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FAQ

Frequently Asked Questions

The information on this page is intended to answer the most frequently asked questions about Zeeco, the industries we serve, and the products, services, and support we provide. Simply click on any question listed below to reveal the answer.

Can’t find the question or answer you’re looking for? Enter your question into the FAQ Inquiry form listed on this page.

For immediate needs and inquiries, speak directly with a combustion expert by calling +1 918 258 8551 or emailing sales@zeeco.com.

GET IN TOUCH

About Zeeco

Q: What is Zeeco?

Q: What is combustion?

Q: Do combustion systems go against green initiatives?

Q: Does Zeeco recommend a maintenance cleaning & inspections training?

Q: Do you recommend a combustion survey before ops training?

Burners

Q: What is a process burner and what are the components of a process burner?

Q: What is a process burner used for?

Q: What methods can be used to reduce NOx emissions from process burner systems?

Q: What is a process burner pilot or igniter?

Q: What is a gas tip in a process burner?

Q: What is a burner tile?

Q: Should my pilot shield be glowing?

Q: My pilot won’t light. What should I check?

Q: What is CFD and how is it used?

Q: Is it possible to control a boiler operation only with a BCS without a BMS?

Q: What is tramp air?

Q: Why would operators set burner fuel isolation valves to anything other than full-open or full closed?

Q: Should the pilot tip glow during normal ops?

Q: Could you please explain burner performance test at shop?

Flares

Q: What is a flare pilot?

Q: Can a flare pilot operate under extreme wind and rain conditions, such as a hurricane?

Q: What is the EPA’s Petroleum Refinery Sector Rule (RSR)?

Q: When is my facility required to be compliant with the EPA’s Petroleum Refinery Sector Rule (RSR)?

Q: How can I ensure my facility is compliant with the EPA’s Petroleum Refinery Sector Rule?

Q: Should I use fuel gas or nitrogen to purge my flare system?

Q: What is the difference between a gas (buoyancy) seal and a velocity seal?

Q: What is the purpose of a liquid seal drum?

Q: When should I use a liquid seal drum?

Q: Can I increase the life expectancy of my flare tip by using a higher temperature metal or alloy than 310ss?

Q: What inlet flare gas pressure is required for a high-pressure flare system?

Q: Which type of pilot ignition system is better or more reliable – Flame Front Generator or High Energy Ignition?

Q: What methods are available for smokeless assist?

Q: Does my flare tip need continuous steam or air injection?

Q: Can Zeeco system be used for landfill gas?

Q: Is having smoke is a sign of incomplete combustion?

Q: What are the purposes of the tabs shown in the utility flare tip? Flame stability? Do they improve efficiency?

Q: Are you able to perform maintenance to the blower you mentioned with the flare in service? You don’t have trouble with the radiation level at the base of the flare?

Q: How does a heavy component gas affect the combustion temperature at the flare?

Q: What do you use burn pits for?

Q: What spares for maintenance are needed for steam assisted nozzles?

Q: Is the use of steam or air only meant to extend flare tip life?

Q: What factors affect noise level of flaring?

Q: What flare tip designs does Zeeco have for smokeless operation without air or steam injection?

Q: What is the reason for no radiation at grade level for enclosed ground flares?

Q: Are there any special requirements for the foundation of an Enclosed Ground Flare and Multipoint Ground Flares, such as shall use heat-proof stone, special type of mortar, special type of refractory, etc.?

Q: Does Zeeco supply a protection wall for a ground flare? How can you be sure that there is no broken piece from the wall since it may be unsafe for an operator?

Q: When would a liquid seal vessel be required for flare stack?

Thermal Oxidizers

Q: What is the difference between a thermal oxidizer, vapor combustor and enclosed flare?

Q: Does Zeeco have test incinerator facility?

Q: Does Zeeco always perform CFD for TO design?

Q: Can the waste gas rate vary?

Vapor Control

Q: Are there different types of Vapor Recovery Units (VRUs)?

