Operation & Training Manual.
Duel Fuel High Velocity Burner Equipment. • • •
8 million Btu Therma Thermall Capacity Burner. Duel Fuel Control Train. 11 KW Combustion Air Fan.
Equipment Serial Number : • •
Set 1 Set 2
CHM 003 CHM 004
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Contents
System Overview
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1.0
Safety
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2.0
System Requirements .
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3.0
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4.0
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5.0
Duel Fuel Burner System............................................
6.0
System Components ...................................................
7.0
Safety Systems
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8.0
Components & Fuel Delivery .....................................
9.0
The Gas System ..........................................................
10.0
The Diesel System
11.0
Basic Gas / Air Factors Heat Transfer
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Control Box Components
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13.0
Fault Finding & Maintenance ......................................
14.0
Parts Lists
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15.0
Component Data Sheets................................................
16.0
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1.0 System Overview The Stork Cooperheat Duel Fuel High Velocity Gas Burner has been specifically designed to permit safe, effective and flexible use in many varied applications that require portable in situ thermal heat input. The system is particularly well suited to the following applications. • • • •
In situ Post Weld Heat Treatment Of Spherical Tanks / Pressure Vessels / Tanks and Fabrications. Refractory Dry Out Applications – In situ. Furnace Firing Applications. Glass Tank Heat Up & Cool Down Applications.
The burners are designed to provide opt imum flexibility of use and can operate on the following Fuels. • • • • •
Diesel Fuel – Commercial Standard. (if you purchased the dual fuel version) Natural Gas. Propane Butane. Coal Gas.
The burners have the following capacity / Ratings • • • • • • •
Max Temp – operating – 1200 d eg Celsius. Thermal Rating – 8 million Btu / hr – Max (3200 Kw) Voltage – Combustion Fan – 415 Volt / Components 110 Volt. Fuel Pump – 240 Volts. Turndown Ratio – 30 : 1 Excess Air viable – 3000%. Fan capacity 15 Hp, 11 Kw motor 2950 rpm.
IMPORTANT NOTE The System Components have been designed and installed to provide the optimum safety features available, however use of non standard components and replacement parts not specified herein should be avoided. Furthermore, due to the dangerous nature of the fuel sources handing of the fuels and the burner systems should only be performed by trained and competent personnel – safety steps defined herein should always be followed – additional safety steps and components that may be required by client and or local government regulations / bodies should be incorporated in this system if required within your territ ory. It is the Purchasers responsibility to make themselves fully aware and liable to the local government regulations within their own territory.
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2.0 Safety Only qualified personnel who have undergone extensive Cooperheat training in the use of in situ combustion systems may operate this equipment. Failure to safely operate this tool may result in serious injury or death. •
•
Inspect all Burner, Fan and ancillary components as they are removed from the shipping container. If damage is found to any component, contact your shipper /Cooperheat representative immediately. Do not use the equipment. Failure to follow correct tool usage could result in personal injury, co-worker injury, and /or damaged tools and equipment. Ensure that your working area is clean and unobstructed before beginning any application or testing of the equipment - maintenance and repair must be performed by a qualified Electrician / combustion Technician.
•
Modifying a Cooperheat Burner, control train or accessory is dangerous and invalidates the warranty.
•
Fully inspect the Equipment before each use. Replace any obviously worn or damaged parts.
•
•
When not in use, properly store the equipment and accessories, protecting electrical equipment from moisture and flame relay / ignition system from loss or damage. Always ensure fuel supplies are clean and free of leakage and that the connections and supplies meet local and government regulations.
•
Ensure that all areas are free of workers not involved in the firing testing of the equipment.
•
Wear proper safety equipment.
•
Have adequate quantity of fire extinguishers located around the work area.
•
Ensure all necessary hotwork permits are approved and that it is safe to fire / test the equ ipment.
•
Ensure (where possible) the burner is lit outside of the vessel / chamber to ensure no build up of fuel inside the chamber.
2.1 Personal Prot ective Equip ment •
•
•
•
Always wear the appropriate personal protective equipment when operating a Cooperheat Equipment including – as a minimum, gloves, safety goggles, hearing protection, hard hat, and safety shoes. In addition always ensure that technicians are aware of additional regulations that may be required from the particular site being worked on. Always ensure that adequate first aid facilities are available within easy reach and that trained first aid personnel are in the work area. Where possible advise the nearest Medical site facility of the work being done and the possible hazards that may be experienced during the site operation. Where possible ensure that a trained safety officer is present during the firings and that all relevant JSA and safety procedures are constantly being monitored.
