OPERATING MANUAL

FOR

60’ BURNER BOOM

SUPPLIED BY

PARVEEN INDUSTRIES

PVT. LTD.
 CONTENTS

1. INTRODUCTION

2. TECHNICAL DATA

3. COMPONENTS & FUNCTIONS

4. INSTALLATION

5. PRE-START CHECK UP

6. START-UP PROCEDURE

7. TROUBLE SHOOTING GUIDE

8. DO’S & DON’T’S

9. SAFETY
 1. INTRODUCTION

The Parveen model – ‘Anshoo 2009 Burner’ is

equipment designed primarily to provide a means for

disposing of crude oil or condensate produced during the

production testing of oil or gas wells. The burner is

versatile for operating in offshore as well as onshore

locations. In addition, the burner provides an excellent

means of pollution free disposal of unwanted hydrocarbon

liquids such as waste oil, tank bottoms, oil base drilling

fluids etc.

As a result of detailed research work, The “Parveen–

Burner”, burner head that forms the heart of Parveen’s

‘Burner Range of Atomizer heads’ was developed. The

burner head is unique and has been tested for combustion

and absolute maintenance free operation.

The basic concept of the design has taken care to

completely eliminate fall out of liquid hydrocarbon while

operating and affect a pollution free combustion.

 2. TECHNICAL DATA

Capacity
(a) Crude Oil = 12,000 barrels/day
(b) Natural Gas = 0.991 MMSCM/day
(c) Water requirement = 12,000 – 15,000 Bbl/day

Pressure Rating
Size
Sl.No Nomenclature Grade / Schedule No. (Psi)
(Inches)
W.P T.P
1. Oil Line (1) 3” ASTM A-106/80 1,440 2,175
2. Gas Line (1) 3” & 6” ASTM A-106/80 1,440 2,175
3. Water Line 3” ASTM A-106/80 1,500 2,250
4. Air Line 3” ASTM A-106/80 1,500 2,250
ASTM A-312/20 Grade
5. LPG Line ¼” 500 750
304
Piping

Suitable for Sour Service.

Pressure Rating (Psi)

Sl.No Nomenclature Capacity
W.P T.P
1. Parveen Engineers 12,000 – BOPD 1,440 psi. 2,175 psi.
Burner Head

Hammer Unions

Pressure Rating (Psi)

Line Manufactured By Size
W.P T.P

Oil, Gas, Water & Air Parveen Engineers 3” & 2” 1,440 2,175

Valves

Pressure Rating (Psi)

Sl.No Line Type Size
W.P T.P
1. Oil 3 pc Ball Valve 2” 1,440 2,175
 Ball Type NRV 3” 1,440 2,175
2”
2. Water 3 pc Ball Valve 1,440 2,175
3”
3 pc. Ball Valve 1½” 1,440 2,175
3. Air
Ball type NRV 2” 1,440 2,175

All Valves are suitable for Sour Service application.

BOOM
Shape : ‘U’
Material of Construction : Square tubular Section Conforming to IS 1239
Total Boom Length : 27,700 Mtrs
No. of Boom Section : 4 (Including working Platform)
Weight of Boom : 9500 Kg

Design Loads
a) Wind Load : 160 KMPH
b) Max. Load on main : 12,900 Kg (at 160 KMPH wind speed)
c) Breaking strength
of Suspension line : 35,562 Kg

Design Condition
Boom suspended from Drilling Vessel with following dynamic conditions. Rolling :
+/- 7.5 ° Max. Period 12 sec.
Pitching : +/- 5.0 ° Max. Period 12 sec.
Heaving : 1g (g = acceleration factor)

Certification
Inspection and Certification by DNV India

3. COMPONENTS & FUNCTIONS

This chapter describes the major components, which make up the ‘Burner 60’’ Model
Burner Boom.
3.1 BURNER HEAD
The Burner 60’ Model burner has three burner heads, which are designed to effect
complete free combustion and hydrocarbons. The heads allow disposal of effluents such
as crude oil, foam and invert emulsion mud with complete safety in an offshore location
without pollution. The most notable feature of the “Parveen- Burner’ burner head is
that it allows spill-free combustion even at very low flow rates and following pressures.
Also the presence of solid particles in the fluid dose not affects the combustion.
The burner head consists of the components mentioned below:

3.1.1 Atomizer
This atomizes the fluid to be burnt. Atomization is essential to prevent fall out of
unburnt particles and formation of black smoke during combustion, which causes
pollution. Atomization is achieved by utilizing the energy resulting from the pressure of
the fluid issuing out of the nozzle, and supplying additional energy by injecting air into
the nozzle. The former predominates at high flow rates whereas the latter at low flow
rates. The final atomization is the result of the above two processes. The main atomizer
nozzle is designed to allow passage of particle upto 6mm in diameter to avoid the risk
of plugging.

