Wesman Thermal

Engineering Processes Pvt Ltd

WESMAN CENTER 8 MAYFAIR ROAD KOLKATA 700019
TEL: +91 (33) 22405320, 22816406 FAX: +91 (33) 22816402, 22478050
EMAIL: combustion@wesman.com INTERNET: www.wesman.com

FUEL FIRING EQUIPMENT

OPERATION AND
MAINTENANCE MANUAL

CONTRACT NO WT-20211100009

SUPPLIED TO M/S. THERMAX LTD

ORDER NO 521013

ORDER DATE 07/10/2010

INSTALLED AT M/S. SIMHADRI POWER PVT LTD

HYDRABA GSAL PREMISES
MALLIVEEDU
SREERAMPURAM
L KOTA MONDAL
VIZIANAGARAM
ANDHRA PRADESH
 INDEX

SECTION PAGE

1. Technical Data Sheet for Boiler(s) 3

2. Specifications 4

3. List of Drawings 5

4. Operating, Installation and Maintenance Instructions 6

for the Burner

5. The Gas/Electric Igniter 9

6. Installation, Operating and Maintenance Instructions 11

for the Oil Pumping and Heating Unit

7. General Notes on Oil Firing 14

8. General Precautions for the Burner 16

9. General Care and Servicing for the Burner 17

10. General Plant Precautions 18

11. Adjusting for Efficient Combustion 19

12. Troubleshooting 20

13. List of Recommended Spares 23

CAUTION NOTICE
THIS MANUAL IS FOR THE EXCLUSIVE USE OF THE CUSTOMER (END-USER)
TO PROVIDE GUIDANCE ON OPERATION AND MAINTENANCE OF THE
EQUIPMENT SOLD BY WESMAN. CARE SHOULD BE TAKEN TO STRICTLY
ENSURE THAT THIS MANUAL IS NOT MISUSED IN ANY WAY FOR ANY
UNAUTHORIZED PURPOSE OR ACTIVITY PREJUDICIAL TO WESMAN’S INTEREST.

PAGE 2
 SECTION 1

TECHNICAL DATA SHEET FOR BOILER(S)

Type of boiler FLUIDISED BED BOILER
Number of boilers 1 (One)
Evaporation capacity at MRC 210 Ton/Hr.
Evaporation capacity at peak load Not specified
2
Steam pressure at SH outlet 86 Kg./Cm
Steam temperature 515 ± 5º C
Feed water temperature Not specified
Combustion air temperature Not specified
Ambient temperature Not specified
Combustion air temperature Not specified
Location of Burner Rear wall of the Boiler at an
elevation of about 1950 MM from
Bed floor.

Register draught loss at MCR 195 MM WG

Fuel data Light Diesel Oil
Number of Start Up Burners per boiler 3 (Three)
Burner capacity 1500 Kg./Hr.
Fuel pressure at Burner 12 Kg/Cm2
Fuel temperature at Burner Ambient
Compressed air/steam pressure at Burner 5 – 7 Kg/Cm2
Compressed air pressure for pneumatic 80-100 psi
cylinders
Excess air at burner 10%
Estimated flame length 4 Meter
Estimated flame diameter 1.5 Meter
Electric supply 230 V AC, 50 HZ

PAGE 3
 SECTION 2

SPECIFICATIONS

ONE SET OF COMBUSTION EQUIPMENT CONSISTING OF :

_____3 Nos.____ Wesman ___D-455_ __ compressed air atomized

assisted pressure jet burners, each having a capacity of ___1500 Kg/Hr___

at ____15 Kg/Cm2____ while operating at register draught loss

of ____195 MM WG____ with _____10_______% excess air.

START-UP DESIGN DATA:

Oil pressure _____170_____ psig and temperature _ Ambient

at the burner inlet with 1500 Seconds Redwood-I Oil

Each sprayer is arranged for automatic operation.

OIL PUMPING UNIT

To supply oil to the Burners at the desired pressure ok. It is essential that a
positive pressure is maintained at the inlet of the Pumps.