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CAUTION Always be aware of site regulations and that proper permits to work are approved prior to starting work or testing. Always follow work site procedures for PPE .
•
•
3.0 System Requirements The following requirements / Site facilities need to be in place for the proper firing of the equipment.
3.1 •
•
•
•
3.1 •
•
•
• •
Gas System. Electrical supplies 3 phase, neutral and earth 415 Volts 30 Amps per phase, 50 / 60 Hz – for the combustion Air Fan. L.P.G / Butane or Natural Gas – properly regulated to the correct pressure at the Control train of between 2 to 4 p.s.i.g. with a capacity for flow of at least 120 Kg / hr per burner. Adequate gas supplies for the firing duration from a certified gas storage facility or from temporary 50 kg cylinders. Proper entry locations for the burner including adequate support for the burner at the firing location and for the Fan within 3 metres of the burner location. Adequate exhaust h oles (16”).
Diesel Oil System. Electrical supplies 3 phase, neutral and earth 415 Volts 30 Amps per phase, 50 / 60 Hz – for the combustion Air Fan. Clean diesel fuel oil properly strained from a supply tank meeting the national regulations, fed to the pumping station via a proper leak free feeder system. A capacity to supply a max of 70 gallons /hr (5 ltr/hr) per burner for the firing duration at 80 p.s.i.g. A 220 volt supply for the pump station – (1 Kw, 1 Hp) Compressed air – cleaned and strained delivered to the burner control train at a pressure of not less than 82 psi (6 bar pressure) and a flow capacity of 5 m3 per hr per burner.
Note For both Gas and Diesel oil systems the control train draws power from the combustion Fan which has a 110 volt outlet.
All other supplies / alarms and features are provided on the train or Fan, however the lengths of cables and hoses may need extending according to the site condition or application. If this is done care should be taken to ensure proper connections are made, waterproof and properly marked.
CAUTION •
Always check Fuel supplies are clean and delivery of fuel is leak free.
•
Never use a fuel not specified herein for burner use .
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4.0 Basic Gas / Oil Data and conversi ons Important information / Data Fuel – Fuel gas / or oil
:
A mixture of hydrocarbons which when reacted with oxygen produce heat.
Calorific Value of gas / oil
:
The calorific value is the amount of heat released when a unit volume of the fuel is burned. 3
This is normally expressed in Btu / hr ft or kcal m
3
3 : 1 Btu per ft
= 9.547 k cal m 3.
And 1 Therm is 100,000 Btu, when dealing with combustion equipment we express the rating or size as the amount of heat released over a fixed period of time – eg 1 million Btu/hr. Note:
1 Btu/hr = 0.293 watts ; therefore 1 Therm = 29.3 Kw. Appr oved Fu els fo r Co op erh eat B ur ner s an d t hei r c alori fi c v alues. 3
Natur al Gas - a Natur al Gas - b Propane Butane Coal Gas Light Fuel Oil - diesel
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1,020 Btu /ft (9,740 k cal/m ) 3 3 800 - 1,100 Bt u/ft (7,640 – 10,500 k cal /m ) 3 3 2,560 Btu/ft (24,400 k cal/m ) 3 3 3,350 Btu/ft (26,500 k cal/m ) 3 3 500 Btu /ft (4,770 k cal/m ) Confirm with your local suppliers in territory
Therefore a burner rated at 6 million Btu / hr will require a natural gas flow of 5,882 ft3 /hr or a propane flow rate 2,344 ft3 /hr Note
LPG is a trade name and the gas consists primarily of a mixture of Propane / Butane and its calorific value will depend on the ration mix of t he two gases – this can vary from territory to territory.
4.1
Combus tio n Air System.
Stoichiometric combustion air is the minimum theoretical amount of air which will as a minimum burn all the fuel. The stoichiometric requirements for the most common fuels are : • • •
Natural Gas Propane Butane
: : :
9.76 vol / vol 23.8 vol / vol 31.0 vol / vol
Cooperheat Burners are however designed to run on excess air and combustion fans are rated to provide excess air – up to 3000% excess air for some refractory curing applications.