Q: What is the difference between a mechanical and a carbon bed or adsorption type vapor recovery unit (VRU)?

Q: I work at a truck loading facility. On average, how much gas can I recover with a carbon bed vapor recovery unit (VRU)?

Q: What is Flare Gas Recovery?

Q: If I have H2S in my gas stream, can I still use flare gas recovery?

Q: What is a vapor combustor?

Q: How do I decide if I should use a vapor combustor unit (VCU) or a vapor recovery unit (VRU)?

Q: What do I do if my vapor recovery unit (VRU) needs maintenance?

Aftermarket

Q: How long do I have to wait for Zeeco’s Aftermarket team to respond to an inquiry request?

Q: Where can I get spare parts for combustion equipment?

Q: If I have another manufacturer’s equipment, can Zeeco provide spare parts?

Q: Will I receive service/support after the sale?

Rentals

Q: What is a flame arrester?

Q: If I use a flame arrester, do I still need to send purge gas to the flare?

Q: Can I use a continuous sparking device instead of a pilot?

Q: What are the standardized flare sizes and capacities of Zeeco’s rental fleet?

Q: How large can a trailer mounted flare be before it needs guy wire support?

Q: How do I determine which rental solution is right for me?

Q: What information do I need to provide to size a flare?

Q: Do I need to design my flare for 100% smokeless capacity?

Combustion Electronics

Q: Where do the Flame scanners get placed?

Q: Does the Proflame use a different technology compared to competitor designs to improve reliability and prevent nuisance trips?

Q: Can competition scanners can be replaced with Zeeco Proflame scanners with few modifications at site?

Q: How near/far do we need to install the FlareGuardian? Any limitation distance from the flare to FlareGuardian? What is the maximum working distance of the FlareGuardian?

Q: Can the FlareGuardian be used on a mobile unit?

Q: Is the FlareGuardian safe for hazardous areas?

About Zeeco

Q: What is Zeeco?

Headquartered in Broken Arrow, Oklahoma, USA, Zeeco, Inc. is the global leader in advanced combustion and environmental systems for the refining, gas processing, production, petrochemical, LNG, power, pharmaceutical, marine and offshore, and biogas industries. For more than 40 years, Zeeco has engineered and manufactured ultra-low NOx burners, gas and liquid flaring systems, thermal oxidizers, equipment rentals, and parts and service. Zeeco also offers an array of vapor control products, including vapor recovery units (VRUs), vapor combustion units (VCUs), and flare gas recovery systems (FGRs). With thousands of installations worldwide, Zeeco has successfully executed more than 35,000 projects in more than 100 countries and offers aftermarket products and services for Zeeco equipment and other manufacturers. Zeeco also operates the world’s largest industrial-scale test facility and the first of its kind to be ISO-certified.

As a privately held company, combustion and environmental solutions are Zeeco’s focus, ensuring a high standard of excellence in our people, products, and processes. Our management team is comprised of the world’s leading combustion experts and our global experience provides innovative solutions and seamless project execution. Zeeco has more than 1,000 employees, 20 global locations, and six manufacturing facilities around the world to ensure we are always available for our customers.

Q: What is combustion?

Simply put, combustion is the process of burning something. A combustion reaction occurs when suitable levels of fuel mix with oxygen for a duration long enough to burn, at a temperature high enough to sustain a chemical reaction.

Q: Do combustion systems go against green initiatives?

No; in fact, combustion systems function to decrease the harmful impact of human activity on the environment. Zeeco’s equipment ensures that companies around the world comply with the most stringent environmental and safety regulations by increasing efficiency and decreasing output of carbon monoxide (CO) and other volatile organic compounds (VOCs), such as nitrogen oxides (NOx), sulfur oxides (SOx), and more.

Q: Does Zeeco recommend a maintenance cleaning & inspections training?

A combustion survey would be good to conduct before any maintenance cleaning & inspections training. This allows us to focus specifically on any maintenance, cleaning, or inspection challenges during the training session with operators.

