Operating Manual - Jatco · 244 N.W. 111th St. • Oklahoma City, Oklahoma 73114 • 405/755-4100 • 405/755-4101 Fax Revised 10/2010 1 . JAT CO Inc. Operating Manual . System I,

244 N.W. 111th St. • Oklahoma City, Oklahoma 73114 • 405/755-4100 • 405/755-4101 Fax Revised 10/2010

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JATC

O Inc.

Operating Manual System I, II, III

INDEX

System Operations Page 3 Operating Instructions Page 4 BTEX System I P&ID Page 5 BTEX System I Drawings Page 6 & 7 BTEX System II P&ID Page 8 BTEX System II Drawings Page 9 & 10 BTEX System III P&ID Page 11 BTEX System III Drawings Page 12 - 14 Starting Procedure Page 15 Shutting Down Page 16 Service & Maintenance Page 17 Trouble Shooting Guide Page 18 Recommended Spare Parts Page 19 JATCO Tank Service Page 20 - 22 JATCO Low Pressure Liquid Separator Page 23 Spec Sheet Page 24 High Liquid Level Shut Down Page 25 K-Dyne Manual Reset Valve Page 26 & 27 Kimray 30 PGR Relays Page 28 & 29 ¼" Humphrey Valve Page 30 Actuated 3-Way Ball Valve Page 31 - 37 ENARDO Flame Arrestor Page 38 & 39 INVALCO Micro Valves Page 40 - 42 Taylor Relief Valve Page 43 & 44 244 N.W. 111th St. • Oklahoma City, Oklahoma 73114 • 405/755-4100 • 405/755-4101 Fax Revised 10/2010

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SYSTEM I, II, III SYSTEM OPERATION

The JATCO “BTEX ELIMINATOR” is designed to condense the emissions from the still column of glycol dehydrators. The hot vapors are routed through the heat exchanger, reducing the temperature and volume of the steam and hydrocarbons produced by the dehydration process. The liquids condensed are routed by gravity into a small tank placed at the base of the condenser. The tank dumps these liquids automatically, and must be connected to a holding tank. The vapors remaining uncondensed are routed through a separation and filtering media, then to either the main burner of the dehydrator, or to the exhaust stack. All V.O.C.’s are either condensed into liquids which may be separated and sold, or are burned.


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System I, II, III

Operating Instructions JATCO BTEX Eliminator Systems

See P&ID: The V.O.C.’s are routed from the condenser through a manual valve (BA-001), then emergency shut down valve (ABV-1200), and the gas liquid separator (SP-1100). Then though a filtering and separating medium (ME-1101), the flame arrestor (FA-1101), then either to the burner or to the exhaust stack through the actuated 3-way ball valve, (ABV-1100). The actuated 3-way ball valve (ABV-1100) is controlled by a relay valve (PY-1101) that receives it's pilot signal from output the of the main burner fuel supply valve (SDV-Main Fuel Gas Supply) this is controlled by the temperature controller (TC). During normal operation, when the thermostat (TSH) supplies pressure to operate the burner supply valve (SDV-Main Fuel Gas Supply), the main burner fuel pressure also gives positive signal to the pilot side of (PY-1101) to allow supply gas to actuate the 3-way ball valve, (ABV-1100). When actuated the condenser residual vapors are routed to main burner. A JATCO air mixer adaptor allows the drift of fuel gas to mix the vapor with primary air in the main burner. When the set temperature of the glycol in the re-boiler is reached, the thermostat removes pressure from the valve, allowing the waste vapors to be diverted into the exhaust stack, where they are mixed with hot air being drafted into the fire tube and stack and ignited. An over temperature controller (TSH) supplies pressure to the thermostat (TC) to operate the control valves. This pressure is also used to operate a 2” actuated ball valve (ABV-1200) mounted on the heat exchanger. This valve (ABV-1200) allows the vapors to be vented to the atmosphere during start up and automatic shut down. It will switch automatically in the event the over temperature control (TC) or the high level shut down (LSH-1000) is tripped.