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Note:
The greater the percentage of excess air / the more inefficient the system will be, however in some applications the pressure created by excess air promotes temperature uniformity whilst in some higher temperature applications a greater fuel efficiency is required and less excess air should be utilized.
A Gen eral Gui de PWHT vessel heat treatments Refractory Dry Out
High Excess air Very High Excess Air
Furnace Firings
High Excess at low temps reducing to Low axcess at High temps
4.2
Promotes temp uniform ity. Promotes temp uniform ity and moistu re removal.
Exhaus t / Flue Gas.
Flue gases are the byproduct of the combustion process and are the term for the byproduct exhaust that exits the burner / vessel during firing. Generally these consist of nitrogen, water vapour and others depending on the fuel mix. The analysis of the flue gas will indicate the level of excess air being used as the oxygen content will increase as per the table below. 10 9 8 7
% n 6 e g 5 y x O 4 3 2 1 0 10
20
30
40
50
60
% Excess Air
A presence of High levels of CO2 in the flue gas is an indication of incomplete combustion due to insufficient excess air. This results in significant loss of energy and possible soot formation. With Diesel oil systems the soot can be very obvious as a content of the flue gas and can lead to discoloration of the chamber – Increase levels of combustion air / Excess air will bring the condition back to Stoichiometric. Diesel fuels are far more sensitive to soot production and carbon build up and this can adversely effect the firing process and on occasion cause the UV cell to misread flame indications and cause burner shut down furthermore the products lead to bad site conditions and should be avoided.
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4.3
Specific Gravit y.
The specific gravity of the fuel gas is the weight of that fuel relative to air. Important Note - the fact that propane and butane are heavier than air – therefore any leakage of these products will cause pockets of “the gas” to build up in drains or within the chamber being fired. This can lead to serious explosion and therefore all areas need to be well ventilated – similarly when burner flame is not present care must be taken to ensure no gas is inside the vessel or furnace prior to restart – purging of the chamber is very important. Similarly diesel oil is a serious hazard when ignited near storage facilities.
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GAS AND FUEL OIL LEAKS & FUEL BUILD UP IN FIRING CHAMBERS LEADS TO EXPLOSIONS AND FIRE. Always take care to PURGE chambers and ventilate gas storage areas. When burners will not ignite always purge adequately at regular intervals BEFORE ATTAEMPTING REIGNITION. Ignition temperatures of most gases and light fuel oils is in the range of 650 to 750 deg Celsius (somewhat dependant on the gas to air mixture at time of ignition.
5.0 Heat Transfer Heat can be transferred from one source to another by t he following means.
Conduction
Radiation
Convection
The term to describe the rate at which heat passes through a solid object – e.g. the steel being treated or through the furnace wall. By choosing products with low capacity for conduction – i.e. insulation products we can influence the heat losses during the firing. The term used to express the rate at which heat passes from one body to another through space due to the fact they are at different temperatures. The rate of heat transfer depends on the temperature differential between the two, and the emissivity of the two bodies. Emissitivity is the term used to describe the ability of a substance to absorb r adiant heat, a dull material i.e. cast ir on will more readily accept radiant heat than a polished material such as stainless steel, which has heat reflective properties The term used to express the rate at which heat is transferred from a fluid or a gas to a solid. Once again the rate at which this occurs is dependent upon the differential of the solid and the gas and on the velocity of the gas.
Cooperheat Burners utilize both conductive and radiant heat to provide heat input however generally heat by convection is more common due to the high velocity of the Cooperheat burner design.
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6.0 The Cooperheat Duel Fuel High Velocity Burner System The Cooperheat Duel Fuel burner you have purchased provides up to 2,000,000 k cal/hr (8,000,000 Btu /hr) of on site heat from a flame supervised, manually controlled, nozzle mix high velocity gas burner, which will operate on most commercially available gases and on light diesel fuel when the appropriate Diesel Firing Lance is fitted. !
Important : The diesel Lance – must be inserted for use with diesel fuel – and must be removed for Gas firing applications – see sketch this section.
