ISO 9001 Certified Firm

VAREC


Vapor Control Inc.

5000/5010 Series
Flame Arrester
INSTRUCTION, OPERATION AND MAINTENANCE
MANUAL

33-07765 Rev. E
5000/5010 SERIES FLAME ARRESTER

TABLE OF CONTENTS
Disclaimer of Warranties 3
Limitations of Seller's Liability 3
Safety Precautions 3
Safety Precaution Definitions 4
CAUTION 4
General 5
Construction 5
Practical Limitations 5
Operation 6
Installation 6
Maintenance 7
Replacement Parts 10
Flow Capacity 15

LIST OF TABLES
Table 1- 5000 Series, Materials of Construction 12
Table 2 – 5010 Series, Materials of Construction 14

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5000/5010 SERIES FLAME ARRESTER

Disclaimer of Warranties
The contract between the Seller and the Buyer states the entire obligation of the Seller. The contents of
this instruction manual shall not become part of or modify any prior or existing agreement, commitment
or relationship between the Seller and Buyer. There are no express or implied warranties set out in this
instruction manual. The only warranties that apply are those in the existing contract between the Seller
and Buyer.
The Varec 5000/5010 Series Flame Arresters have not been tested by Varec under all possible
operational conditions, and Varec does not have all the data relative to your application. The
information in this instruction manual is not all inclusive and does not and cannot take into account all
unique situations Consequently, you should review this product literature in view of your application.
If you have any further questions, please contact Varec for assistance.

Limitations of Seller's Liability

If it is determined that this instruction manual created some new warranties, Varec’s liability shall be
limited to repair or replacement under the standard warranty clause. In no case shall Varec’s liability
exceed that stated as Limitations of Remedy in the contract between Varec and our customer.

Safety Precautions
READ AND UNDERSTAND THIS INSTRUCTION MANUAL BEFORE INSTALLING,
OPERATING OR PERFORMING MAINTENANCE ON VAREC 5000/5010 SERIES FLAME
ARRESTERS. FOLLOW ALL PRECAUTIONS AND WARNINGS NOTED HEREIN WHEN
INSTALLING, OPERATING OR PERFORMING MAINTENANCE ON THIS EQUIPMENT.

WARNING
Flame arrester should be installed upstream and not more than 15 feet from the ignition source for use in
accordance with UL approval.
Flame Arrester must be isolated from the gas piping before performing maintenance. All gas must be
blocked and pressure safely vented.
Flame arresters are not capable of stopping a flame front in mixtures of air with hydrogen, acetylene,
ethylene oxide, or carbon disulfide.

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5000/5010 SERIES FLAME ARRESTER

Safety Precaution Definitions

CAUTION
Damage to equipment may result if this precaution is disregarded.

WARNING
Direct injury to personnel or damage to equipment which can cause injury to personnel may result if this
precaution is not followed.

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5000/5010 SERIES FLAME ARRESTER

General
The VAREC Model 5000/5010 Series Flame Arresters are designed to stop the propagation of flame
from external sources. They are used on storage tank roofs, digester covers, and in waste gas piping
systems. These units are installed where fire protection is required in combination with pressure relief
or shut-off valves in vapor balancing, recovery, or open vent piping systems.

WARNING
Flame Arresters are not capable of stopping a flame front in mixtures of air with hydrogen, acetylene,
ethylene oxide, or carbon disulfide.

Flame Arrester should be installed upstream of and not more than 15 feet from the ignition source for
use in accordance with UL aproval.

NOTE
Varec Flame Arresters bearing UL approval are tested for use on oil storage tanks, installed not more
than 15 feet from the open end of the vent pipe. (Reference UL 525.) These test conditions may not
represent the actual service conditions or piping system design. API Publication 2028 states that the
Arresters should be independently tested under actual service conditions before installation.

Construction
The standard unit is constructed of a heavy cast housing containing a removable multiplate bank
assembly with aluminum extensible frame. A fixed 316 S.S. frame is also available. Working pressure
rating is 10 PSIG (69.0 kPa). For material selection see Tables 2 & 3.

