Bespoke Systems

When the requirements of a contract cannot be fully met by standard equipment, we will design a system to suit the application. The system is usually based on standard designs, which, with a few modifications, can be adapted to suit the application. The following are examples of a few recent bespoke systems.

• A customer needed a system to simultaneously  ignite three burners with a single torch. The burners are close together forming a triangle and there is a single port in the centre of the triangle through which the torch is to be inserted. Our solution was to design a three-way burner head that fits onto a standard J250EI  torch. The burner head was hand made from alloy 800HT and diverts the flame in three directions.
• A customer needed a mobile, battery operated system. The solution was to design a trolley onto which three explosion-proof enclosures were mounted. The first enclosure houses a 12V sealed lead-acid battery, the second enclosure houses a 12V dc to 110V ac inverter, and the third enclosure houses a CU6/5 control unit. A gas control line was mounted onto the trolley and there was space for a 26Kg propane bottle and the torch. Provision was also made for the connection of a battery charger.
• A customer needed a portable spark-only system for use in a potentially explosive atmosphere. The solution was to design a carrier onto which two explosion-proof enclosures were mounted. The smaller of the two enclosures contains a 12 V sealed lead-acid battery and the larger enclosure contains a 12V dc spark generator. We also designed a spark-only torch based on the P78E, making it lightweight and easy to handle.
• A customer needed a system to ignite a pair of flare stacks that burn off waste gas from an industrial process. The system is exposed to the elements on the coast and is located on the roof of a tall building. The system is also exposed to high temperatures from the flare stacks. Maintenance time is limited due to the second flare stack being in use whilst the first is being in overhauled, and vice-versa. Our solution was to locate a CU6 control inside the building well away from the elements. A premix unit, based on the CA170, was housed inside a stainless steel enclosure and  installed close to the flare stack. A bespoke torch was designed. It is loosely based on a J250E torch. The torch is split into two parts; a base that is attached to the flare stack and the remainder is removable for maintenance away from the elements. The two sections are joined by a flange arrangement, with the conductor rod being joined by a sprung plunger. A flame elbow on the torch tip deflects the flame 90 degrees into the flare stack. An SA82 encapsulated coil is mounted onto the torch base.
• A customer needed two systems for use on process system. Each igniter system consists of a CU7/3 control unit, J170E torch with retraction mechanism and premix unit. The two CU7/3 control units were housed in a single enclosure. Each J170E torch incorporated a thermocouple to monitor the temperature at its tip. The pneumatic retraction mechanisms were designed for the contract. The premix unit was mounted on top of the retraction mechanism. A sealing gland prevents any gas from the process escaping to the atmosphere and a ball valve prevents the escape of process gas when the igniter is removed for maintenance.