The burner Body – All high grade Hi Temp stainless steel – nozzle mix with combustion air input at the side of the burner. A removable firing cone separately installed either with straight firing direction or angled to 45 degree where ordered. Fuel – (Gas ) Natural gas or propane LPG, at a supply of 2 to 4 p.s.i.g. from the gas train. Fuel – (Diesel) Light fuel oil at a supply of 80 p.s.i.g. combined with compressed air at 80 p.s.i.g – both via regulation at the gas train. Combustion Air – Combustion Air enters the burner via a side inlet with damper facility / adjustable.
Diesel Lance – A removable section that deli vers diesel fuel combined with compressed air to the ato mizer section at its tip – at the point of ignition. The diesel lance should be removed when firing with gas as an alternative to diesel. Combustion Air Fan – 11 Kw motor, Class H – delivering 2950 rpm (max 40,000 cu ft/hr) requires 3 phase, earth and neutral – 30 Amps per phase. The motor is wired at Star Delta and therefore Amps will drop to 20 Amps per phase in th e Delta mode. Air Hoses - Air hose is 152mm dia and is manufactured using double layer canvass reinforced with coiled wire. Standard lengths are 3 m.
Gas hose should be industrial rubber proven delivery hoses of 2” diameter, wire Gas Supply Hose reinforced ,rated to a minimum of 150 psi. Diesel Supply Hose - Diesel supply hoses are industrial oil delivery hoses in reinforced rubber rated to at least 300 psi. All fittings should b e leak free hydraulic type couplings.( ¾ “) Compressed Air Hose – Compressed air hose (¾”) fitted with hydraulic couplings – air hose is colored blue and is rated at 300 psi. Gas / Diesel Control Train – the gas / diesel train is housed within a strong frame fabricated to a suitable size to house all components and be mobile at site – fitted with castors. The tain comprises the following components.
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Gas Trains – 2” inlet supply line fitted with Camlock connector. • Pressure Gauge – inlet supply. • ¾” pilot line with Diaphragm valve and double in line solenoid valves for system open / shut off. • 2” main gas line with 2” diaphragm valve, slow open Actuator safety valve, 2” shut off solenoid • valve and outlet supply line with 2” Camlock connector. Control Box comprising ignition, alarm, safety shut off, alarm mute, flame status and main gas on • functions. Flame management by Honeywell Flame monitoring devices. •
•
Ignition coils are separately housed and can be remotely installed near the burner with connections to the control box at the back of the unit. Flying leads to the burner facilitate the U.V (Magic eye device Honeywell) fed back into the control box via secure sockets.
Diesel Trains •
•
•
•
•
¾ ” diesel inlet supply line fitted with hydraulic connector, the line incorporates a ¾” needle valve for fuel control and a regulator adjustable for diesel control – a pressure gauge is fitted to the regulation device. Double block solenoid valves provide fuel on and off functions via the flame management system. ¾” compressed air inlet supply line fitted with hydraulic connector, the line incorporates a ¾” shut off valve and a regulator adjustable for air control – a pressure gauge is fitted to the regulation device. Control Box comprising ignition, alarm, safety shut off, alarm mute, flame status and main gas on functions. Flame management by Honeywell Flame monitoring devices. Ignition coils are separately housed and can be remotely installed near the burner with connections to the control box at the back of the unit. Flying leads to the burner facilitate the U.V (Magic eye device Honeywell) fed back into the control box via secure sockets.
In addition to the above diesel system comprise a fuel supply train comprising • • • • • • •
1” Inlet connectors Pressure gauge. Diesel oil pump – 240 volt 0.75 Kw 1 Hp. 100 psi at 40 m head. Pressure gauges and Tee piping Pressure bleed off valve – for return OF EXCESS Pressure to the supply tank. Shut off valves and gauges. Connectors for 3/4'” diesel supply hoses to feed the burner.
Note
Cooperheat Dual fuel systems provide a combination of both systems above mounted on the same train. If firing with Gas – Remove the diesel lance from the fitting
Plug back section with the plug From side entry and enter gas line into the open side entry.
IMPORTANT When using Dual Fuel systems r emove the diesel Lance and plug the 2” o pening
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11.
The Gas System Incoming Supply Regulated to between 2 and 4 psi Camlock – f/male
Camlock – Male Pressure Gauge
x o B l o r t n o C
Diaphragm Valve 2” Diaphragm Valve ¾” Solenoid Valve 3/4 “
Slow Open Fast close solenoid – 2” Safety Shut off valve 2”
y l p p u s t l o v 0 1 1
Ignition coil Ignition Probe U.V Sensor Removable firing Cone Combustion Air Fan 415 Volt – 3 phase. 30 Amp 11 Kw
Note Gas supply – Normally will be regulated in the following means. 1” 2”
Fuel Supply Min 120 Kg / hr Per Burner
Gauge
Shut off valve
Regulator 80 – 25 psi
Regulator 25 – 3 psi
Connect to train
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12.