Practical Limitations
While Flame Arresters decrease the possibility of flame propagation in a system, certain variables must
be evaluated to ensure safety. The relative fire hazard of flammable mixtures can be judged by the
upper and lower explosive limits. These limits are expressed as percent by volume of the gas or vapor in
air. The explosive range is that span of concentrations lying between the lower and upper limits. The
upper limit is the point at which the mixture is too rich to burn, i.e., contains too little oxygen to support
combustion. The broader the explosive range, the easier it is to create an air-gas explosive mixture.
Conversely, when the explosive range is narrow, the chance of developing a hazardous air-gas mixture
decreases.

Table 1 gives the approximate limits of flammability of some single gases, vapors, and industrial
mixtures in air at common temperatures and at atmospheric pressure.

WARNING
In all cases where the ratio of upper limit/lower limit exceeds 10, the use of Flame Arresters is not
recommended. Also, the presence of any O2 is dangerous because of the lack of homogeneity which is
possible in gas mixtures. Any surplus of oxygen provides the potential for rapid explosion.

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5000/5010 SERIES FLAME ARRESTER

Operation
Flame Arresters do not prevent ignition of flammable mixtures, but do prevent the propagation of a
flame. The Varec 5000/5010 Series Flame Arresters stop flame propagation by absorbing and
dissipating heat through the surface area of the bank sheets. Heat is absorbed as ignited gas attempts to
pass through the small passages within the bank assembly. This action lowers the temperature of the gas
below its ignition point and quenches the flame.

Product Limits in Air Product Limits in Air Product Limits in Air

Pressure Pressure Percent
Lower Higher Lower Higher Lower Higher
Acetyldehyde 4.1 55.0 Ethy-Alcohol 4.3 19.0 Methyl-Alcohol 7.3 36.0
Acetone 3.0 11.0 Ethyl-Bromide 6.7 11.3 Methyl-Chloride 10.7 17.4
Acetylene 2.5 81.0 Ehtyl-Chloride 3.8 15.4 Methyl-Ethyl-Ketone 1.8 10.0
Ammonia 15.0 28.0 Ethyl-Ether 1.9 48.0 Methyl-formate 5.9 20.0
Benzene 1.4 7.1 Ethyl-Formate 2.7 13.5 Methyl-Proply-Ketone 1.5 8.0
Benzine 1.1 Ethylene 3.1 32.0 Natural Gas 3.8 17.0
Blast Furnace Gas 35.0 74.0 Furfural 2.1 Noriane 0.8
Butadiene 2.0 11.5 Gasoline 1.4 7.6 Octane 1.0
Butane 1.9 8.5 Hexane 1.2 7.5 Pentane 1.5 7.8
Butylene 2.0 9.6 Heptane 1.2 6.7 Propane 2.1 9.5
Carbon Disulphide 1.25 44.0 Hydrocyanic Acid 6.0 41.0 Propyl-Alcohol 2.1 13.5
Carbon Monoxide 12.5 74.0 Hydrogen 4.0 75.0 Propylene 2.4 10.3
Cyclohexane 1.3 8.0 Hydrogen-Sulhide 4.3 5.0 Pyridine 1.8 12.4
Cyclopropane 2.4 10.4 Isobutane 1.8 8.4 Styrene 1.1 6.1
Decane 0.8 5.4 Isopentane 1.4 7.6 Toluene 1.4 6.7
Ethane 3.0 12.5 Isopropyl-Alcohol 2.0 12.0 Water Gas 7.0 72.0
Ethyl-Acentate 2.5 9.0 Methane 5.3 14.0 Xylene 1.0 6.0

Reference: Bureau of Mines Bulletin 503, Limits of Flammability of Gases and Vapors, 1952
Table 1 – Flammability Limit of Gases and Vapor

Installation
The 5000 Series Flame Arrester (ref. Figure 1) is designed for vertical application in pipe lines and on
tank or digester roofs. The 5010 Series Flame Arrester (ref. Figure 2) is designed for horizontal
positioning in pipelines, however, it may be in either direction.

The cover, roof or piping system must have the appropriate flange(s) installed for mating with the Flame
Arrester. Flame Arrester with aluminum housings should be mated with an ANSI Class 125 F.F. flange.
The 316 stainless steel housing should be mated with an ANSI Class 150 R.F. flange. The Arrester must
be located with clearance allowed for removal of the bank assembly.