3.1.2 Cylindrical Hearth

The cylindrical hearth around the atomizer helps in supplying channelized air to the
flame, which is essential for combustion, and also stabilizing the flame.

3.1.3 Water Ring

The ring is fitted with twenty specially designed nozzles, which causes fine water
droplets to penetrate deeply into the flame with great kinetic energy. Water
injection had two effects:
(a) Reduces radiation of flame.
(b) Modifies combustion to eliminate black smoke. The reaction is the combined
effect of the improvement of combustion by the turbulence of water
 droplets penetrating the flame and the air they carry with them. The mode
of injection is very important. Best results have been obtained with ratio of
water flow to oil flow of 1:2:1.5. The proportion varies depending upon the
quality of atomization of water. Finely atomized water produces a steam
cloud whereas coarsely atomized water falls as rain causing oil fall out.
Excess water produces a thick grey smoke. Correct adjustment produces
clear flame without any smoke.

3.1.4 Pilot Light System

The gas pilot system can be lighted using LPG. A spark plug (heavy-duty
industrial type) is situated at the head end of the burner, which can be energized
remotely from an igniter box situated at the base end of the burner.

3.1.5 SUPPORTING FRAME

The three atomizer nozzles are supported on a frame fabricated out of stainless
steel. The frame in turn is mounted on a rotating base. This permits the rotation
of the frame on its base upto 30 deg., on each end to operate with prevailing
wind direction.

3.1.6 SUPPORTING BOOM

The supporting boom of the burner is fabricated out of square tubular section.
This not only provides support to the burner piping but also extends the burner
heads and permits orientation to keep heat radiation to an acceptable limit. The
18,300 Mts. Long boom also supports an independent gas flare.

The U-shape of the boom provides an inherent safe to work walkway to approach
the working platform at the head end of the burner.

The base end of the boom is hinged on to a universal base plate. The universal
base permits the burner boom to be turned at any angle to the rig to facilitate
operation in conditions where frequent change in direction of wind is encountered.
The base also permits vertical movement of the boom. This is particularly useful
where the burner assembly need to be stacked in a vertical position on a rig when
it is not in use. The total boom length is made up of two sections of equal length.
Individual sections can unbolt off easily in field to facilitate transportation and can
also be joined together with equal ease. The relatively lightweight boom is
attached to the platform by a simple plate and pin arrangement and supporting
cables.

4. INSTALLATION

STEP NO.1
Join the 1st two half section of the burner boom (Front & Rear) if the same has
been transported separately on to a rig. Check tightness of bolts after joining the
two sections. Check tightness of all other bolts on the main structural frame.
Similar way joins the Center and Rear Sections.

STEP NO.2
Determine the most suitable type of installation and location for mounting the
boom. The boom should be installed such that it is horizontal, with the burner
flame as far away as possible from the support structures of a rig during
operation. In selecting the mounting location of a burner boom, the following
variable should be considered:
1) Prevailing wind direction – to keep flame away from the burner.
2) Access from the boom to service lines, crude processing system and wellhead
should be easily accessible.
3) Space for operational personnel – should be adequate.
4) Arrangement to install the boom and retract boom to storage position – crane
facility should be available.
5) Structure to mount and support pivot at the base of the boom and cable tie
down points – should be at a convenient location.

STEP NO.3
Connect all burner piping by tightening the unions at the center of each piping on
the boom.

STEP NO.4
Flush all lines by using rig pump at high flow rates use strainer at the suction of
the rig pump while carrying out this operation.

STEP NO.5
Hydro test all pipelines to its rated working pressure.

STEP NO.6
Flush airline and LPG line with air to ensure no water is left inside.