The Diesel System
Return to Tank – pressure relief
Diesel Pump 240 volt 0.75 Kw 1 Hp 90 psi 40 mtr head 70 gallons per hr per burner Strainers • • • • • •
Note: Most Cooperheat Pump stations can supply 2 burners via a TEE piece as shown.
Diesel Line
Site Air supply – 6 Bar 5 cu mtr /hr per burner
x o B l o r t n o C
Compressed Air Line
Compressed Air 6 bar Diesel Lance c/w atomiser
y l p p u s t l o v 0 1 1
Ignition coil Ignition Probe U.V Sensor Removable firing Cone
Combustion Air Fan 415 Volt – 3 phase. 30 Amp 11 Kw
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Dual Fuel System Site Air supply – 6 Bar 5 cu mtr / hr per burner
x o B l o r t n o C
Diesel Line
Compressed Air Line
Ignition coil Ignition Probe U.V Sensor Removable firing Cone Combustion Air Fan 415 Volt – 3 phase. 30 Amp 11 Kw
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IMPORTANT When using Dual Fuel systems remove the diesel Lance and plug the 2” opening
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13. Control Components Safety Systems Control Box
Gas Control Box
IGNITION
FLAME ON
MAIN GAS
FRONT
UV SENSOR IN
IGNITION OUT
Diesel Control Box IGNITION
FLAME ON
FRONT
UV SENSOR IN
IGNITION OUT
Dual Fuel Control Box Selector Switch for Gas / Oil
IGNITION
FLAME ON
MAIN GAS
FRONT
UV SENSOR IN
IGNITION OUT
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All of the designs above share the same safety features. Honeywell Flame Monitoring Devices
The 110 Volt flame management system provides constant flame monitoring and via a system of relays controls the supply of gas / oil to the burner. The Flame unit utilizes a signal from the U.V detector at the burner to determine the presence of flame. When no flame signal is present the unit shuts down power to the Normally closed solenoid valves on the train – within 1s (one second) and shuts off all fuel to the burner. Part No: R4343E – Data Sheets attached. Honeywell Flame sensor U.V – Purple peeper
The Honeywell U.V Sensor device is installed at the burner and monitors the flame status within the firing chamber. A positive flame signal provides a signal the flame monitor to open solenoid valves / fuel supplies. A negative flame signal will cause supply to the solenoids to be shut off and make the system safe. Part No: C7027 – Data Sheets attached.
+ / - ve
Emergency Stop
An emergency stop button is installed in the front fascia – this will shut down all power to all instruments in the controller and also shut down all fuel supply to the burner. Alarm siren
A 110 volt alarm device is installed that will raise an audible alarm in the event of flame failure or non presence of flame. Alarm Mute
A red alarm mute button is installed on the front panel. This is utilized when in standby mode or when attempting burner ignition. In the event of alarm mute there will still be no power to the solenoids until such time either manual ignition is commenced or flame is detected. Pressing of Ignition resets the Alarm. Ignition system
Depressing the ignition button on the front of the burner will raise the relay providing power to the ignition coil, the coil provides high voltage to the ignition probe and facilitates spark at the burner chamber for the duration of time the button is depressed. Simultaneously the depression of the button temporarily opens pilot fuel supplies to the burner to facilitate ignition of fuel while the igniter is sparking. Removing pressure to the ignition button takes power off the
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igniter and the fuel solenoids instantly and therefore halts fuel input to the burner when no ignition is present. In the event that ignition causes flame presence the system automatically takes power off the igniter and the solenoids – power monitoring of the solenoids is taken over by the flame monitoring device. .
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Important : Do not keep the ignition button depressed as constant supply to the ignition coil w ill lead to burnout.