The flange of vertical mounting must be plumb and level to ensure proper operation of the pressure
relief valve (when used in combination with the Flame Arrester).
The flange for horizontal mounting must be oriented to ensure that Arrester drain hole will be at the
extreme bottom (6 o’clock) position.

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5000/5010 SERIES FLAME ARRESTER

Remove the Flame Arrester from the shipping container or pallet. Remove flange protectors. Inspect
for and remove any packing or other loose material in the inlet/outlet chambers of the housing.
Remove cover and extract bank assembly. Inspect for shipping debris or damage, and correct as
required. Insert bank and replace cover. Tighten cap screws uniformly.

WARNING
The aluminum bank assembly weighs from 10 to 80 pounds and the 316 S.S. assembly is substantially
heavier. Use the appropriate tools and equipment when handling these units to avoid injury.

4. Place the appropriate full face flange gasket (by others) on the flange.

CAUTION
If it is necessary to mate an ANSI Class 125 F.F. flange with an ANSI Class 150 R.F. flange, use the
proper spacer to convert the raised face to a flat face.

5. Place the Arrester on the flange, and position the unit so that the bank assembly can be readily
extracted for inspection and maintenance.

NOTE
When installing the Model 5010 in a horizontal position, check the drain hole to see that it is functional.
Install the appropriate drain piping along with a Varec Drip Trap or an isolation valve.
Install mounting hardware and tighten uniformly.

The Flame Arrester is now installed and ready for use.

Maintenance
Maintenance is the most important factor in the operation of the Flame Arrester. The bank sheets must
be kept clean to prevent a decrease in gas flow through the system and loss of heat absorbing efficiency.

WARNING
Failure to properly maintain the unit could result in reduction of safety and impairment of system
operation.

A regular inspection program is important. The frequency of inspection is determined by the

application. Consideration should be given to the amount and nature of water or solids in the gas, and
the corrosivity of the process stream. Generally, the first inspection should be made 30 days after
commissioning. Inspections should continue on a 30 day schedule unless excessive deposits or
accumulation of foreign matter are found. If so, the frequency of inspections should be increased.
Adjust inspection frequency to maintain free and unrestricted flow through the Arrester.

WARNING
Flame Arrester must be isolated from the gas piping before removing cover plate. All gas must be
blocked and pressure safely vented. Ensure that Arrester is cool after a fire, or wear appropriate
protective clothing.

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5000/5010 SERIES FLAME ARRESTER

1. Remove cover cap screws and cover plate. Pull out bank assembly by pulling on bank handle. If
desired, the bank assembly may be removed from the housing.

WARNING
The aluminum bank assembly weighs from 10 to 80 pounds and the 316 S.S. assembly is substantially
heavier. Use the appropriate tools and equipment when handling these units to avoid injury.

a. Extend the aluminum frame to its full open position. Both sides of each grid sheet
may be inspected and cleaned without removal from the frame.
b. The 316 S.S. frame is non-extensible and must be disassembled to access the bank
sheets.

2. Check for corrosion, bent, warped or otherwise damaged sheets that could cause an opening for a
direct flame path. Replace with a full bank sheet set if necessary.
47176. Bank assembly cleaning procedure is based on the type of residue to be removed.
Determine if residue type is Group I, II, or III. Follow the cleaning procedures for the selected
group.

WARNING
Use all volatile and flammable solvents carefully to avoid ignition or prolonged breathing. Use
protective clothing and gloves when using acid to avoid burns from contact with skin.

Group I
Residue Type: Soil, sand, pollen, and metallic salts.

Cleaning Procedure:
a. Wash bank sheets with a mild solvent such as petroleum naphtha or commercial
petroleum derived cleaning fluids.
b. Rinse sheets with a solvent that does not leave an oily film. This is necessary to
avoid collecting foreign matter.
c. Blow out dry particles with compressed air.
d. Wash bank sheets with hot water.
e. Steam bank assembly clean.

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5000/5010 SERIES FLAME ARRESTER

Group II
Residue Type: Metallic oxides and metallic carbonates.
Cleaning Procedure:
a. Wash bank sheets as described in Group I, Step 1.
b. Soak entire bank assembly in cold 35% nitric acid.

CAUTION
Use acid only on aluminum or stainless steel bank assemblies. Do not use on carbon steel or monel.