PAGE 4
 SECTION 3

LIST OF DRAWINGS

WH-D-4345 (R1) - P & I Diagram

(Sheet 1 of 2 to sheet 2 of 2)

WT-PH-1763 (R1) - General Arrangement of Duplex Oil Pumping Unit

WT-PH-1764 (R0) - General Arrangement of Control Valve Train

WT-SK-1765 (R0) - General Arrangement of Valve Station

WT-PJ-8645 (R1) - General Arrangement of modified D-455 Burner for

(Sheet 1 of 2) Start Up

WT-PJ-8645 (R1) - General Arrangement of modified D-455 Burner for

(Sheet 2 of 2) Start Up

WT-SK-1817 (R5) - Layout for atomizing air, LPG and oil pipeline
(Sheet 1 of 2 to sheet 2 of 2)

WT-PH-1776 (R1) - General Arrangement of Unloading Pump Station

WT-SK-1694 (R2) - General Arrangement of Service Tank

(Capacity = 35 KL)

PAGE 5
 SECTION 4

OPERATING, INSTALLATION AND MAINTENANCE

INSTRUCTIONS FOR HIGH PRESSURE BURNERS
Please read the complete instructions carefully.

PRELIMINARY:
Use firebrick of suitable quality and provide expansion joints in the furnace brickwork
Install any number registers in correct position
Check depth of windbox (if any), also piping and furnace arrangement against burner drawings
Avoid unnecessary obstructions to air flow in windboxes
Do not twist hose in installing — it will leak
Clear boiler and breaching of soot and ash
Lock dampers securely on shafts and provide stops
Check and mark direction of damper opening
Check dampers for operation and full travel
Install sensitive and convenient fuel and air controls at furnace front
Pack scruffing boxes of strainers, valves and pumps
Test all fuel piping under pressure and suction piping under vacuum
Flush piping of scale, dirt and pipe compound
Tightly seal against air leakage the setting, breaching and access, inspection tube and stack clean-
out door
Dry out brickwork with slow wood fire
Do not lag piping until the plant has operated for several days — there may be leaks
If practicable, fix mirror to reflect stack top to detect smoke

CARE OF EQUIPMENT:

Clean burner guns at regular intervals

(Hard carbon in burner guns indicates improper assembly or operation)
Use copper wire for cleaning tips — never use steel
Keep tips, plugs and cap nuts in good condition — discard badly worn or damaged parts
Use only clean components in burner gun
Assemble tip and plug tightly
Remove dead burner gun from register immediately
Replace hot burner gun in paraffin immediately on removal from air register
Keep foreign matter off registers, diffusers and throat
Keep burner blocks in good state of repair
Do not alter Burner blocks contour
Maintain equipment tight against air leakages
Keep flue gas sampling lines tight
Check CO2 meters regularly with an Orsat
Keep heaters free of air and condensate
Clean strainers regularly

PAGE 6
STARTING-UP PRELIMINARY:
Ensure automatic valves are bypassed
Ensure all individual burner valves are shut
Allow for variation in temperature for different batches of fuel
Check suction piping for leaks if service pump loses suction
Throttle circulating valve and check pump pressure
Close circulating valve
Wipe coupling faces clean
Ensure damper is open and there is adequate air flow
Turn fans over slowly
Clear furnace of gases — allow air to flow through furnace
Notify proper authorities of “lighting up”

LIGHTING UP:
Assemble burner gun with all clean parts and tip of correct size
Install burner gun in register
Couple burner gun to pipes
Prepare lighting torch over burner tip
Ensure no one is in the setting or looking through the furnace peephole
If a large torch flame is blown out, reduce draught
Open oil supply valve slowly
If the coupling leaks, shut off oil — wipe coupling faces
If spray does not ignite and stay ignited after torch is removed, shut off oil, remove the burner gun,
insert clean burner gun, clear furnace of gases and repeat “Lighting Up” procedure
When fire is lighted, regulate with burner supply valve until flame is steady, then open burner valves
WIDE
Control fuel and air with master controls, if provided
Increase air flow and furnace draught before lighting additional burners
Adjust fuel control to maintain capacity of burners in service as another burner is being lighted
Use a torch for lighting each burner
Light and adjust additional burners using burner guns with same size of tip and plug as those in
operation

ALWAYS USE A TORCH TO LIGHT A BURNER — NEVER FROM HOT BRICKWORK

OPERATION:
Use a torch for lighting each burner
Adjust oil pressure to compensate if larger or smaller tips are inserted
(straight mechanical burners)
Ensure correct size of tips are employed
Change tips one at a time
Use excess air when lighting burners on increasing loads
With forced draught increase furnace draught first then increase forced draught for more air but not
sufficiently to produce a positive furnace pressure
For forced draught installations keep furnace draught at all loads at about one-tenth of an inch
negative at furnace top
If furnaces with air-cooled walls, keep furnace draught negative to air-lanes win walls
Remember high excess air at very low loads chills the flame
Prevent air leaking into the setting; all useful air should pass through the burner. If black smoke
2 2 2
issues from stack, even with low CO in the last pass, check, CO in first pass. If CO in the first pass
2 2
is over ½% higher than CO in lass pass, leaks must be plugged. Last pass CO along means
nothing if the setting leaks.