Ignition Coil
The ignition coil is a 110 v 50 Hz unit converting input power of 110v to a min 23 mA 2200v output which via a high tension lead provides power to the ignition probe. Ignition Coil Box
110 V
e g a t l o V h g i H
Solenoid Valves Gas
All Gas trains have the following valves. • •
•
Note :
¾” Pilot valves – 110 volt normally closed – fast shut off – double block for double protection. 2” Main Gas line – Actuator shut off valve – Slow open (adjustable) / Fast close (1s). This valve stops a dangerous surge in the event of high fire main being employed unexpectedly. 2” Safety shut off Valve – normally closed. The model of solenoid valve on your train may differ – please see appendix A for the data sheets.
Gas Control Valves
Cooperheat Gas Trains utilize Saunders diaphragm valves for both pilot ¾” lines and Main 2” lines. The Diaphragm valve has increased safety features and allows finer more accurate and uniform control than other types of valve. ( Data Sheets in Appendix A) Pressure Gauges
Stainless steel glycerin filled pressure gauges (0 – 15 psi) are used on the gas li nes. Flow Gauges.
The use of Dwyer Magnehelic gauges on the gas line allows the operator to monitor the flow W.G that is being put through the burner.
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Connectors.
2” Camlock type fitting are used i n all connections for gas systems. Hyflow hydraulic fittings are used for all diesel lin e connections. Piping and Fitting
All piping and fittings are leak tested and joint tested prior to dispatch and meet local regulations. Colour coding as follows Fuel lines – Gas Bright – pipe y ellow – hose black. Fuel Lines Diesel – pipe yellow – hose black. Air line (compressed) – pipe white – hose blue. 110 Volt Supplies.
The combustion Air Fan houses a step down transformer providing 110 Volt power to the control train via flexible power cable 3 core. Fittings are via yellow industrial plug & socket connections. The reason for the supply from Fan is that we ensure that loss of power to the combustion air of the system will also lead to the shut off of the fuel system. An additional outlet is located on the Fan to provi de power to the Temperature Recorder if required. Note: Diesel Pump – Lines
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Important : The diesel line contains strainers inline with the diesel supply from the pump to the burners – these must be regularly cleaned and serviced. In Addition to these you must ensure that the fuel line from the tank to the diesel pump station also has strainers in line from the fuel discharge valve so as to avoid damage to the pump.
Auxilliary Equipment – Fuel Suppy and Regulati on • • • • •
Regulators Vaporisers Manifolds Storage tanks Diesel Pump Trains
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Fuel Delivery and Standards cont:
IMPORTANT NOTE If you have purchased the above fuel delivery / regulation equipment with your Cooperheat Gas / Diesel System the data sheets are attached in Appendix A. Note: The client must at all times ensure that the fuel delivery system at site meets requirements detailed herein. Cooperheat hold no liability for warranty claims / damage or other claim of any sort resulting from client misuse of the equipment / wrong fuel delivery systems / pressures / fuels / Leakages etc The client must Leak test all systems prior to use / test and satisfy themselves the system is safe for proper use before firing the burners at site.
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Important : Different Territories have different regulations governing the piping / regulation / control / safety features of equipment. This equipment meets the standards of Malaysia at time of design – It is th e responsibility of the customer to ensure that the equipment purc hased is s uitable for use in t he territory and the application for which it is being used.
The Gas System -
Gas enters the regulators (where required) via wire reinforced at a maximum supply pressure of 100 psi. and is reduced through two stages by the regulators, firstly high to medium regulation ( regulator capacity must meet required flow for qty of burners used) to 25 psi thereafter via a second regulator to between 2 and 4 psi. Where site gas at the required 3 psi exi sts the regulators above will not be required. Where insufficient pressure or flow exist the use of proper and approved “Boosters” is permitted with our system. Gas flow to the train is via another reinforced flexible hose, gas is held at this stage between the valve / line and solenoids and cannot pass to the burner until such time the solenoids and control valve are opened. Initially ignition is always started only with the pilot line – the Main line only being required during firing when additional heat and fuel is required – do not ignite the burner utilizing main line supply.
The diesel System
As above but fuel regulated to 45 psi with the ability to increase pressure upward to 90 psi as required.
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13.0 Setting Up the System The Gas system Stage 1
Set Up Fuel Supplies / Regulators / hoses and ensure gas to the train is available at 3 psi per burner at 120 kg/hr per burner.
Set Up Electrical Supplies 415 Volts 30 Amps to the Combustion Air Fan.