NOTE
If residue still remains, place bank assembly in boiling 35% nitric acid. Once all residue is removed,
soak bank assembly in a solution of baking soda and water (8 ounce baking soda to 3 gallons water) to
neutralize any remaining acid. Blow dry using compressed air.
Group III
Residue Type: Organic tars, organic gums and sulfur organic residues.
Cleaning procedure:
a. Wash bank sheets as described in Group I, Step 1.
b. Blowout with compressed air.
c. Wash bank sheets with a strong solvent such as benzol, xyol, carbon tetrachloride,
acetone, carbon disulfide, paint thinner (not lacquer), or a mixture of 1/3 each of
benzol, alcohol and acetone.
4. If residue cannot be removed by the above procedures, replace with a new bank sheet set.

WARNING
Clogged bank assembly can restrict flow and reduce ability to stop flame propagation.

5. Place the bank assembly into the Arrester housing. Install new gasket, cover plate, and cap screws.
a. The aluminum extensible frame bank assembly may not go entirely back into place.
The force needed to compress bank into place is supplied by tightening cover plate
cap screws.
b. The 316 S.S. fixed frame bank assembly should allow cover to close readily.
6. Install all cap screws hand tight. Cross tighten all cap screws evenly around cover per below
drawing. Torque to 40-50 ft/lbs.
47292. The Flame Arrester is ready to be placed back into service. Perform soap test. If any
leakage is detected, further tighten cap screws (maximum torque not to exceed 60 ft.-lb.)

Replacement Parts
When ordering replacement parts specify Flame Arresters by Model number, series number, and pipe
size. Identify replacement parts by item number, description, and material as shown on reference
drawings. Include part number where possible.

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5000/5010 SERIES FLAME ARRESTER

Size 2 3 4 6 8 0 1
Nominal 2 In. 3 In. 4 In. 6 In. 8 In. 10 In. 12 In.
Pipe Size 50 MM 75 MM 100 MM 150 MM 200 MM 250 MM 300 MM
Bank Assembly BM 6027 BM6055 BM6090 BM6126 BM6245 BM6269 BM6716
Alum Ext. Frame
w/Alum Sheets
Bank Assembly BM18996-000 BM18998-000 BM19000-000 BM18956-000 BM18958-000 BM19002-000 BM19004-000
Alum Ext. Flame
w/316 S.S. Sheets
Bank Assembly BM19882-600 BM19883-600 BM19884-600 BM19885-600 BM19886-600 BM19887-600 BM19888-600
316 S.S. Fixed
Frame w/316 S.S.
Sheets
Gasket Kit 13-09101-02 13-09101-03 13-09101-04 13-09101-06 13-09101-08 13-09101-10 13-09101-12
Compressed Non-
Asbestos
Figure 1 – 5000 Flame Arrester

Dimensions
Size (A) B C D F
2” In. 9 12-5/8 4-5/16 19
MM 229 321 109 483
3” In. 11-3/4 13-7/8 5-3/4 23-1/4
MM 298 353 146 591
4” In. 14-1/2 16-5/8 7-3/8 28-1/8
MM 368 422 187 715
6” In. 16-1/2 21-1/2 8-3/8 31-1/8
MM 419 546 213 791
8” In. 21-5/8 27-1/4 10-7/8 38-5/8
MM 549 692 276 981
10” In. 24 28-3/8 11-7/8 41-5/8
MM 610 721 302 1057
12” In. 31 34-3/8 14-5/8 50
MM 787 873 372 1270

Material Table
Item Description Material
Model Model Model Model
5000X1 5000X2 5000X3 5000X6
1 End Housing Aluminum Aluminum Steel 316 S.S.
2 Cover Plate Aluminum Aluminum Steel 316 S.S.
3 Side Plate Aluminum Aluminum Steel 316 S.S.
4 Washer Zn Pl Stl An Pl Stl Zn Pl Stl 304 S.S.
6 Cap Screw Zn Pl Stl An Pl Stl Zn Pl Stl 304 S.S.
7 Gasket, Cover Plate Compressed Compressed Compressed Compressed
Non-Asbestos Non-Asbestos Non-Asbestos Non-Asbestos
8 Gasket, Side Plate Compressed Compressed Compressed Compressed
Non-Asbestos Non-Asbestos Non-Asbestos Non-Asbestos
9 U.L. Listing Tag Aluminum - - -
10 Drive Screw 18-8 SST 18-8 SST 18-8 SST 18-8 SST
11 Bank Assembly Alum. Ext. Alum. Ext. Fixed 316 S.S. Fixed 316 S.S.
Frame/Alum Frame/316 S.S. Frame/316 S.S. Frame/316 S.S.
Sheets Sheets Sheets Sheets
12 Cover Tag Aluminum Aluminum Aluminum Aluminum