PAGE 7
 FLAME APPEARANCE:
VERY SMOKY — insufficient air through burners
SMOOTH LIGHT SMOKE WISPS ON ENDS — about right
RAGGED SPARKS - toom much air, oil too hot, as in fuel

PULSATION:
Generally due to incomplete combustion caused by:
Not enough air through burners
Oil much too hot
Burner tip too far in throat — Improper mixture of air and oil
Pulsating draught due to wind loose damper or fan hunting

SMOKE:
LIGHT BROWN — from stack — is correct
HEAVY WHITE — too much air
BLACK — incomplete combustion
o With high uptake CO² — air deficiency — any burner
o With low uptake CO² — setting leakage i.e. air deficiency through burners
o Not same size tip in all burners
o Worn tip or plug in any burner
o Dirty burner gun
o Component missing from atomizing end of burner gun
o Cap nut not properly tightened
o Burner gun too far out — spray striking throat or diffuser
o Burner gun too far in — poor mixture of oil and air
o Fluctuating oil pressure — this must be steady
o Oil too cold — too high viscosity
o Windbox depth too great creating a large space between air register and throat
o Air pressure uneven in windbox

BLOWING SOOT:
Always increase furnace draught before blowing
Blow at fairly high load
Never blow with burners shut off

SHUTTING DOWN:
Close burner valves — supply valve first
Blow through burner gun with air or steam (if connections available)
Withdraw and remove burner gun immediately.
NEVER LEAVE A DEAD BURNER GUN IN THE REGISTER
Close air register door
Wipe oil off hot burner gun ; place tip end in paraffin
Swab oil out of diffuser pipe
Repeat procedure with other burners
Shut down fans
Leave uptake damper open slightly until furnace clears
Then close uptake damper

DO NOT ALLOW AIR TO FLOW FREELY THROUGH THE HOT FURNACE OTHERWISE THE
FURNACE BRICKWORK AND BURNER TILL WILL SPALL

PAGE 8
 SECTION 5

THE GAS / ELECTRIC IGNITER

IGNITER HEAD
The design of the igniter head is such that it can be used on igniters requiring internal or
external air supplies, i.e. taking air from the windcasing through hotels in its outer tube or a
separate supply from a compressed air line. This supply is normally piped to the port in which
the plug is located. For this contact air is to be supplied at approximately 3 psig. The
consumption is approximately 3 scfm.

The gas enters the assembly through a 1/2” O/D pipe. On entering the igniter head the gas
splits between the main and pilot gas tubes. The amount to which this gas supply splits
depends on the setting of the pilot gas supply valve. This valve is fitted into the igniter head
and once it is set it should be locked in position with the locknut provided. FOR PROPANE OR
BOTTLED GAS, THE PRESSURE SHOULD BE ADJUSTED TO ABOUT 15-20 PSIG.

IGNITER TUBE
Air for the igniter enters through a port provided for this purpose. The Igniter itself is in the form
of a tube containing the pilot and main gas tubes, and an electrode, which when energized
ignites the gas. An HT spark ignites the pilot gas supply across the tube. This gap is set to
1/16”. The pilot gas flame thus established, remains stable by virtue of the stabilizing tube
which allows air pass into it from its rear. The external compressed air supply is maintained all
the time, keeping the igniter tip and the tube cool and ensuring longer life.

The main gas supply passes down the tube, emerging at a suitable point where ignition is
readily obtained via the pilot flame.

SPARK PLUG ASSEMBLY

The spark plug assembly consists of a central electrode insulated over its full length by a
ceramic sleeve. The connection to the electrode from the transformer is by a special cable. IT
IS VERY IMPORTANT THAT THIS IGNITER IS HANDLED WITH GREAT CARE AT ALL
TIMES. If the ceramic sleeve is damaged the HT could short to one of the tubes thus
preventing the gas from being ignited.

IGNITION TRANSFORMER
The ignition transformer is continuously rated and has a single HT terminal. The input voltage
is 220/110 volts, 50Hz AC and the output is 10 KV approximately. The igniter is held in position
by a flange bolted to the back cover of the burner box.

CONTROL VALVE
It is recommended that the gas supply be fitted with an adjustable governor control valve
together with a pressure gauge downstream of the governor control valve. It is necessary to
adjust the gas pressure in relation to the draught loss through the burner even though the
design of the igniter enables it to be lit up under the influence of full air pressure.