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SYSTEM I, II, III

STARTING PROCEDURE See P&ID: The glycol pump should be stopped before beginning the starting sequence. All gas and waste vapors must be allowed to clear from the fire tube and exhaust stack before lighting the pilot. When lighting the pilot, the system should be bypassed by closing valves (BB-001) and (BA-001) set the thermostat (TSH) to desired temperature. When the glycol reaches temperature, start the glycol pump and begin circulation through the contactor and re-boiler tank. The BTEX ELIMINATOR is designed to handle the vapors generated under normal conditions. If the glycol is saturated with water, it will be necessary to allow the excess water to dissipate before opening valves (BA-001) and (BB-001)


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SYSTEM I, II, III SYSTEM I, II, III SHUTTING DOWN SHUTTING DOWN

SEE P&ID: SEE P&ID: The BTEX ELIMINATOR may be isolated from the burner and exhaust stack at any time by closing valves (BB-001) and (BA-001). The BTEX ELIMINATOR may be isolated from the burner and exhaust stack at any time by closing valves (BB-001) and (BA-001). This allows the vapors to vent through actuated ball valve (ABV-1200). This allows the vapors to vent through actuated ball valve (ABV-1200). The dehydrator may then be serviced or operated normally. The dehydrator may then be serviced or operated normally. NORMAL OPERATION:NORMAL OPERATION: It is important to keep the glycol flow to the minimum necessary to achieve the desired dew point of the gas stream. Any excess in flow rate will cause additional hydrocarbons to be absorbed by the glycol in the contactor. These hydrocarbons must then be condensed or burned. If a two or three phase separator is used in the wet glycol stream, the load on the condenser is greatly reduced. If no separator is used, any excess glycol flow rate may cause an over rich fuel mixture, smoking or flames from the exhaust stack.

SYSTEM I, II, III SERVICE AND MAINTENANCE

SEE P&ID: The JATCO BTEX ELIMINATOR system has very few moving parts. Mainly Kimray valves which are used extensively in the oil industry. Maintenance of the JATCO tank is covered in the service instructions. A pressure gauge is provided to assist in determining operation of the actuated ball valve (ABV-1200). This pressure gauge will indicate any blockage or restriction of flow in the filtering media or flame arrestor. Operation of the vent valve can be confirmed by either a drop in system pressure, or if manual valve (BA-001) is closed briefly, no increase in pressure.


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SYSTEM I, II, III Trouble Shooting Guide

If the vapor relief valve (PSV-1100) at inlet is relieving pressure, first close valve (BB-001) which will switch 2” actuated ball valve (ABV-1200) to system by-pass. If switching valve (ABV-1200) relieves pressure from vapor relief valve, then either mist eliminator (ME-1101) or flame arrestor (FA-1101) may be clogged or obstructed. If switching 2” System by-pass valve (ABV-1200) does not relieve pressure from vapor relief valve, first check operation of JATCO tank. If tank is dumping by depressing manual dump plunger, check bottom headers, outlets, and tubing for blockage. If JATCO tank will not dump completely or at all, check for adequate pressure (40 psi) directly at instrument supply inlet of tank. For better performance turn pressure up to (100 psi) max. Also check all down stream lines of the tank for blockage.


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RECOMMENDED SPARE PARTS FOR VERTICAL PANELS

JATCO BTEX ELIMINATOR

Qty. Item # Description

1 JM5001X 3 way Micro-Valve for JATCO Tank 1 JM5008X ¼” Pilot Valve for JATCO Tank 1 K040 Repair Kit for Kimray 30 PGR Relay 1 K036 Repair Kit for Kimray 3 PGM 1 JB11-15 Flame Cell for Burner Mixer Adapter (for 1 ½”, 2”, 3” or 4”) 1 INV49 316 F1-B 3 way Micro-Valve for High Level Control

Contact JATCO Inc. for replacement parts

J-5000cx Service Guide

JATCO J-5000cx Environmental Tanks

Listed below are a series of steps to follow if the JATCO tank fails to dump properly. Be sure there is an adequate supply of gas pressure (40-100 psi), to the inlet connection on the micro valve. If there is enough pressure at the inlet connection, press down on the manual dump plunger. This should cause the tank to dump, then vent when the cycle is complete. If the Jatco tank fails to dump manually, remove connector tubing to pilot valve (10) to test for pilot pressure from 3 way micro valve (1). If the 3 way micro-valves are not sending pressure to pilot valve when depressing manual dump plunger (#4), removal and or inspection of micro-valve will be necessary and proceed to step #2. If pressure is present but pilot valve fails to operate, removal inspection, and or replacement may be necessary. To remove the micro-valve, remove the top vent tube connector and the bottom gas supply connector to allow access and removal of the two hex socket cap screws. Remove the cap screws and the micro-valve from the valve body. Inspect the inlet port to see if any obstruction has lodged in the orifice which could clog the micro-valve. If no obstruction is visible, apply gas pressure to the inlet port and operate the toggle spring. Flipping the toggle up should allow gas to flow out center ¼” npt port. If operating the toggle does not allow gas to flow, the micro-valve must be replaced. To re-install the micro-valve and mounting plate assembly on the 2” valve body, flip the toggle to the down position and insert toggle spring through the center hole in the valve body. Reinstall the two mounting cap screws, the vent connector, and the gas supply connectors. Check system by depressing manual dump plunger. To remove the install 2” valve body: Remove micro valve as previously described. Remove manual dump plunger. Loosen hex nut on top of valve body and tap down pivot pin. This allows the float arm assembly to swivel while turning valve body out of tank. Remove float assembly carefully to avoid bending the float arm. To install valve body, insert float arm into the tank with the float toward the gauge cock end of the tank. Hold the float pivot with a screwdriver, keeping the slot on the pivot positioned ninety degrees to the float arm. Tighten the 2” valve body into the tank, positioning the machined surface toward the gauge cock end of the tank, while holding the float pivot with a screwdriver; tighten the hex nut to lock the float arm in place. Re-install manual dump plunger and depress it while observing the trip lever through the toggle hold on valve body. The trip lever should be visible and centered. Re-install gasket and micro-valve.