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5000/5010 SERIES FLAME ARRESTER

13 Rear Plate Aluminum Aluminum Steel 316 SST

Table 1- 5000 Series, Materials of Construction
Figure 2 - 5010 Series Flame Arrester

Dimensions
Size (A) B C D F G
2” In. 4-5/16 18-3/4 14-1/2 5-3/8 9
MM 110 476 368 137 229
3” In. 5-5/8 2-7/8 16 7-1/4 11-3/4
MM 143 581 406 184 298
4” In. 7 27 20 9 14
MM 178 686 508 229 356
6” In. 8-1/4 30-3/4 24-3/8 10-3/4 16-3/8
MM 210 781 619 273 416
8” In. 10-3/4 38-1/4 32-1/8 14-3/8 21-5/8
MM 273 972 816 365 549
10” In. 11-7/8 41-5/8 35-1/2 16 24
MM 302 1057 902 406 610
12” In. 14-1/2 49-1/2 34-3/8 20 31
MM 368 1257 873 508 787

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5000/5010 SERIES FLAME ARRESTER

Material Table
Item Description Material
Model Model Model Model
5010X1 5010X2 5010X3 5010X6
1 Bank Assembly Alum. Ext. Alum. Ext. 316 S.S. Fixed 316 S.S. Fixed
Frame/Alum Frame/316 S.S. Frame/316 S.S. Frame/316 S.S.
Sheets Sheets Sheets Sheets
2 End Housing Aluminum Aluminum Steel 316 S.S.
3/15 Side Plate Aluminum Aluminum Steel 316 S.S.
4 Cover Plate Aluminum Aluminum Steel 316 S.S.
6 Gasket, Cover Plate Compressed Compressed Compressed Compressed
Non-Asbestos Non-Asbestos Non-Asbestos Non-Asbestos
7 Cover Tag Aluminum Aluminum Aluminum Aluminum
8 Washer Zn Pl Stl Zn Pl Stl Zn Pl Stl 304 S.S.
9 1/2” NPT Plug Zn Pl Stl Zn Pl Stl Zn Pl Stl 316 S.S.
10 Cap Screw Zn Pl Stl Zn Pl Stl Zn Pl Stl 304 S.S.
11 Gasket, Side Plate Alum. Ext. Compressed Compressed Compressed
Frame/Alum Non-Asbestos Non-Asbestos Non-Asbestos
Sheets
12 U.L. Listing Tag Aluminum - - -
13 Rear Plate Aluminum Aluminum Steel 316 SST
14 Drive Screw 18-8 SST 18-8 SST 18-8 SST 18-8 SST
Table 2 – 5010 Series, Materials of Construction

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5000/5010 SERIES FLAME ARRESTER

Air Flow (CFH) at 22°C and 14.7 PSIA may be determined as follows.

Multiply Air Flow from chart (SCFH) times the factor 1.0223.

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 VAREC

REVISIONS
REV. DESCRIPTION APPROVAL/DATE
C ECN #01-1229 S.WILLIS 8-17-01
G.SETZER 9-24-01
D.WYANT 9-24-01
D ECN #01-1807 S.WILLIS 11-28-01
G.SETZER 11-29-01
D.WYANT 11-29-01
E.TEZZO 11-29-01
E ECN #03-0590 S.WILLIS 4-10-03
D.WYANT 4-10-03
E.TEZZO 4-10-03

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DWN INSTALLATION, OPERATION & MAINTENANCE

CHK MANUAL FOR 5000/5010 SERIES
APPR FLAME ARRESTER
APPR
APPR SIZE REV.
APPR A 33-07765 E

FORM NO. 1500 REV. A 5/93