Q: Do you recommend a combustion survey before ops training?

Ideally, we would recommend conducting a combustion survey on the furnace prior to any operations training for the furnace. This combustion survey can help identify any issues that can be covered during the operations training.

Burners

Q: What is a process burner and what are the components of a process burner?

A process burner is a device designed to inject, mix, and combust fuel with an oxidizer in a controlled manner within a process furnace. The two main components are the fuel injection and the combustion air injection.

Q: What is a process burner used for?

Process burners operate in heaters and furnaces of refineries, petrochemical plants, and chemical process facilities to provide the necessary heat for a process while meeting emissions, flame dimensions, and performance criteria.

Q: What methods can be used to reduce NOx emissions from process burner systems?

Several methods can be introduced individually, or in combination with one another, to reduce NOx emissions from process burner systems. Some examples are:

  • Staged air
  • Staged fuel
  • Internal flue gas recirculation
  • External flue gas recirculation
  • Lean premix combustion
  • Steam / Inert injection

Q: What is a process burner pilot or igniter?

A process burner pilot – also known as a process burner igniter – is the component of a process burner used for the ignition of the combustion process. A pilot provides a stable source of combustion to the main burner from a separate fuel manifold.

Q: What is a gas tip in a process burner?

A gas tip in a process burner is the orifice that meters the amount of fuel introduced to the furnace and controls where the fuel gas is mixed with an oxidizer and/or flue gas for combustion.

Q: What is a burner tile?

A burner tile is the main orifice that meters the amount of combustion air introduced for combustion. In some process burner designs, the tile acts as the stability device to maintain a stable combustion reaction.

Q: Should my pilot shield be glowing?

Yes. The pilot flame should stabilize internal to the pilot shield causing the shield to glow. The presence of a glowing pilot shield is an indication that the pilot is properly operating. Pilot shields are a consumable item and must be checked and replaced to maintain safe operation.

Q: My pilot won’t light. What should I check?

Check pilot fuel gas composition, local to the pilot. Fuel piping may have been purged with inert prior to commissioning. High levels of inert can prevent proper pilot operation. Please note that attempting to purge a fuel gas line through the pilot orifice may take a considerable amount of time, as the orifice size is typically nominal (1/16'' diameter).

Check pilot fuel gas pressure, local to the pilot. Typically, operating pressure is from 7 to 12 psig (0.5 to 0.85 kg/cm2).

Check to see if the electronic components are wired, energized, and grounded properly.

Confirm the pilot configuration matches the supplied drawing.

Q: What is CFD and how is it used?

CFD stands for Computational Fluid Dynamics. CFD is used to mathematically simulate real-world conditions for many industries. Zeeco typically focuses on the use of CFD for combustion-related simulation.

Q: Is it possible to control a boiler operation only with a BCS without a BMS?

Per NFPA 85, all boiler burners must include a BMS and BCS, independent of one another. There are other code compliant control systems that have integrated BMS built into the BCS itself. These systems are typically installed on commercial packaged boilers falling under CSD-1 code which are smaller BTU units ranging from 1-12.5 MMBtu/hr.

Q: What is tramp air?

Tramp air is any combustion air that enters the furnace in a location other than through the throat of the burner. As a burner designer, we require that all the combustion air enter the furnace through the burner throat. This allow Zeeco to design the burner to properly mix the fuel and combustion air to provide acceptable flame characteristics that meet the emissions requirements for the project.

Q: Why would operators set burner fuel isolation valves to anything other than full-open or full closed?

Generally speaking, it is normally just human error when fuel isolation valves are set to anything other than full open or full closed. This normally occurs after burner maintenance is completed, and the operator opens the fuel isolation valve but does not achieve the full 90° movement on the valve handle.

Q: Should the pilot tip glow during normal ops?

Yes, the pilot tip and shield should glow during normal operations. This indicates that the pilot flame has stabilized in the proper location on top of the pilot tip inside the pilot shield.