The gas/air mixture rather critical as propane and other similar gases have a fairly low limit of
inflammability.

PAGE 9
 START PUSHBUTTON
A push button or automatic sequence switches on the high-energy igniter and opens a gas
solenoid valve to admit gas. The gas flame and high-energy discharge will continue while the
push button is depressed or until it is sequenced out automatically. Ensure that the electric
supply to the transformer is earthed.

OPERATION OF MANUALLY OPERATED IGNITER:

Ensure that the gas supply is available at the required pressure. Also check if, when using external
compressed air, air is available at the required pressure. Check the connections to the solenoid valve
and high energy ignition transformer.

BEFORE STARTING AN IGNITER IN A FURNACE ENSURE THAT NO ONE IS IN THE

FURNACE AND THAT THE FURNACE HAS BEEN PROPERLY PURGED.

Open the gas supply to the solenoid valve and press the igniter push button. The solenoid valve will
open and the gas will flow to the igniter. The HT transformer will energize simultaneously and spark will
be produced igniting gas. Open the oil valve to the burner. The burner will flash and fire.

If the main flame is not established in a few seconds, shut off the main fuel valve and purge the
combustion chamber. Purge the burner and while doing so press the igniter start button if not
automatically sequenced. Purge the burner for about 40 seconds. After this purging the combustion
chamber should be purged again.

Explore why the burner did not light up. Some of the reasons this could be due to are :

low oil pressure

too much draught
choked tips
atomizing air not available

Then re-light the burner.

The reason for bringing in the igniter during burner purging is that no unburned fuel should be in the
combustion chamber as to avoid explosions.

PAGE 10
 SECTION 6

INSTALLATION, OPERATING AND MAINTENANCE

INSTRUCTIONS FOR OIL PUMPING AND HEATING UNIT

DESCRIPTION OF DUPLEX OIL PUMPING AND HEATING UNIT

The major components that go to make up the pumping unit are :

2 x motorized rotary triple screw oil pumps mounted on m.s.fabricated base plate. The
motor is suitable for operation on 415 ± 5% volts, 3-phase, 50 Hz AC supply.

Filter located on the suction side of the pump.

Diaphragm operated Pressure Regulating Valve

4 X 60 KW Vertical Type Electric Heater

Diaphragm operated Pressure Regulating Valve with bypass assembly

located in the return oil line

Dial type Oil Pressure Gauge and Digital Temperature Indicator

Interconnecting pipe work with connecting flanges

ο From oil service tank to pump suction
ο For connection to ring main or burners
Drip trays are provided. In general all components are supplied with interconnecting piping work.

INSTALLATION OF OIL PUMPING AND HEATING UNIT

The pump is the heart of the pumping unit and therefore, before installing the unit, must be aligned
properly. The pump is aligned and coupled to the motor mounted on the base plate when supplied from
our factory. However, it is possible that in transit the alignment may be disturbed. Before installing the
pumping unit, therefore, the alignment of the pump should be carefully checked. In correctly aligned
pump, the shaft will be easily rotatable by hand. After alignment of the pump has been checked, the
pumping unit is ready for installation on the concrete bed.
The foundation bed should be allowed to set and dry thoroughly before the unit is placed in position.
The base frame should be aligned with the help of a spirit level and if necessary, shims should be
placed under the base frame. After aligning, the base should be grouted with quick setting cement
fixture.

PIPELINES :
SUCTION LINE FROM SERVICE TANK
Reliable operation of the pump depends largely on the correct installation of the suction line from the oil
service tank. It is essential that this be absolutely leak proof and installed in such a way as to prevent
the formation of their air pockets. A globe valve should be installed between the tank and the pump
suction and this valve must be kept fully open during operation.

PAGE 11
 DELIVERY LINE TO THE RING MAIN AND RETURN FROM THE RING MAIN
These lines should also be leak proof. A globe valve or gate valve should be installed in both
delivery line to the ring main and return line from ring main.

While connecting the pipeline, no undue force should be used. Failure to observe this is likely to
damage the pump. It is also important to flush the lines before putting into use.

Pipe bends should be used wherever necessary, the use of elbows and sudden changes of cross
section and directions should be always avoided. care should be taken to ensure that the gaskets
between flanges do not project into the bore of the pipe.

It must also be ensured that the globe valve is correctly positioned with arrow on its body pointing in the
direction of flow.

