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MANUAL
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START-UP BURNER AND FIRING SYSTEM
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START-UP BURNER AND FIRING SYSTEM
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START-UP BURNER AND FIRING SYSTEM
• Keep the surrounding area of the firing system and its associated
equipment clear of debris, dust and rubbish.
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• Due to the nature of the product, local high temperatures (hot spots) in
the direct vicinity of the burner unit are unavoidable. Plant operators
shall be aware of this and ensure protective measures for operation.
Piping systems for fuels and auxiliary media together with their associated
valves and flange connections have to be checked daily for tightness by
suitable methods.
Any identified defects have to be corrected as soon as possible.
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- Check valves and piping system of gaseous fuels for tightness (visual
check and test with soap sud).
- Check valves and piping systems of fuels, purging media and auxiliary
media for tightness.
- Checking flame detection system (remove unit and check flame with a
flame of a lighter for example). There must result a signal at the flame
detector;
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Directly upstream the swivel mount the sighting tube can be manually
isolated by a ball valve. The flame monitor is also equipped with connec-
tions for cooling air (which also acts as purge air) to avoid rough contami-
nation and excessive heat from the furnace.
- The optics (lens) of the flame monitor should be regularly checked (e.g.
every 4 weeks) for dust and debris and cleaned when necessary. If the
outside of the lens regularly accumulate deposits, the purge air flow
should be adjusted to alleviate this problem.
- Remove deposits with oil-free compressed air or a soft lint free cloth
(optical cleaning cloth or microfibre cloth) and if necessary with water
and alcohol.
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Danger!
The firing system must have been put out of operation prior
to start any maintenance work at the flame monitor!
Danger!
High voltage. Danger of fatalities due to electrical current!
Coming into contact with live parts poses a direct risk of fatalities.
- Before removing the casing or guard, check that the devices are
deenergised.
Caution!
Danger of burns due to hot surfaces or hot gases!
- Take care when touching the flame monitor. It might be warm. If
necessary, use heat protection gloves.
- Pay attention of hot gases, coming out of the sighting tube.
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For details of maintenance of the flame monitor with scanner refer to the
manufacturer’s instructions in the DURAG manual “D-LX 100 All-In-One
Flame Scanner”, assorted in Vol. C 5, Reg. 03-2_item no. 0111.
C 2.2 Ignitor
Each burner is equipped with 1 fully electric ignitior, consisting of a high
energy ignition device with separate lance.
For protection of the lance against excessive thermal stress after igniting
the diesel / air mixture, it will be retracted from the combustion zone by a
pneumatic cylinder.
The lance is furthermore mounted into a guide tube which can be manually
isolated by a ball valve. This enables removing of the lance for mainte-
nance work even under diesel oil firing conditions.
The ignitor should be inspected at regular intervals, e. g. every 3 months,
or more frequently depending on local operating conditions.
- Check cables for correct fit, ageing and wear. The same applies to any
plug connections. Have porous cables, defective insulation or plug con-
nectors replaced immediately by original spare parts.
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- Check for deformation and damage to the housing and reliable fitting of
the devices on the assembly panel or flange.
- Check the device for dirt. If there is contamination due to high relative
humidity or sticky dust, the device is to be cleaned from outside with a
(damp) cloth or with compressed air. Cleaning is then to be repeated at
regular intervals.
The ignition tip is subject to natural wear. Under operating conditions, this
can result in a service life from several months to several years.
Danger!
Fatal danger due to high voltage!
The high energy ignition device contains capacitors whose dis-
charge time is a minimum of 60 seconds. Only then can work be
carried out safely on the device and ignition tip (in the Ex zone wait
at least 5 minutes due to possible spark generation). Check the
device has been de-energised.
Caution!
Danger of burns due to hot surfaces or hot gases!
- Take care when touching the ignition lance. It might be warm. If
necessary, use heat protection gloves.
- Pay attention of hot air, coming out of the guide tube.
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The lance is furthermore mounted into a diffuser tube which can be manu-
ally isolated by a ball valve.
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Danger!
The firing system must have been put out of operation prior
to removing of the oil lance!
Caution!
Danger of burns due to hot surfaces or hot gases!
- Take care when touching the oil lance. It might be warm.
If necessary, use heat protection gloves.
- Pay attention of hot gases, coming out of the diffuser tube.
Note: Prior to maintenance, stop burner operation and apply purging program
sequence in accordance with the instructions of the control system supplier.
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• the start program in the higher-level control system has been blocked.
Action steps for dismantling of the oil lance and lance inserts:
Note: Do not use sharp or hard tools for cleaning of nozzle insert and tip of
oil lance.
Before remounting of the lance check all sealings and renew, if necessary.
Clean sliding surface of the diffuser tube.
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Danger!
- The firing system must have been put out of operation prior
to working on the burner!
- For maintenance works carried out from inside the furnace: Do
not enter the furnace until it has been cooled down and venti-
lated sufficiently!
The swirler can be exchanged from the furnace inside wall. Therefore, the
fixing screws at the front side of the diffuser tube have to be loosened.
Then the swirler can be removed from the diffuser tube.
In particular case, the swirler cannot be reached from the furnace inside
wall, e.g. due to special furnace geometry, the centre plate of the burner
has to be disassembled. Therefore, all relevant connections have to be
removed.
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Warning!
Prior to maintenancing and repairing of instruments, valves
and equipment it is necessary to check that the components
are free of pressure and voltage!
In general, qualified personnel only must carry out maintenance and repair
work!
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START-UP BURNER AND FIRING SYSTEM
C3 Storage / Preservation
All system sections, e.g. valves, apparatus and pipes must be rendered pres-
sureless and drained completely.