Q: Could you please explain burner performance test at shop?

Zeeco will fabricate a production test burner for the performance testing that is carried out in our Test Facility. Zeeco has 17 Test Furnaces, and we work with the End User to select the best available Test Furnace to be used for the performance test. Zeeco uses the furnace radiant temperature, furnace floor heat density, and radiant height to select a proper Test Furnace.

The production test burner would be installed, and we would operate the burner according the test procedure. The test procedure would be an approval document, and this allows Zeeco and the End User to agree on the number and type of combustion test points. Zeeco would install the production test burner into the Test Furnace and pre-run the burner to verify that it meets all of the project requirements and performance parameters. The End User would be invited to attend the demonstration of the burner, where we would run all of the test points from the test procedure. After the witness testing was completed, Zeeco would issue a formal burner test report to detail the performance.

Flares

Q: What is a flare pilot?

A pilot is a critical component of a flare system that ensures proper ignition of waste gas streams. Without a pilot, toxic gases could potentially vent to the atmosphere.

Q: Can a flare pilot operate under extreme wind and rain conditions, such as a hurricane?

Yes. Temperature, inert flare purge, flame impingement, environmental conditions, and weather events are just a few of the various extremes that flare pilots are vulnerable to. The ZEECO HSLF flare pilot is proven to withstand hurricane-force winds of 170 mph (274 km/h) and rainfall amounts of 51.7 in/h (131.2 cm/h) at Zeeco's Combustion Research and Test Facility.

Q: What is the EPA’s Petroleum Refinery Sector Rule (RSR)?

On December 1, 2015, the U.S. EPA declared a new rule for petroleum refineries following a lengthy Risk and Technology Review (RTR) process required by the 1990 Clean Air Act Amendment, referred to as Petroleum Refinery Sector Rule (RSR) (USEPA, 2015a). The rule imposes new requirements for monitoring flares, among other requirements, at most refineries in the U.S. The method specified in the Refinery Sector Rule for monitoring flare performance is a surrogate method with a more stringent definition of the surrogate parameter, i.e., changing Net Heating Value of the Vent Gas (NHVvg) to Net Heating Value of the Combustion Zone (NHVcz).

According to the EPA, successful implementation of the Petroleum Refinery Sector Rule (RSR) will reduce 5,200 tons of hazardous air pollutants (HAPs), and 50,000 tons of volatile organic compounds (VOCs) per year.

Q: When is my facility required to be compliant with the EPA’s Petroleum Refinery Sector Rule (RSR)?

By January 30, 2019, all US refineries must be compliant with the EPA’s Refinery Sector Rule.

Q: How can I ensure my facility is compliant with the EPA’s Petroleum Refinery Sector Rule?

A method that will comply with the EPA’s newest regulations and optimize flare performance requires a long-term, simplified, and accurate solution. Contact Zeeco to find out how the implementation of new technology utilized in Zeeco’s FlareGuardian™ flare monitoring system can generate real-time continuous monitoring to meet this demand and satisfy compliance with ease.

Q: Should I use fuel gas or nitrogen to purge my flare system?

Both gasses are acceptable and compatible with Zeeco flares. Local environmental requirements and availability of nitrogen or fuel gas at site usually help determine the specific purge medium.

Q: What is the difference between a gas (buoyancy) seal and a velocity seal?

Zeeco uses gas and velocity seals to keep air from flowing back into the flare header and to reduce the amount of required purge gas.

Gas (buoyancy) seals are separate, larger drums that utilize the difference between the buoyancy of air and the buoyancy of purge gas to seal the flare stack from air.

Velocity seals increase the velocity of purge gas within the seal so that air is pushed out and prevented from entering the system below the seal.

Compared to a gas seal, a velocity seal is less complex, requires less maintenance, and has a lesser impact on the stack design; however, a gas seal offers a greater reduction in purge gas requirements than a velocity seal.