STARTING-UP PRELIMINARY
After the pumping unit has been correctly installed and pipe connections made, the unit is now ready for putting
into operation. The flowing checks should, however, be carried out before starting:

The pump shaft rotates easily and freely by hand

After thoroughly satisfying yourself about the alignment of the pump and also about the correctness of
electrical connections, the unit can now be put into operation. Before starting the unit, Operating and
Installation Instructions should be read.

STARTING-UP
The following procedure is to be followed to start the unit:

The globe valve between the service tank and pump is to be “fully opened”
Prime the suction strainer, releasing the captive air.
The glove valves to the ring main as well as in the return line from the ring main are also to
be kept fully open.
The power supply to pump can now be switched on. Observe that pump rotates in the
correct direction as indicated by arrow. As soon as the pump is switched on the pressure
gauge would indicate the pressure that is being developed. The required pressure of 250
p.s.i. can be set by adjusting the nut on the pressure regulating valve. It may be found
necessary to release any trapped air in the oil lines which should be released from the valve
provided for this purpose.
The isolating valve in the return line should now be closed.
Open oil valve to one burner and fire the burner

SHUTTING DOWN:
The following procedure is to be adopted while shutting down the pumping unit:

Close the isolating valves located in the branch lines to the burners.
After about 5 minutes interval, switch off the pump
Close the globe valves in the pump suction line and ring main lines

PAGE 12
MAINTENANCE:
Trouble-free performance of the unit depends on intelligent servicing and an understanding of the
various parts that make the complete unit. No special maintenance is required, but regular checks and
cleaning of the filter elements, especially the cold oil filter element will ensure trouble free service.

MOTOR BEARINGS
The greatest cause of bearing failure in motor is over-greasing rather than under-greasing.
The bearings are packed with grease by the manufacturers and will operate for at least one
year without needing re-lubrication. If they are fitted with grease feedings, they can be re-
lubricated at six-month intervals.

Most motors have a relief plug located on opposite side of the grease feeding. This plug
should be removed to allow excess grease to be expelled during lubrication to prevent
overpacking. Some motors’ bearings are totally enclosed without any provision for re-
lubrication to prevent over-greasing.

Such bearings should be repacked with grease every year by removing the bearing cap and
wiping out the grease entirely. The bearings should not be fully packed with grease, if the
bearing chamber is completely filled, over-heating will occur.

Some of the greases used are:

Shell multi-purpose or Alvina No.3 grease by Burmah Shell
Esso multi purpose grease grade “H”
Mobilus No.3 by Indian Oil Corporation Limited.

PAGE 13
 SECTION 7

GENERAL NOTES ON OIL FIRING

INTRODUCTION
In a set of Operating Instructions it is useful to discuss oil firing in general terms, in order that a better
appreciation can perhaps be made of the functions of various items of equipment and also to allow a
better understanding of why certain points are considered to be so very important.

NOTES ON FUEL:
Fortunately, for the oil burner designed, oil is a fairly standard fuel, its specific gravity and
calorific value and ash content only vary within fairly narrow limits, when compared with coal.
Oil is sold generally on a basis of viscosity -- i.e. the higher the viscosity, the cheaper the fuel.
The temperature / viscosity chart illustrates that the range of viscosities that are generally
available, and also shows the increased temperature to which the more viscous grades of oil
must be heated in order to reach satisfactory atomizing viscosity, which for steam atomized
burner is 100 seconds, Redwood No.1.

THE REASON FOR ATOMISATION:

It is very important to realize that the reaction between oil and air which we call burning, can
only occur in the vapor phase. That is to say that the oil must vaporize from the surface of the
droplet, and mix with air before it can burn. If we imagine a single drop of burning oil, (see
below) the drop is heated because of the radiation of the flame and its outer skin will be
evaporating.

DIAGRAMATIC PICTURE OF BURNING DROP

The vapor so formed, mixes with air which has diffused through the flame front and the flame
front is established where the mixture ration between the oil vapor and the air is in the correct
ration of approximately 14:1 of air to fuel by weight. It is obvious, therefore, that a pre-requisite
of rapid combustion is to expose as large a surface of the oil as is possible. This is achieved
by splitting the oil into very small droplets. The process is known as atomization.

Immediately the question arises as to what size droplets are needed for good combustion. It is
generally accepted that a droplet diameter of less than 120 microns is necessary (1 micron =
10'6 cms). Since in any spray of oil all the droplets are not the same size an arbitrary definition
of droplet size is used. This is known as the Sauter Mean Diameter (S.M.D) which is defined
as the diameter of droplet which has the same mean volume to surface area ratio as the spray
as a whole. The significance of the Sauter Mean Diameter will become apparent when
pressure jet atomizers are discussed.

