Burner Training Book

8/3/2019 Burner Training Book

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BURNER TRAINING BOOK



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Content

I. overview of the kiln .................................................................................... 3

1. Kiln Has To Be Reliable and Economical……………………………………. 32. Types of Kilns…………………………………………………………………... 3 2.1 Electric Kiln……………………………………………………………………. 3

2.2 Gas Kiln………….………………………………………………………... 4

2.3 Oil Fired Kilns………..……………………………………………………. 4

II. Burner Of Kiln ……………………………………………………………………. 5

1. Parts of kiln………………………………………………………………………….. 52. Fuel supply system……………………………………………………………. 5 3. Air system……………………………………………………………………… 9

3.1 Conbustion Fan…..………………………………………………………. 93.2 Atomizing Fan…………..……………………………………………….. 103.3 Air Valve …..………………………………………………………………12

4. Fuel system………………………………………………………………………………….…. 144.1 Ratio …….……………………………………………………………….….154.2 Fuel Fiter………………………………………………………………….…. .214.3 Three-way-valve…………………………………………………………….. 23

5. Electric system ………………………………………………………………….…...25

5.1 KEROSENE SOLENOID VALVE …………………………………………... 255.2. HIGH SENSIBILITY PROBES UV-2 SERIES …....…..………………. 265.3. IGNITION ELECTRODE 27 5.4. MICROPROCESSOR-OPERATED BURNER CONTROLDEVICE – ESA ESTRO SERIES ………………………………………..… 28

6. Setup to the burners …………………………………………………………….… 30

6.1 Preheating drying step……………………………..………………………….. 306.2 Firing step………………………………………………………………………. 30



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I. overview of the kiln

1.Kiln Has To Be Reliable and Economical

A good kiln should be able to fire ceramics up to maximum temperatures in the range of 1400˚C

and have the ability to show temperature to the accuracy of 1˚C. A temperature of 1400˚C is avery high temperature and very few metals and materials can withstand that. A good kiln has to bereliable and economical in terms of fuel cost.

2.Types of Kilns

There are electric fired kilns, gas fired kiln, wood fired kiln, oil fired kilns and coal fired kilns.Today, firing kilns with wood, coal and oil is like being an old alchemist, whilst firing kilns withelectricity and gas is like being a modern day chemist who has a great degree of control over the

end results.

2.1.Electric Kiln

kilns operated by electricity were developed in the 20th century, primarily for smaller scaleuse such as in schools, universities, and hobby centers. The atmosphere in most designs ofelectric kiln is rich in oxygen, as there is no open flame to consume oxygen molecules, howeverreducing conditions can be created with appropriate gas input

As soon as your kiln reaches the temperature of 1100˚C, every 1˚C rise in temperature requiresyour kiln to draw energy at a very high rate. Depending on the size of your kiln, you can buildtemperatures very fast up to 1100˚C using a single phase source of electricity but after 1100˚Cyou may need three phase source of electricity (today, electricity is no longer distributed using twophase alternators). The logic is that the energy needed to raise the temperature from says 1200˚Cto 1210˚C is far much mor e than the energy needed to raise temperature from 30˚C to 40˚C (thisis especially serious in gas fired kilns as the more gas you add means more cooling) – really? – yes, the rate of energy loss to the atmosphere increases more at that point and you can onlycontrol the heat loss rate only if you can increase the atmospheric pressure, which you can’t. Ifyour power source can not allow you to draw that extra power surge, then forget about reachingstoneware and porcelain temperatures. If you must use a medium to large size kilns, then youshould have electricity power supply in 3-phase, otherwise go for small sized kilns. The other bigdrawback with kiln fired with electricity is that it is a bit difficulty to create a reducing firingatmosphere – you do it by adding moth balls which can strike on electric filaments. A reducingatmosphere is the creation of an atmosphere inside the kiln that has reduced oxygen so that themetal oxides can fuse in clay in beautiful colours that you like and that you can not get in anoxidizing atmosphere.