Q: What is the purpose of a liquid seal drum?

A liquid seal drum is used to create a water seal barrier between the flare stack and the upstream flare header. They can also be used to provide back pressure for staging systems, flare systems, and upstream equipment.

Q: When should I use a liquid seal drum?

Zeeco recommends using a liquid seal drum when there is a possibility of oxygen in the gas stream or excessive flame propagation; or when the purge gas may not be reliable or adequate.

Q: Can I increase the life expectancy of my flare tip by using a higher temperature metal or alloy than 310ss?

Generally, no. Flare tips most often fail because of distortion and cracking due to differential heating and cooling, not pure oxidation, or strength loss at temperature – attributes of some higher alloys.

Q: What inlet flare gas pressure is required for a high-pressure flare system?

The required flare gas pressure for high pressure systems will depend on the application.

Gas production or processing applications typically require 50 to 80 psig (3.44738 to 5.51581 bar). In this case, Zeeco recommends a Varijet flare.

Petrochemical applications typically require 20 to 25 psig (1.37895 to 1.72369 bar). In this case, Zeeco recommends using a multipoint ground flare.

Q: Which type of pilot ignition system is better or more reliable – Flame Front Generator or High Energy Ignition?

Both systems are very reliable; however, you may favor the advantages of one system over the other, depending on your preference.

The Flame Front Generator (FFG) is easier to access for maintenance, as all operating components are at grade, and it has the option of a manual ignitor at grade; however, it requires regular maintenance to ensure smooth operation.

The High Energy Ignition (HEI) is easier to operate and requires a less complex piping arrangement; however, components must be replaced over time, requiring a shutdown of the flare or retractable system.

Q: What methods are available for smokeless assist?

There are many methods for smokeless assist; however, the four main smokeless assist options are air, steam, gas/fuel, and pressure.

Q: Does my flare tip need continuous steam or air injection?

Yes, because assist medium injection components are near the flame, some minimum continuous flow of steam, air, or other assist media is typically required to protect the equipment from high temperatures.

Q: Can Zeeco system be used for landfill gas?

Yes, we have supplied many systems in the biogas industry. We also have rentals specifically designed for biogas applications.

Q: Is having smoke is a sign of incomplete combustion?

Smoke is a sign of incomplete combustion; however, it does not necessarily mean you aren’t still achieving 98% DRE. We have seen many heavily smoking flares that when designed correctly, still achieve 98% DRE.

Q: What are the purposes of the tabs shown in the utility flare tip? Flame stability? Do they improve efficiency?

Yes, the flame tabs on the utility flare are to improve flame stability. Flame stability is a direct indication of an efficiently designed flare so by improving flame stability, you are also improving efficiency.

Q: Are you able to perform maintenance to the blower you mentioned with the flare in service? You don’t have trouble with the radiation level at the base of the flare?

Typically, flare heights are selected to allow access/work to occur at the base of the stack during normal operations and safe egress from the stack during maximum relief scenarios. Depending on the site HSE protocol, it is commonly allowed to access the base of the stack during normal, stable operation of the plant.

Q: How does a heavy component gas affect the combustion temperature at the flare?

Properly operated and designed flares should combust gases outside of the flare tip barrel and minimize flame impingement as much as possible, thereby preventing premature damage from higher combustion temperatures. Very generally, heavier hydrocarbons have higher adiabatic flame temperatures and may have some impact on flare tip longevity.

Q: What do you use burn pits for?

Burn pits are employed when a flare stream can be two-phase, both liquid and gas. If a vertical flare ejects liquids, burning droplets can disperse widely and fall to grade as an ignition source. If liquids cannot be removed from the flare scenario, they are fired horizontally in a pit designed to accommodate the liquid fire safely.

Q: What spares for maintenance are needed for steam assisted nozzles?