AIR REGISTERS:
When considering an oil burner it is convenient to divide the burner into two components — both
equally important. One is the register, and the other is the atomizer. The function of the latter, as
we have seen previously, is to break up the oil into a condition in which it can be burned. The
function of the register is twofold; one is to ensure that the flame is stable, and the other is to
ensure the air mixes intimately with the oil so as to promote rapid and complete burning in the
space available in the combustion chamber.

PAGE 14
Dealing firstly with the problem of stability, it must be remembered the flame speeds are generally
low 200-300 ft./min. even for highly turbulent gas flames — and the effective flame speed of an oil
droplet/air mixture will be less than this. The forward air speed from a register, working at say
4”WG is about 8,000 ft /min. and it is necessary therefore, to reduce the forward velocity at some
local point so that it is less than the flame speed to ensure that the flame can anchor on to this
point. All of them operate by forcing the air to form a reversal. The reverse flow carries some
small proportion of the burning gases back to the root of the flame, so providing a continuous
source of ignition.

The simplest method uses a flat baffle or cone. These are still used on many registers today. The
disadvantage is that, in forming the reversal, the burning gases also carry burning droplets of oil
and if these impinge on the baffle then carbon can be built up on the stabilizer. Attempts are made
to avoid this problem by serrating the baffle by drilling holes or cutting slots. This is a difficult
operation because when so doing, the baffle becomes less effective as a stabilizer. There are
many designs on the market, some successful, some not. Another problem is to prevent the
stabilizer from burning away when it is exposed to direct radiation from the flame.

A further type of stabilizer, used extensively, is the axial swirler. It does not normally suffer from
carbon build-up because it is totally serrated. It can, however, be damaged by back radiation
especially if it is left in position in a register which is shut down whilst other burners are running.

The above methods of stabilizing are used essentially with pressure jet, or steam atomizing
burners.

The points to watch for in this part of the design are therefore:

It must provide stability over all parts of the range

The flame shape must be such that no carbon built-up takes place anywhere

The other function of the register is to mix the air intimately with the fuel.

It is necessary to impart a sufficiently high velocity to the air so that the turbulence produced will
scrub surface of the droplets. This removes the oil vapor and exposes fresh surfaces from which
oil can evaporate, mix with the air and burn. This high air velocity is useless unless the air is
directed in the spray of oil. The air velocity is obtained by converting pressure energy into kinetic
energy. This gives rise to the pressure drop through the register. It must be remembered,
however, that this pressure drop through the register governs the horsepower of the fan and this
must not be unreasonably high. It is difficult to lay down hard and fast rules as to what pressure
drop should be used in any particular case. It happens very frequently that the pressure drop is
fixed by the turndown on the burner. For example, if a 2:1 turndown is required, then 4:1 variation
in P.D. will be involved, if one assumes that a reasonable minimum is 1/2” WG then top load will
automatically give a 2” P.D. and this would be perfectly satisfactory for a register burning, say, 500
lbs per hour of oil at the maximum condition. However, if, maximum were 5,000 lbs an hour per
register then this pressure would be insufficient. Something in the region of 8-10” WG would be
required, if complete combustion were to be obtained in a reasonable length of flame.

It can be clearly seen that the pressure drop through register affects the air velocity and hence the
degree of mixing of the air with the oil. This in turn determines the combustion intensity of the
flame i.e. the volume of the flame needed to burn a certain amount of oil, this being frequently
expressed in B.T.U/ft.³.

PAGE 15
 SECTION 8

GENERAL PRECAUTIONS FOR THE BURNER

To obtain maximum burner safety and efficiency the following points are emphasized:

Do not attempt to light burners hot brickwork.

Keep the complete burner installation free from accumulation of fuel oil bur remedying any
slight fuel oil leak.

Keep the atomizing tips in perfect condition. clean them, immediately the sprayer is removed
from the burner, with paraffin and nothing harder than soft copper wire. The atomizing tip is
manufactured to close tolerances and the knife edged orifice will be damaged if steel wire is
used for cleaning.

Protect the atomizer seat face, by keeping an atomizing tip screwed on to the sprayer, when
removed from the furnace. This face has to mate perfectly on the inner face of the atomizer
tip. Damage to the surface will mean that the fuel oil bypasses the grooves and the resulting
atomization will be poor with consequent bad combustion.