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2.2.Gas Kiln

Gas kilns are the most popular type of fuel kilns used today. If you’re looking for a way to add awhole different dimension to your ceramic art then you’ll want to investigate gas kiln firing. With

gas firing, you can control the atmosphere your work is exposed to, which directly affects the finaloutcome of your glazes and clay bodies. Here you’ll find expert advice from ceramic artists andpotters who use gas kiln firing to add a unique dimension to their work

Gas kilns are heated by either natural gas or propane. The gas is delivered through pipelinesand travels to burners that mix the gas with air. Natural gas is often preferred when operating gaskilns, as it is safer for the environment and is easier to manipulate and disperse due to its lightweight. Many potters prefer gas kilns because they facilitate reduction firing, which allows morecolor manipulation and control over heat. Gas kilns require venting and are often installedoutdoors

2.3.Oil Fired Kilns

Oils are organic and carbon based, they burn readily. Until recently, all kilns were Oil burning;even now when we have ready access to easily fired electric kilns, many ceramists continue touse Oil-burning kilns: this kind of firing has an enduring appeal.Very simply, there are certain kindsof visual effects that can only be obtained from a fuel-burning kiln.

In updraft kilns the firebox is at the base of the kiln: the flame moves up through the ware to an

exhaust and a chimney at the top of the kiln. In kilns of the crossdraft design the flue is on the side

of the kiln - the side opposite the burners - so the heat travels through the ware and is then drawn

up the chimney. In downdraft kilns the flame begins at a firebox in front or on the sides of the firing

chamber. It is directed up over the ware and then back down again through the ware. The flame

is exhausted into an underfloor chamber and from there is drawn up the chimney. The crossdraft

and downdraft designs are the most complex and efficient: it is much easier to reach the high

temperatures required for stoneware and porcelain temperatures using kilns of the crossdraft and

downdraft type.

Most fuel-burning kilns are built by the ceramist rather than a commercial firm. To build themrequires knowledge, time, and skill. Many kilns are the result of innovative and creative thinkingand have a real impact on the life and work of the ceramist

We have two oil fired kilns from IPEG company. So we focus research anh learn about it toachieve better results when the kiln operation



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II. Burner Of Kiln

1. Parts of kiln.

- Fuel supply system: Electric pump, minimum pressure switch, pressure

gauge,filter,…. In this system, the burners aresupplied with liquid fuel, which circulates bymeans of a pushing unit made up of a pump, takingthe liquid from an auxiliary tank and sending it, ata max.pressure of 10 bar, to the kiln main manifold

- Air system : air valve (solenoi valve), combustion fan, atomizing fan,…

- Fuel system : fuel filter, solenoi valve, Ratio ……..

- Electric system : Burner control Box, Flame detector (sensibility probe UV2), IgnetionElectrode….

2. Fuel supply system

Here below are some simple remarks concerning this system.

The kerosene suction pipe must have a perfect sealing, as even the smallest airinfiltration would reduce the sucked flow rate passing through the burner system,

until annulling it.A misalignment should always be avoided; possibly the suction pipe joints should

be made through truncated-cone fittings.

The kerosene oil bottom suction valve, with relevant filter, must be positioned toavoid possible turbulences that can create possible air inlets and at a distance

from the bottom that avoids possiblecondensate water inlets as well: these bottomsshould be kept perfectly cleaned, to avoid sucking impurities.

If the pump operates with suction under pressure or closed circuit, it’s advisable

to install a lock valve on the suction pipe; if instead it operates with vacuumsuction, this valve shouldn’t used. Anyway, aperfect sealing of the stuffing box of the

lock valve should be kept, to avoid air inlets.



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TABLE OF THE FUEL SUPPLY UNIT COMPONENTS:

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

1

2

3

4

5

6

7

8

9

- degasser tank

.

.

1

- kerosene on-off ball valve

- kerosene filter

- Electric pump, capacity = 1500 l/h - 1.5 kW

- check valve

- pressure gauge with cock

- flow rate adjuster

- minimum pressure switch

- ball valve for tank gas vent

- three-way ball valve

- safety solenoid valve

- three-part joint

- grounding

Pos. 10

Pos. 11

Pos. 12

Pos. 13



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Fuel fiter



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3. Air system

3.1 Conbustion Fan

The centrifugal fan installed on the kiln with the double function of combustion andcooling air is of the high head type.

A common feature for all the fans is that the vacuum created in the central point becauseof the propeller generates an air flow entering the fan axially and exiting radially. Asmanifold for such air flow exiting the wheel a scroll diffuser is used, that is also used for a

pressure recovery, that is an increase of the fan static pressure.

The blades of this fan are “flat and reversed” and enable, with the same motor power, toreach high performance. The building structure of the used fan is directly coupled with themotor. The motor bearings are life lubricated with a remarkable grease reserve. The

labyrinth seal ring prevents the grease from being contaminated, ensuring an efficientlubrication in time.