Steam injections nozzles are generally maintenance-free and simply require a continuous cooling flow. In the case of damage, Zeeco does not supply steam nozzles as individual units. If a steam nozzle appears damaged, there is likely damage to the entire steam ring assembly. To ensure the integrity of the overall system we supply complete replacement steam ring assemblies in lieu of individual steam castings.

Q: Is the use of steam or air only meant to extend flare tip life?

The primary function of steam or air is to entrain oxygen into the combustion zone for added smokeless capacity. The use of steam and air has a secondary benefit of extending flare tip life because it shapes flame to prevent impingement on the tip and pilots.

Q: What factors affect noise level of flaring?

Flaring noise is comprised of the total heat output (combustion noise), jet noise of the flare gas exiting the flare tip, jet noise of the assist media for smokeless flaring (steam or air injection).

Q: What flare tip designs does Zeeco have for smokeless operation without air or steam injection?

If pressure is available, the resulting high exit velocity can be used to enhance smokeless performance. Zeeco has three styles of pressure assisted flare tips: UFX (sonic utility tip), MJ (multi-jet), and VJ (vari-jet)

Q: What is the reason for no radiation at grade level for enclosed ground flares?

Radiation is line of sight from the flame, so there is only radiation from the flame if it has a line of sight to the object, and because the chamber blocks visibility of the flame from grade there will not be and radiation.

Q: Are there any special requirements for the foundation of an Enclosed Ground Flare and Multipoint Ground Flares, such as shall use heat-proof stone, special type of mortar, special type of refractory, etc.?

Due to the heats within a unit, Zeeco recommends covering any foundations with suitable 1” nominal aggregate gravel to prevent any damage to the foundations within the flare field.

Q: Does Zeeco supply a protection wall for a ground flare? How can you be sure that there is no broken piece from the wall since it may be unsafe for an operator?

There is a wind fence around the multi-point ground flare which also provides for protection from entering into the system. The wind fence is designed per the wind/seismic codes, and the space from the fence to the burners ensures that there is no early damage to the fence that would cause failure.

Q: When would a liquid seal vessel be required for flare stack?

For a flare gas recovery system, you need to have a positive disconnection between the FGR unit and the flare otherwise the FGR unit may suck back O2 into the flare stack in certain conditions.

Thermal Oxidizers

Q: What is the difference between a thermal oxidizer, vapor combustor and enclosed flare?

Typically, a thermal oxidizer (TO) will be designed for continuous flows that do not change suddenly. It will typically take several hours to heat up the TO to its operating temperature. A TO will have a more finely tuned control system that controls both the incoming utility fuel gas (for keeping the vessel hot), waste gas (sometimes), and combustion/quench air. As such, it is recommended to follow NFPA 86 for safety standards. The unit is controlled on operating temperature and residence time to obtain VOC destruction efficiencies up to 99.9999%.

A vapor combustor unit (VCU) is typically designed for loading terminals or tank batteries with batch processes. A VCU can preheat within minutes to a determined temperature. Generally, a VCU has rudimentary controls for the combustion air and utility gas for preheat/enrichment. Streams are usually laden with oxygen and therefore the VCU will have anti-flashback tips in the design. The VCU is usually controlled by chamber temperature and can meet VOC destruction efficiencies up to 99.9%.

An enclosed ground flare (EGF) is a safety relief device that primarily is designed to combust rich/flammable waste gases with the intent to reduce noise and eliminate flame visibility. Combustion air is usually not controlled but drawn in through natural draft. An EGF usually does not control the temperature inside the unit and will achieve a minimum VOC destruction efficiency of 98%.

Q: Does Zeeco have test incinerator facility?

Yes, Zeeco has the largest combustion equipment test facility in the world.

Q: Does Zeeco always perform CFD for TO design?

Zeeco does not always perform a CFD analysis for our TO designs however, there are applications when we find it necessary. Often, we are able to modify an existing design for similar applications without requiring the added cost and time for CFD analysis to be performed, thus saving the customer in those areas.

Q: Can the waste gas rate vary?