STEP NO.7
Attach shackles at cable tie down points (pad eyes) on the boom to attach main
hanging cables and guy ropes. Check rated capacity of each shackle (refer the
attached details on shackle capacity) Add turn – buckles to each rope at the rig
end for final adjustment of tension on ropes.
STEP NO.9
Lift burner boom with crane and align the horizontal pivot at the base of the
boom with that of the base. As soon as alignment is achieved, hammer the pivot
pin to secure the burner base of the King Post.

STEP NO.10
Attach all the wire rope (except guy ropes) tie down points and secure guy ropes
to some convenient points on the rig.

STEP NO.11
Lower the front end of the burner by crane and attach guy ropes to their proper
tie down points.

STEP NO.12
Tension up all ropes by using turnbuckles to make them taut and slack off load
from the crane hook, and remove crane slings.

5. PRE-START CHECK UP

STEP NO.1
Check all valves at the burner head and leave them in open position.

STEP NO.2
Check cleanliness of spark plugs. In case of carbon deposit, use find (00) emery
paper to clean all spark plugs.

STEP NO.3
Connect all Piping at the base end of the burner to process lines coming from
manifold at the downstream of separator. Connect water line to rig pump, airline
to rig air supply source and LPG line to manifold from LPG bottles.

STEP NO.4
Connect rig power supply to Ignition control panel. The supply to the panel can be
either 110 VAC or 220 VAC depending on the supply available at rig. The
transformer terminals are generally attached to 220 VAC leads this need to be
changed to 110 VAC, if rig supply is 110 VAC. Switch on power supply – the
supply on lamp should be glowing.

STEP NO.5
Check all needle valve in the instrument control panel they should be open
excepting the one on the bleed line (which should be closed).

STEP NO.6
Crack open the rig air supply line connected to the 2” Air line and check for free
flow upto the burner heads.

STEP NO.7
Crack open the rig air supply line connected to the 2” Air line and check.

6. START-UP PROCEDURE

The Parveen Model “Anshoo 2009 Burner” is a part of production test equipment.
The total system starting from the well will consist of control head, flow lines,
manifolds, separator and burner. The burner is made ready to operate along with
the other equipments. During a production test operation the procedure to be
followed is described in following steps:

STEP NO.1
Open the LPG Cylinder/Cylinders and allow LPG to flow upto the burner head.

STEP NO.2
Press the ignition button on the ignition control panel and keep it pressed for 5
seconds. Sparking will occur at the burner head and pilot frame will ignite. In
case, the pilot flame does not ignite, press the ignition button again after 10
seconds. All 4 (3 in oil line and 1 in gas line) pilots will ignite together.

STEP NO.3
Crack open rig air supplies line and allows air to flow through the 2” Airline of the
burner. Control airflow to minimum.

STEP NO.4
Open up Water Supply of rig to supply water to the water rings at the burner
heads.

STEP NO.5
Start up separator and after attaining desired pressure in the separator open up
gas line of separator through pressure control valve and manifold (at
downstream of separator) to pass to the burner gas line. The pilot flame at the tip
of the 6 “flared end of the gas line will ignite the gas when it reaches that point.

STEP NO.6
After crude oil reached a minimum level in the separator, open up oil line of
separator through level control valve and manifold (at the downstream of
separator) to the burner oil line. The pilot flame at the tip of the burner head will
ignite the crude oil.

STEP NO.7
When crude oil catches fire at the heads, immediately adjust the airflow rate to
effect combustion. Too much air at the beginning may extinguish the flame.
 Whereas too little of air supply may cause dropping of burning crude oil droplets
into the sea.

STEP NO.8
Adjust crude output to maintain level in separator and correspondingly adjust
combustion. Adjustment of water flow rate through the water rings at the heads
will help in eliminating formation of black smoke – adjust water output through
the water ring nozzles at the head to achieve same.

STEP NO.9
Adjustment of airflow and water has to be continued till the separator stabilizes to
achieve complete combustion.

7. TROUBLE SHOOTING GUIDE

I PILOT IGNITION SYSTEM

Sr.No SYMTOMS CAUSE REMEDY

Check Rig supply source and

1. No Sparking No Power Supply
indicator lamp in ignition panel.
 Check and replace fuse in ignition
Blown Off Fuse
control panel.