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J-5000cx J-5000cx


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(A) Inlet Check Valve 1” NPT (B) Discharge Check Valve 1” NPT (C) Supply Gas Inlet ¼” Compression

(D) ¼” SS Vent Tube

(E) Pressure Relief Valve

(F) Manual Dump Plunger Assembly

(G) Three Way Pilot Valve

(H) Vessel Vent ¼” NPT

(I) Gauge Cocks & Sight Glass

J-5000cx Tank

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No. Item# Description 1 JM5001X 3 way micro valve w/ mounting plate 2 JM5002 -125 Pressure Relief Valve 125 PSI 2 JM5002 -200 Pressure Relief Valve 200 PSI 3 JM5003 Manual Dump Plunger Assembly 4 JM5004-SS Stainless Steel Float Arm & Pivot assembly & Float 5 JM5005 1” Check Valve 6 JM5006 2” Valve Body Assembly 7 JM5007 10-Gallon ASME code vessel 8 JM5008X ¼” Pilot Valve 9 JM5009 Gauge Cock Set 10 JM5010 Gauge Glass JM5011 Complete Float Control Assembly (Item #1,3,4,6) JM5012 Complete Control Set (Item #1,2,3,4,6,8) JM5012-200PSI Complete Control Set 200 PSI STAINLESS OPTIONS 1 JM5001x-SS 3-Way Micro Valve (stainless steel) 2 JM5002 -100-SS ¼” Stainless Steel 100 PSI 2 JM5002- 200-SS ¼” Stainless Steel 200 PSI 5 JM5005- SS 1” Stainless Steel Check Valve 8 JM5008x-SS ¼” Pilot Valve (stainless steel) KLS 9 JM5009 –SS ½” Gauge Cock Set (stainless steel) JM5011 –SS Complete Float Control Assembly JM5012-NBO Complete Control Set (No Brass Option) JM5012-NBO-SS Complete Control Set 200 PSI (NBO) JM5012 –SS Complete Control Set JM5012 -200-SS Complete Control Set 200 PSI


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JATCO Low Pressure 1” Liquid Separator

1” N.P.T. Outlet

1” N.P.T. Inlet

13” Weir

17 3/8”

1/2” N.P.T. Liquid Drain

4 ½”


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JATCO Vertical Panel Air Cooled Heat Exchangers

Full stainless steel condenser with stainless steel skid base, using stainless steel aluminum wound 1" 1.0 fin tubes. A multi-pass tube construction with each pass draining to the lower liquid line, that is connected to a JATCO automatic blowcase. Units can be configured in series to increase cooling capacity.

Specifications:

Test pressure: 20 psi

Operating pressure: 1 psi

Max operating temp: 225° F

Max Condenser Vapor Outlet Temp: 10° F approach to ambient temp

Headers: 304 Stainless Steel

Fin Tube Description: 1" x 16 ga x SA249 TP316 Aluminum L-Foot

Fin Tube Length: 6' 0"

Fin Dimension: .015" x 2.5"

No. of Max H20 Maximum

Regen Model # Passes Removed # of Tubes Compatibility

System I 3 834 lbs./D 8 125,000 BTU/HR

System II 5 2,500 lbs./D 16 375,000 BTU/HR

System III 7 3,334 lbs./D 24 500,000 BTU/HR


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Documents

Operating Manual - Jatco · 244 N.W. 111th St. • Oklahoma City, Oklahoma 73114 • 405/755-4100 • 405/755-4101 Fax Revised 10/2010 1 . JAT CO Inc. Operating Manual . System I,