Yes, the waste gas rate can vary. It is best for all process cases, including varying LHV and flowrates, to be identified during the sales/ design phase of the project to be certain the thermal oxidizer is designed to handle all cases applicable to the application.

Vapor Control

Q: Are there different types of Vapor Recovery Units (VRUs)?

Yes, there are two completely different pieces of engineered equipment for different applications that are both referred to as Vapor Recovery Units.

Q: What is the difference between a mechanical and a carbon bed or adsorption type vapor recovery unit (VRU)?

A mechanical VRU is a compression package that is often used to recover tank vapors- gas formed when liquid in a storage tank is heated by outdoor temperatures and collects in a space at the top of the tank. Tank vapor is routed to a mechanical VRU, where it is then compressed and sent to a pipeline that delivers the gas to another part of the facility or to a sales pipeline.

A carbon bed or adsorption type VRU is essentially a large filtration system. These are used to handle vapors that are offset during liquid loading of trucks, railcars, marine vessels, or tanks. Vapor is routed to the VRU, where it passes through a bed of activated carbon that adsorbs hydrocarbons and allows clean air to exit the system. When the carbon bed reaches its maximum capacity, a vacuum pump can then extract the hydrocarbon vapor, send it to an absorber tower, and return the vapor back to a liquid state, so it can be put back into the tanks.

Q: I work at a truck loading facility. On average, how much gas can I recover with a carbon bed vapor recovery unit (VRU)?

On average, a typical carbon bed VRU can recover 1 gallon of gasoline for every 1000 gallons of gasoline loaded onto a truck.

Q: What is Flare Gas Recovery?

Flare Gas Recovery (FGR) is the process of recovering waste gases that would normally be flared, so they can be processed and used as fuel gas elsewhere in the facility.

Q: If I have H2S in my gas stream, can I still use flare gas recovery?

Yes. A flare gas recovery system can compress gas containing H2S to a high pressure (typically 100 to 120 psig or 6.89476 to 8.27371 bar) and route it to an amine system that will remove all H2S from the gas stream. Once all H2S is removed, the remaining gas can be sent back to the facility and used as fuel.

Q: What is a vapor combustor?

A vapor combustor unit (VCU) is typically designed for loading terminals or tank batteries with batch processes. A VCU can preheat within minutes to a determined temperature. Generally, a VCU has rudimentary controls for the combustion air and utility gas for preheat/enrichment. Streams are usually laden with oxygen and therefore the VCU will have anti-flashback tips in the design. The VCU is usually controlled by chamber and can meet VOC destruction efficiencies up to 99.9%.

Q: How do I decide if I should use a vapor combustor unit (VCU) or a vapor recovery unit (VRU)?

It depends how high your flow rates are, the cost of the equipment, and how often your facility is operating. For example, marine loading facilities have higher flow rates, require larger, more expensive vapor recovery equipment, and experience a lot of downtime between shipments. Therefore, a marine loading facility will often use a vapor combustor unit because the cost of capital equipment is much lower than a large chemical VRU and the facility is less likely to recoup their costs by recovering vapor.

Q: What do I do if my vapor recovery unit (VRU) needs maintenance?

Zeeco can deliver a temporary or rental vapor combustor unit (VCU) for your facility to use while your VRU is offline. See our Combustion Rentals section or call +19188937795 to find the right combustion rental for your application.

Aftermarket

Q: How long do I have to wait for Zeeco’s Aftermarket team to respond to an inquiry request?

Zeeco offers 24/7 response and our inventory of key components ensures the fastest delivery to your facility.

Q: Where can I get spare parts for combustion equipment?

Our Aftermarket and Rapid Response teams will support all critical spare parts requests. Our team can also custom engineer and fabricate a solution for our competitor’s equipment to ensure reliable operation.

Q: If I have another manufacturer’s equipment, can Zeeco provide spare parts?

Yes. We will replace Zeeco parts, or other OEM parts, in-kind or better.