Position Burner at vessel / Furnace entry port – do not install put in entry – firing outside the chamber is recommended
Position Gas Control Train at chosen location ensuring Hose and cable lengths are sufficient.
Position Combustion Air Fan within 3 metres of the Burner location and Attach securely all supply hoses.
” 110V u.v Ignition Connect Ignition Leads and box to Igntion Probe at Burner port
Connect U.V Sensor to Burner Port
Connect Fuel Supplies and turn on – Testing for Leaks at every joint – Repair leaks areas as required
Stage 2
Connect 110 Volt supply from Train to Fan
Turn on Electrical Supplies – Test Rotation of Fan. Test Alarm Function on Gas Train
Ensure Correct Pressure at the Gas Tain 3 psi.
Open ¾” Pilot Line valve about Half a turn
Set Air Damper at burner inlet to 25%
Check all connection made
Push Ignition Button in Very short bursts.
Flame presence will be indicated By lighting up of the FLAME ON neon on the
Stage 3
No Flame will be indicated by an audible alarm – Press Al arm Mut e and ret ry it may be necessary to adjust gas or air flow as per training.
Continue Firing as per Training Continued no f lame – see Fault Finding Section Herein – See WARNING BELOW
Note : To switch off main Gas – press ignition Button – this will reset the main to closed position.
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The Diesel System Set Up Fuel Supplies / Pumps / hoses and ensure oil to the train is available at 90 psi per burner at 70 gal/hr per burner. Check Compressed Air supplies.
Set Up Electrical Supplies 415 Volts 30 Amps to the Combustion Air Fan.
Position Burner at vessel / Furnace entry port – Firing outside the chamber is recommended
Position Gas Control Train at chosen location ensuring Hose and cable lengths are sufficient.
Position Combustion Air Fan within 3 metres of the Burner location and Attach securely all supply hoses.
110V u.v Ignition Connect Ignition Leads and box to Igntion Probe at Burner port
Connect U.V Sensor to Burner Port
Connect Fuel Supplies and turn on – Testing for Leaks at every joint – Repair leaks areas as required
Ensure Correct Pressure at the Gas Tain and that relief valve feeder back to the tank
Check all connection made
No Flame will be indicated by an audible alarm – Press Alar m Mu te an d r etr y it may be necessary to adjust fuel or air flow as per training.
Open Pilot Line valve about 3 & Half a turn WITH Diesel reg set at 14 psi
Push Ignition Button in Very short bursts.
Connect 110 Volt supply from Train to Fan
Turn on Electrical Supplies – Test Rotation of Fan and pump. Test Alarm Function on Gas Train
Set Air Damper at burner inlet to 35%. Set compressed air to 10 psi
Flame presence will be indicated By lighting up of the FLAME ON neon on the
Continue Firing as per Training Continued no flame see Fault Finding Section Herein – See WARNING BELOW
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IMPORTANT NOTE We recommend that burners are lighted outside of the Chamber and then inserted into the firing position, this is not always feasible – however in every instance we recommend that operators become familiar with the firing system and in particular the ignition systems prior to site situations. In every instance you should avoid periods of attempting burner ignition with no result as this leads to filling the chamber with fuel – a dangerous situation – Always purge the chamber between ignition attempts. With diesel systems this is just as important as diesel inside the chamber will later burn off and cause fire damage internally similarly this fire can fool the UV devices as to actual presence of burner flame.
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Important : Alway s pu rg e th e sy st em pr io r to ig niti on – leave burn er ru nnin g wi th fan on to clear out firing chamber. When attempting ignition only use short burst with the ignition button – if unsuccessful after 4 or five short bursts re-purge the system for 5 minut es and follow the fault finding s teps detailed herein.
Fixing Of Burners.
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Important : Once firing commences always fix the burner in place with chains very securely as the presence of back pressure due to insufficient exhaust sarea can cause the burner to “ blow out ” of its entry port.
Control of the Burners • •
•
• • •
Burner control is in all cases Manual. Increases to the fuel air mixture / ratio in small and consistent increments will allow good control to end user specification. Always ensure adequate pressure of fuel is being maintained and that regular leak tests are being carried out. Manually check flame status regularly Regularly check air input status and that the fan is working properly. Check through back site glass of the burner to ensure flame is not too rich – ie soot or vey yellow flames require more air mixture in order to burn efficiently.