It is better to steam the boiler with a small size atomizer tip at maximum oil pressure than to
use a single large atomizer tip at a lower pressure.

Keep the fuel oil temperature correct of the grade of fuel used. The chart in the Appendix is a
guide to the correct atomizing temperature and it will be seen that the best range of
atomization lies in the part of the graph between 70 to 100 Seconds Redwood No.1 The
former for air at ambient temperatures, and the latter when pre-heated combustion air is
used.

Purge each burner register with some quantity of air. This will keep them cool.

Always operate with the burner air and oil supply values fully opened. Each burner will then
be carrying the same load.

PAGE 16
 SECTION 9

GENERAL CARE AND SERVICING FOR THE BURNER

Cleaning and servicing of the burner and associate parts should be carried out regularly. It is
far easier to clean a small amount of oil spillage as it happens than to leave it to go hard.

Periodic checks should be made to see that all the connections are still air tight and that the
signal air valves etc are being kept clean and in sound working order.

The cylinder rod and the plungers, along with the bearings for the moving parts, should have
a very slight amount of high temperature grease applied to them.

When it is required to remove this burner, the following sequence of events should be
carried out:

o Shut the oil and air hand isolating valves

o Isolate the burner electrical equipment
o Disconnect the flexible coupling and remove the sprayer
o Remove the safety locking device complete with the union half of the coupling
o Disconnect all the supply pipes to and from the bulkhead connections

NOTE: To re-assemble the burner take the above stages in the reverse order. Minor
repairs can be carried out without removing the burner from register, but make sure that all
the systems are ISOLATED prior to work commencing.

As mentioned previously in these notes items as the transformer cannot be serviced. Should
a fault develop on them, they should be replaced and the faulty items sent back to the
makers.

The sprayer assemblies should be kept very clean. If they are not purged, they should be left
to drain and then washed out with paraffin. The sprayer assembly should be properly stored
and great care must be taken not to damage the atomizer end. A cap nut with or without
atomizer should be fitted after cleaning.

It is customary to supply the burner sets with spare sprayers, thus allowing rapid changeover
for dirty units. The sprayer rack and vice, together with a special spanner to facilitate proper
storage and handling, when changing atomizers should be provided.

The igniter is a simple device but care should be taken to ensure that the spark plug gap is
not incorrect. This gap should be between 1/16” and 3/32”. The igniter should be checked
periodically to ensure that the electrode points and the pilot nozzle are clean and free from
carbon or dust build ups. Always handle the igniter with great care as a crack in the spark
plug insulation could result in the spark shorting and thus the ignition flame would not be
established. The filter in the gas supply head is to protect the pilot nozzle from dirt in the
supply. The ' life'of this filter depends entirely on the state of the gas supply. Initially these will
require frequent changing due to the internal pipe scale etc. but once this has been removed
the filter should last for a considerable time.

PAGE 17
 SECTION 10

GENERAL PLANT PRECAUTIONS

Should any joint or piece of equipment leak, rectify it as soon as possible. A small amount of oil in an
incorrect place can cause a lot of damage.

Ensure that all relief valves and instruments are set at, or calibrated to, the correct pressure.

Lubrication of moving parts should be carried out as stated by the makers. This information can be
found from the attached leaflets.

Inspect all electrical contacts at regular intervals and adjust as necessary.

Prior to any work being carried out on an item isolate the supplies to it.

The burner damper air door is for ON/OFF operation. Do not attempt to adjust the air pressure with it.
Use the main fan dampers.

Always isolate the item of equipment on which work has to be carried out.

PAGE 18
 SECTION 11

ADJUSTING FOR EFFICIENT COMBUSTION

Final adjustments to give efficient combustion should be made after several days of experience on
firing the installation. In adjusting, CO² and excess air recorders should be used along with the following
rule of thumb.

Adjust the fire to a maximum for the load required.

Do not attempt to carry too small a minimum fire.

Adjust oil/air mixture to give a light gray haze at the top of the stack.

Do not run a smoky fire in an attempt to get highest possible CO² reading. The soot formed
will more than off-set the higher combustion efficiency by loss of heat transfer and cost of
boiler cleaning.

Seal all places in the boiler into which air can leak.

Use the maximum amount of air at both high and low fire to prevent the oil from impinging on
the PF burner.

NOTE: When lighting burners the procedure set out above should always be followed

Never attempt to light one burner from another

Always remember when lighting up, a small error can cause a great amount of damage.