Centrifugai fan G -pr opeller D - scroll diffusor



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3.2 Atomizing Fan



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3.3 Air Valve



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Assembly

The solenoid valve standard position is vertical (the electromagnet is vertical). The solenoid valve has a flow

direction, thus it must be fitted according to the printed instructions.

Capacity adjustment

The (min. and max.) capacity adjustment is made by the screws and lock nuts ( 19-20 and 23-24) places

at the back of the electomagnet.

It is advisable to carry out the capacity adjustment while the burner is opereting

Cleaning and maintenance

Maintenance must be caried out inside the terminal board box(11) , disassenble the letter and remove

dust and possible foreign bodies.

Grease the gears (12-13) again and reassemble the box.



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4. Fuel system



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4.1 Ratio



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TABLE OF THE COMPONENTS FOR THE OIL ADJUSTMENT UNIT

Table no. 15

The RFG adjuster is used as fuel flow proportioner in the oil modulating burners. A

pressure signal is taken from the comburent air pipe and, applied to the adjuster directlyor indirectly, defines an oil outlet pressure that is proportional and steady to the signal.

The capacity variation is obtained by the servocontrol of the combustion air valve,operated by the temperature adjuster and by the logic electric control. The direct pressuresignal can be by-passed

by a three-way valve and maxitrol adjuster(indirect type).

A constant oil pressure is required at the RFG inlet. A variation of 0.35 bar at the inlet

can cause a 2% error in flow control.

Pos.

Pos. 3

Pos.

Pos.

Pos.

Pos.

Pos.

1

2

- kerosene filter 1/4”

4

5

6

7

- flow adjuster

- Pos.

- ball valve 1/4”

-

-

-

8 - pressure gauge, scale 0-10 mbar



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The comburent air pressure, through the charging line, operates on the main diaphragm,opening the housing of the kerosene flow adjuster valve.

Air pressure from the load line forces the main diaphragm upwards opening in the outlet

chamber applies pressure on the oil piston which opposes movement of the maindiaphram and tends to close the oil outlet valve.

Since the main diaphragm has an area 30 times larger than the piston area, oil flows

from the regulator at a rate that produces an outlet oil pressure 30 times the inlet airpressure.

The regulator should be installed in a horizontal line with the adjustment stem down.The arrow cast on the valve body indicates direction of flow.

Inlet oil pressure to the regulator should be 0.7 bar higher than the maximum outlet

pressure.

A filter must be installed upstream of the regulator to prevent clogging of the valves.



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TABLE OF FLOW ADJUSTER COMPONENTS

Table no. 16

Pos. Pos.

Pos. Pos. Pos. Pos. Pos. Pos.

Pos. Pos.

Pos. Pos. Pos.

Pos. Pos.

Pos. Pos. Pos. Pos. Pos.

Pos. Pos. Pos. Pos. Pos. Pos.

Pos. Pos. Pos.

Pos. Pos.

Pos.

1

2

3

4

5

6

7

8

9

10

11 12

13

14

15

16

17

19

20

21

22 23

24

25

26

27

28

29

30

31

32

33

-

-

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-

-

- -

-

-

-

-

-

-

-

-

-

-

connecting flange

seal ring

socket head screw M6x12

bottom flanged plug

shutter housing

shutter

seal ring


diesel oil flow shutter control spring

inner diaphragm pressing device

diesel oil diaphragm outer diaphragm pressing device

flanged connecting pipe

diaphragm connecting shaft valve body



air diaphragm upper spring

air adjustment side brass disc

air side adjustment screw

spring guide pipe air side closing plug

air side plug seal ring

lower spring centering metal washer

fiber washer

upper spring centering metal washer

air side diaphragm fastening nut

galvanized platelet air side diaphragm

H.H. screw M6x30

lower cover

cork-rubber gasket

STRAI NER FILTERS WITH FIL TERING ELEMENT IN W IRE GAUZE



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Assembly, maintenance and cleaning

The flow direction, indicated by an arrow on the filter, must be respected scrupulously.The filters can be installed in any position, however we recommend to mount them invertical position, with the

cup turned downwards, in order to facilitate the separation of the water traces and thedeposit of the filtered impurities. Due to their constructive simplicity and their highreliability the filters don’t need any maintenance.

For their cleaning it is sufficient to screw out the drain plug placed under the cup.

For a more complete cleaning, screw out the screws on the cover, take away the cup,wash accurately the filtering element with gas-oil or gasoline and blow compressed airfrom inside to outside, mount the whole and control that the seals are good and in theirplace.

For the models without drain plug, remove the cup as indicate above.