Check for discontinuity in wiring

Discontinuity in wiring downstream of ignition control
upto spark plug panel upto spark plug. In case of
discontinuity rectify it.

Carbon deposition
Clean spark plug with (OO) emery
spark plug, and
paper and set gap to 1.25 to 1.50
improper gap

Check the valve on LPG manifold.

Sparks but does LPG not reaching Head Keep them open. Check weights o f
2.
not ignite. due to closed valve/empty cylinder and replace if
necessary

Disconnect union of LPG line at the

center of the burner boom and
blow air from base end. Connect rig
Choked LPG line
airline to the front half of LPG line
at the centre of the burner boom
and blow down upto head.

II BURNER HEAD

Sr.No SYMTOMS CAUSE REMEDY

1. Dripping Oil during Insufficient atomization air Increase air flow by

operation due to lack of air adjusting rig valve

2. Black smoke during Insufficient water supply, Clean water nozzles.

operation choked water nozzle Increase or supply of
combined with lack of water and air till black
atomization smoke disappear.
 3. Excess water being supplied Control water flow to
Excessive Grey smoke
to flame flame by adjusting valve.

4. Unstable flame which

High velocity at burner head Decrease flow of air by
goes out often
adjusting air supply valve.

Distribute oil & gas flow

through 2 or 3 nozzles
instead of through one.

Adjust water flow rates.

Excess water may
extinguish flame.

8. DO’S & DON’T’S

DO’S

AFTER EVERY WELL TEST OPERATION

 Clean and flush all water nozzles on water rings.
 Plug off all pipelines at the base of the burner to prevent entry of foreign
material during storage.
 Clean spark plug of the pilot ignition system using (00) emery paper.
EVERY 400 HRS OF OPERATION
 Check all bolted connection and gratings of the boom and Walkway.
 Check ropes of burner boom. If damaged due to kinks and Strands corning
off is detected, replace it. Keep ropes greased at all times to prevent
corrosion.
 Clean and grease the rotating base at the base end of the burner.
 Check wall thickness of burner Piping using an ultrasonic Thickness gauge.
If thickness has reduced beyond operating limits replace piping. A
corrosion allowance is built-in in the piping design as per ASTM codes.
 Hydro test the main Piping to test pressure to ensure safety of operation.
 Touch up all areas where paint has burnt off with primer and Epoxy paint
to prevent corrosion.

DON’TS

 Do not exceed maximum allowable pressure limit on any piping or valves

during operation, than as specified.
 Do not use a damage seal in any of the hammer union.
 Do not start ignition of pilot flame before following the pre-start checkups
specified in this manual.
 Do not start flowing at the highest flow rate all of a sudden. Flow start-ups
should be gradual to prevent shocks to burner piping. This will increase the
life of the burner piping.
 Do not interconnect Airline to any of the lines carrying hydrocarbon, while
operating.

9. SAFETY

Use of the burner is the single largest source of ignition during normal rig
operations. The Vulcan Burner is designed for ease of use and is a safe operation.
To maintain safe working conditions, certain guidelines must be followed before
the start, and during the burning operations.

1. The Burner must only be operated by trained personnel who are familiar
with its operation.
2. Before starting any Burner operations all process lines and connections to
the burner must be pressure tested.

3. The burner head isolation valves, and non-return valves on the air, oil and
diesel lines must be operational and pressure tested.

4. Burning operations must only be started upon direction from the

customer. Stopping burner operations is upon direction of the customer
or upon discovery of equipment malfunction.

5. Burning during boat or helicopter operations may be hazardous. Checks

must be made for these, and other operations, that may interfere with
burning.

6. A crew of fire fighters must be standing by during burning operations, to

cool overheated equipment and structures.

7. Information on the estimated flow rate, oil viscosity and gravity should be
obtained before the start of burner operations.

8. Burner set-up may be modified whilst burning, as the burner does not
radiate excessive heat towards the rear. Certain safety rules must be
observed whilst modifications to the burner set-up are made.

 Wear cotton or flame retarding materials. Work clothing must not

be made of Nylon or similar synthetic material.
 Wear work gloves.
 Wear safety goggles & ear protectors.
 Wear a life jacket or buoyancy aid.
 Secure yourself with a safety harness.
 Always have fire fighters and a rescue team present to lend
assistance.