PAGE 19
 SECTION 12

TROUBLESHOOTING YOUR EQUIPMENT

BURNER WILL NOT LIGHT
Fault Ignition — no gas flame
Gas turned off or low gas pressure
Gas solenoid valve not opening
Filter in igniter head completely blocked
Disconnected or defective ignition transformer
Faulty insulation on HT cable (check voltage at transformer primary terminals)
Worn out electrode or ignition plug
Damaged insulation on igniter spark plug
Insufficient air to gas ration causing point to soot up
Selector switch not selected for gas
Incorrect air/oil ratio
Oil supply failed
Oil supply hand isolating valve shut
Draught too high
Water in Oil
No oil pressure — pumps not working
Faulty oil valves
Oil filters choked

BURNER STARTS BUT LOCKS OUT

Photocell not supplying amplifier with signal to operate relay due to
Obscured with soot
Cell worn out or damaged by excessive heat
Polarity of connection reversed
Open circuit between cell and amplifier
Oil supply fails due to leak in supply lines
No oil in tank
Broken flexible oil pipe to burner
Faulty damper
Loose connections (electrical) producing temporary open circuit conditions

BURNER GOES OUT WHILE IN OPERATION

Out of fuel oil
Strainers dirty or clogged
Clogged metering or pressure maintaining valves
Clogged piping or faulty supply valve
Water in the fuel oil
Leak in supply pipes
Oil too cold
Fire burning away from atomizer
Unstable flame condition causing photo electrical cell to fail in registering flame

PAGE 20
BURNER WILL NOT SHUT OFF
Supply valves stuck open
Installation incorrectly connected
Pneumatic valves not closing

BURNER STARTS BUT CONTINUALLY GOES OFF

Faulty flame failure equipment
Faulty magnetic valves
Faulty control valves
Faulty pumps
Faulty pneumatic control valves
Loose electrical connections
Faulty pressure and temperature regulating valves

FIRE PUFFS ON START

Air in windbox at incorrect pressure
Worn atomizer
Lean fire
Insufficient gas pilot flame resulting in poor igniter flame
Water in oil
Oil fuel pressure incorrect

IMPROPER COMBUSTION
Fire puffs or fluctuates:
Fire burning away from atomizer
Poor draught
Water in oil
Unsteady oil pressure
Atomizer not properly located
Carbon in combustion chamber
Wrong shaped fire
Forcing the burner
Damaged atomizer
Lapped faces on atomizer not sealing
Atomizer not properly located
Carbonized atomizer
Boiler house starved of air
Fire smoking
Improper burner adjustment
Insufficient air
Too much fuel oil
Carbon around burner tip
Lean fire burning at low fuel pressure

CANNOT CARRY MAXIMUM LOAD

Oil pressure failing
Draught limiting maximum fire
Incorrect atomizer tips being used for type of load required
Burner too small
Damaged pumps, oil bypassing back to pump section
Faulty coupling

PAGE 21
OIL PRESSURE UNSTEADY OR FAILS
Tank empty
Strainer baskets dirty
Air leakage
Oil draining back to return lines
Relief valves not seating
Faulty pump
Suction lines or connections leaking
Delivery lines or connections leaking
Incorrectly sized piping
Fuel oil too cold
Air blockage in pipes
Pump cavitating (air bound)
Valves leaking at glands

FUSES BLOW REGULARLY

Fuses replaced with incorrect gauge of wire
Fuses replaced with incorrect fuse cartridge
Intermittent earthing fault
Motors being overloaded
Solenoid coils overloading
Faulty micro switches
Broken wiring
Faulty sequence timer
Faulty ignition transformer
Broken contacts on relays

NOISES
Roaring fire — Air velocity too high
Frying — caused by water in the oil striking
Lack of lubrication to moving parts

OIL LEAKS
From furnace front
Atomizer does not extend the correct distance
From combustion chamber
Carbon buildup on burner mouth
Poor atomization
The oil valves do not shut off tightly as soon as the burner is shut down

PAGE 22
 SECTION 13

RECOMMENDED LIST OF SPARES FOR

TWO YEARS TROUBLE FREE MAINTENANCE

BURNERS
— Atomizing Gun with air swirler and cap nut
— Atomizing tips
— Diffusers
— Flexible oil pipes
— Flexible air pipes
— Air pressure gauge
— Oil pressure gauge

FLAME FAILURE SYSTEM

— U V Photocell
— U V Amplifier
— Fuel Solenoid Valve

GAS IGNITION SYSTEM

— Spark plug electrode

— Transformer 220 V AC / 10,000 V
— 1/4” Solenoid Valve (110 V AC)

* * * *

PAGE 23