All system sections must be dried and filled with nitrogen under a pressure of
0.5 to 1 bar in order to prevent corrosion.
C 3.2 Decommissioning
All system sections, e.g. valves, apparatus and pipes must be rendered pres-
sureless and drained completely or dried.
System sections filled with gaseous fuels or air must be filled with nitrogen
under a pressure of 0.5 to 1 bar.
System sections filled with atomising steam must be blown out with air or
nitrogen until they are absolutely dry and subsequently filled with nitrogen
under a pressure of 0.5 to 1 bar.
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System sections filled with liquid fuel must be filled either with fuel oil under a
low pressure or treated analogous to atomising steam pipes. Filling with nitro-
gen is also to be given preference.
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C 4.5 Drawings
Boiler 1
Burner Valve Set Diesel Oil / Plant Air (Burner A) 1612 13-1-14-SH 1/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner B) 1612 13-1-14-SH 2/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner C) 1612 13-1-14-SH 3/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner D) 1612 13-1-14-SH 4/8
M&S item No. 10.14
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Boiler 2
Burner Valve Set Diesel Oil / Plant Air (Burner A) 1612 13-1-14-SH 5/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner B) 1612 13-1-14-SH 6/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner C) 1612 13-1-14-SH 7/8
M&S item No. 10.14
Burner Valve Set Diesel Oil / Plant Air (Burner D) 1612 13-1-14-SH 8/8
M&S item No. 10.14
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V-PA2652/2653/2657
V-PA2662/2663/2667
4.37 stainless steel hose Induflex 10
ICP-N1
PRV PA1043-A1/B1/C1/D1 4.51 air control valve Hochdruck-Re- 14
PRV PA2043-A1/B1/C1/D1 K32-P8-L-N duziertechnik
V-PA1671/1672/1673/1674 4.64 check valve Gestra 11
V-PA2671/2672/2673/2674 RK 86
V-PA1636/1646/1656/1666 4.65 globe valve with throttle cone Alms 15
V-PA2636/2646/2656/2666 and position indication (SWI)
FIG. ABB-11AB-RA1A
XV-PA1043-A3/B3/C3/D3 4.66 pneum. valve Albrecht 13
XV-PA2043-A3/B3/C3/D3 ASV/N
ZSC-PA1043-A3/B3/C3/D3 incl. attachment parts (Omron)
ZSC-PA2043-A3/B3/C3/D3
ZSO-PA1043-A3/B3/C3/D3 (Omron)
ZSO-PA2043-A3/B3/C3/D3
V-PA1638/1648/1658/1668 8.12 ball valve Alms
V-PA2638/2648/2658/2668
V-PA1639/1649/1659/1669 8.13 ball valve Alms
V-PA1636/1656/1676/1696
V-PA1640/1650/1660/1670
V-PA2639/2649/2659/2669
V-PA2636/2656/2676/2696
V-PA2640/2650/2660/2670
FC-PA1043A1/B1/C1/D1 8.22 hose Induflex 16
FC-PA2043A1/B1/C1/D1 GP-N1 - 3/4" NPT
FC-PA1043A2/B2/C2/D2 8.23 hose Induflex 16
FC-IA1043A5/B5/C5/D5 GP-N1 - 1/2" NPT
FC-PA1043/A3/B3/C3/D3
FC-PA2043A2/B2/C2/D2
FC-IA2043A5/B5/C5/D5
FC-PA2043/A3/B3/C3/D3
V-IA1627-1630 9.05 ball valve air distributor Albrecht 17
V-IA1632-1635 4 outlets
V-IA1622-1625
V-IA1647-1650
V-IA1652-1655
V-IA1642-1645
V-IA1667-1670
Issued / Erstellt: Checked / Geprüft: Revision / Änderung: Doc. No. / Dok.-Nr.:
25-02-2015 26-02-2015 Bu 25-02-2015 1612 13-4-099_Vol. C
S. Buck P. Kaphengst Rev. 0 Page / Seite: 36 of 37
OPERATION AND MAINTENANCE
MANUAL
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START-UP BURNER AND FIRING SYSTEM
V-IA1672-1675
V-IA1662-1665
V-IA1687-1690
V-IA1692-1695
V-IA1682-1685
V-IA2627-2630
V-IA2632-2635
V-IA2622-2625
V-IA2647-2650
V-IA2652-2655
V-IA1621/1626/1641/1646/ 9.12 filter regulator Norgren 18
1661/1666/1681/1686 B74G-4AK-AD3-RMN
V-IA2621/2626/2641/2646/
2661/2666/2681/2686
FC-IA1043A1/B1/C1/D1 9.25 rubber hose Induflex 16
FC-IA1043A2/B2/C2/D2 GP-N1
FC-IA2043A1/B1/C1/D1
FC-IA2043A2/B2/C2/D2
SV-DO1043-A1/B1/C1/D1 9.31 3/2-way solenoid valve Norgren 20
SV-DO2043-A1/B1/C1/D1 2401138.0827
SV-DO1043-A2/B2/C2/D2
SV-DO2043-A2/B2/C2/D2
SV-PA1043-A2/B2/C2/D2 9.42 3/2-way solenoid valve Norgren 19
SV-PA2043-A2/B2/C2/D2 9713042.3034
SV-PA1043-A3/B3/C3/D3
SV-PA2043-A3/B3/C3/D3
SVE-DO1043-A4/B4/C4/D4 9.51 5/2-way solenoid valve Norgren 19
SVE-DO2043-A4/B4/C4/D4 9710042.3034
SVE/SVR-DO1043- 9.52 5/2-way solenoid valve Norgren 19
A5/B5/C5/D5 9711042.3034
SVE/SVR-DO2043- impulse type - 2 coils
A5/B5/C5/D5