Q: Will I receive service/support after the sale?

Yes. Zeeco’s Aftermarket support team consists of technicians and service engineers strategically located across the globe to support all your equipment needs after the sale. Zeeco can even provide service and support for our competitor’s equipment.

Rentals

Q: What is a flame arrester?

A flame arrester is a passive device that is used to prevent a flashback from propagating further upstream in the flare header.

Q: If I use a flame arrester, do I still need to send purge gas to the flare?

Essentially, a flame arrester only protects what is upstream of it and therefore does not protect the flare. For this reason, it is still recommended to use purge gas to ensure that oxygen will not ingress in through the flare tip.

Q: Can I use a continuous sparking device instead of a pilot?

No. In the United States, according to EPA 40 CFR 60.18, "flares shall be operated with a flame present at all times” and, "the presence of a flare pilot flame shall be monitored using a thermocouple or any other equivalent device to detect the presence of a flame."

Q: What are the standardized flare sizes and capacities of Zeeco’s rental fleet?

There are no standard flare sizes or capacities in Zeeco’s rental fleet. Essentially, we can add to or modify equipment within our fleet to meet any capacity you may need.

Q: How large can a trailer mounted flare be before it needs guy wire support?

Zeeco’s trailer-mounted flares reach a maximum size of 60 ft (18.29 m) in height and 60 in (152.4 cm) in diameter. For larger rental flares, Zeeco provides skid-mounted/guy wire supported systems.

Q: How do I determine which rental solution is right for me?

If you provide values to work with, Zeeco can advise on what options are available and work with you to find the optimal solution to meet your needs.

Q: What information do I need to provide to size a flare?

To size a flare, we will need to know your available pressure, flare gas composition, and flow rate for each stream.

Q: Do I need to design my flare for 100% smokeless capacity?

Typically, emergency and/or fire cases are not required to be smokeless for the entire capacity. Normally, the smokeless capacity will be sized for events that are not catastrophic (i.e. continuous, routine events, or portion of the overall capacity = 20 % max flow). This helps optimize design and lower costs.

Combustion Electronics

Q: Where do the Flame scanners get placed?

They typically get placed on the burner front looking through the body of the target flame. However, other locations can be used as well depending on the available sight ports and the view to other burner in the furnace.

Q: Does the Proflame use a different technology compared to competitor designs to improve reliability and prevent nuisance trips?

Our ProFlame scanner does use a different detection technology from other manufacturers and is what allows us to be able to detect and discriminate based on the natural laws of Physics and Chemistry (no algorithms needed). This is another reason our scanner is so easy to tune, and works so reliably on applications other manufacturers do not work. The black liquor recovery boilers and the bark boilers in the Pulp & Paper industry is the best example of our scanner’s superior performance.

Q: Can competition scanners can be replaced with Zeeco Proflame scanners with few modifications at site?

Yes, the Zeeco Proflame scanner is designed to be easily implemented onto existing burners and control systems. The scanner only requires 24 VDC power, a loop for the N.C. or N.O. flame relay contact, and a twisted pair for the 4-20ma flame intensity feedback (recommended not required). Zeeco can provide wiring interface drawings with existing harnesses or terminal block setups so that the scanner install is plug and play. Further, if a customer would like to demo a scanner, a quick disconnect cable can be made that will interface with the existing scanner harness.

Q: How near/far do we need to install the FlareGuardian? Any limitation distance from the flare to FlareGuardian? What is the maximum working distance of the FlareGuardian?

The FlareGuardian is preferably installed a minimum of one flare stack length away from the flare. For maximum distance, the FlareGuardian can be installed 1000 feet (330 meters) away from the flare.

Q: Can the FlareGuardian be used on a mobile unit?

Yes, the FlareGuardian is compact enough that it has been installed on vehicles for mobility and monitoring of multiple installations.

Q: Is the FlareGuardian safe for hazardous areas?

Yes, it can be made suitable for hazardous areas.