 Adjust air and gas to achieve smooth
combustion.
5.0.6 Close PILOT #1 ball valve (BV101) and
open PILOT #2 ball valve (BV102).
5.0.7 Quickly press and release FFG Listen for combustion and check for flame
MANUAL SPARK push button on pilot #2.
(1PB90301).
5.0.8 Close PILOT #2 ball valve (BV102) and
open PILOT #3 ball valve (BV103).
5.0.9 Quickly press and release FFG Listen for combustion and check for flame
MANUAL SPARK push button on pilot #3.
(1PB90301).
5.0.10 Close PILOT #3 ball valve (BV103) and
close pilot gas ball valve (BV402).
5.0.11 Place FFG AIR AND GAS OFF/ON
selector switch in OFF position.
Place FFG BACKUP IGNITION
MAN/OFF/AUTO selector switch in
OFF position.
Manual ignition test of FFG is complete.
5.0.12 Open PILOT #1 ball valve (BV101) and
pilot gas ball valve (BV402).

Page 7 of 8
STEP DESCRIPTION NOTES RESULTS

5.0.13 Place FFG BACKUP IGNITION Watch for visual proof of flame at pilot
MAN/OFF/AUTO selector switch in and quickly close PILOT #1 ball valve
AUTO position. (BV101) and open PILOT #2 ball valve
(BV102). Watch for visual proof of flame
at pilot and quickly close PILOT #2 ball
valve (BV102) and open PILOT #3 ball
valve (BV103). Watch for visual proof of
flame at pilot and close PILOT #3 ball
valve (BV103).
5.0.14 Close pilot gas ball valve (BV402). Pilots will extinguish.
Place FFG BACKUP IGNITION
MAN/OFF/AUTO selector switch
(1SS90301) in OFF position.
5.0.15 Secure valve line-up as required.
5.0.16 Testing is complete of Back-Up FFG
operation.
5.0.17 Place the MAIN POWER OFF/ON
selector switch (1SS90001) in the OFF
position.
5.0.18 Remove all electrical power from the
panel as required.

Page 8 of 8