For the model 70450, screw out the cup by taking it manually, clean as indicated aboveand reassemble by tightening moderately.



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4.2 Fuel Fiter



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Diagram of flow and loss of head referring to filters for gas oil and fuel oil.

The flow of the scale N. 1 referring to the viscosity 1,5 Engler degrees hasbeen got byutilizing cartridges with filtering degree of mm. 0.1

The scales N. 2 and N. 3 referring to the viscosity of 3 Engler degrees and 15 Engler

degrees have been got with cartridges having filtering degree of mm. 0.3.

All tests have been made with filters having the biggest connections foreseen fromproduction, and with filtering cartridge perfectly clean.

Eventual choices of filters with reduced connections (inlet and outlet) willinfluence negatively on the flow or loss of head; furthermore, it is opportune to bear inmind, in order to avoid of doing frequent cleanings, to size rightly the filter, according to

the type of fluid to filter.



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4.3 Three-way-valve



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TABLE OF THE COMPONENTS OF THE PILOTING UNIT FOR FLOW

Pos. 12

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

Pos.

1

2

3

4

5

6

7

8

9

- double screw ø 1/4"

- t-shaped connection ø 1/4"

- reduction M= 1/4" x F= 1/8"

- pressure inlet

- pilot solenoid valve ECT 307

- quarter connection 1/4" with hub for pipe ø 8 mm

- straight connection 1/4" with hub for pipe ø 6mm

- plug 1/4"= drill ø 1.5 mm

- reduced double screw 3/8" x 1/4"

- gas adjuster filter

- reduct. M= 3/8” x F= 1/4”

- black pipe ø 6 mm

Pos.

Pos. 10

Pos. 11



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5. Electric system

5.1 KEROSENE SOLENOID VALVE

Is a normally one-way solenoid valve with direct action. Applications as The body is of stamped

brass, the core is blued steel and the seal is synthetic rubber which is suitable for use with air, naturalgas, petrol, chlorate thinners, alcohol, light distillate oils and other fluids compatible with the above.Not suitable for use with water.



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5.2. HIGH SENSIBILITY PROBES UV-2 SERIES

FEATURES

DESCRIPTION



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5.3. IGNITION ELECTRODE



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5.4. MICROPROCESSOR-OPERATED BURNER CONTROL DEVICE – ESA ESTRO SERIES

APPLICATIONS



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Aplications.

Esaquad is designed for the management of a the directly ignited sign burner, with UV scanner or

Flame rad detaction (flame rad can even be shared with the ignition rad)

Since time and cycle can be progammed, the same device can be used to control any gas and oil burner

and meet al relevant requirement. Some application standard, wheareas others are available for

programmation by user , who can change the several funtion of the equiment to fit its application

requirements.

The front plate is equipped with a LED-bar flame signal indicator An advance self-diagnostic systemprovides the display of either the cycle status, the cause that produced shutdowns or the immediate

diagnostic of the fuilures that effect the equipment or th burner.

Remove control and supervision of the burner can be im plemented through traditional electrical

wiring, or through buit-in communication line , which provides an easy management of multiple-burner

systems featuring great simplicity and low cost. The pull-out terminal blocks allow the control device to

be easily replaced during maintenance operation.



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6. Setup to the burners

The adjustment system is pulse type (“PULSAR”) with three stages: OFF - LOW FLAME (stoichiometric

or oxidizing) - HIGH FLAME, with a reciprocal cycle by groups of individual burners or in pairs.

In the high and low flame stages, by increasing or decreasing the combustion air pressure, different

potentiality levels can be selected; spray-drying air is fixed.

6.1 Preheating drying step

The switching-on of each single burner occurs with the max. quantity of combustion airand kerosene.

Data w ith max. Capacity:

Max. combustion pressure 40-50 mm H2O

Max. direct charging air pressure 500 mm H2O

Max. kerosene pressure 1.5 bar (2.5 l/h)

After 3”, air feeding on the flow adjuster from direct into indirect, with exchange on the 3-waysolenoid valve.

The status of burners on has a min. kerosene quantity and combustion air excess, alternated with of burners and air min. flow rate.

Data with burner in air excess:

Comburent air pressure 40-50 mm H2O

Charging air pressure on the kerosene flow adjuster 150 mm H2O

Kerosene pressure 0.6 bar (1-1.5 l/h).

6.2 Firing step

The alternation of the burners occurs between one burner at max. capacity and two burners with

min. combustion air and kerosene capacity:



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Documents

Burner Training Book