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IMPORTANT NOTE If you have purchased the Cooperheat Gas / Diesel System it is assumed that you either have knowledge of Gas or diesel fired Heat treatment / Dry out operations or that you have simultaneously undergone a certified training course. If this is not t he case then a training course by authorized personnel will be necessary. This manual is not a training course and does not constitute the right of the user to assume they can properly and safely utilize combustion equipment without proper training. This manual is a description of the system only.
14.0 Fault Finding & Maintenance Trouble shooting
If problems are encountered in lighting the burner then in most cases the problem can be attributed to one of the following reasons. 1.
Check gas / Fuel is clean and is passing through the valves to the burner port at the correct pressures.
No gas/ oil
GAS
OIL
Ensure gas storage bottles / manifold valves are on and that flow between st the system and the 1 stage regulator are working – pressure gauges should indicate this.
Ensure oil storage tank delivery valves are on and that flow between the system and the pump are working clean strainers – pressure gauges should indicate this.
Check supply to 2nd stage regulators are at correct pressure and they are in turn supplying flow to the control train at between 2 and 4 psi.
Check supply to pump and that pump Power is on – pump operation is ok and that rotation is correct. Check that correct pressure is being delivered from the train.
Thereafter check gas passes t hrough the train to the burner location when solenoids are opened on pushing ignition
Thereafter check oil passes through the train to the burner location when solenoids are opened on pushing ignition and that oil regulator on train operates
Check solenoids open when ignition button is pushed
Check return line from pump – relief valve to tank is working
Rectify Faults
Rectify Faults
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2.
No Spark
Check the spark igniter – this can be done by removing the spark plug from the burner. Do as per the sketch below – ENSURE GAS VALVE SUPPLY IS OFF WHEN YOU DO THIS.
Place igniter on a work bench or suitable location near an earthed point or metal block Keep hands well away when doing and ensure all gas/oil supplies are off.
ACTIONS • •
If spark is not present check voltage to the ignition coil – you may need to replace the coil. If spark is present – put the igniter back in the burner. Check for spark within the burner by standing a safe distance back and ENSURING ALL GAS SUPPLIES AND GAS VALVES ARE OFF. If spark is not present within the chamber but has been present outside the burner check the plug alignment as detailed below.
Ensure the igniter is in good condition and that it aligns in the middle of the entry hole – if it touches either side it will short out the ignition process.
3.
Flame starts but does not hold / lock out
If a spark system is present and you can hear or see that flame ignition occurs then - check the u.v sensor as this may be damaged – check by removing from burner and holding a light source nearby at a safe distance with all fuel supplies shut off – when the light is adjacent to the u.v sensor there should be a corresponding reading being shown on the milliamp sensors on the panel face. If no reading ocurss check wiring polarity of the u.v sensor as sometimes this is reversed either in the lead or the panel. – if no wiring fault occurs it is likely that the u.v sensor is faulty and needs replacing.
Maintenance •
•
•
•
•
Keep all wiring in good condition and ensure that any extensions are made with proper electrical components that are dry joint free and t hey are waterproof and free of damage. Keep the panel components clean and free of water or particle ingress and that all connections are tight after transport. Check all neon’s and push butt ons/ fuses/ relays / alarms function well – replace as required. Ensure all plugs and fittings are tight and screws are maintained in all fittings – all must be waterproof. Protect ignition devices and u.v sensors from damage – store safely.
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•
•
•
•
•
Ensure train and pumps / regulators are kept well painted and that they are free from damage and from leaks at all joints. Regularly check pumps / regulator settings in the workshop to ensure that the psi delivery settings are correct and that no damage to di aphragms etc has occurred. Check burner for structural / heat damage – clean all deposits of carbon. Ensure diesel lance and atomizer are in good condition and leak free. Check damper at burner air port to ensure it operates freely and does not jam. Check combustion air fan ensuring that the star delta system is in good order and that there are no loose connections.
•
Ensure that there is no water ingress to the fan electrical system.
•
Check fan inlet holes to ensure no build up of obstructions to air inlet.
•
Check castors / Wheels at train / p ump and fans to ensure they are easy to move at site.
!
Important : Safety •
•
•
•
•
When working on the burner ensure gas/ oil supplies are off. When testing ignition take care of the high voltage. If the burner is not lighting ensure adequate purge times between tests to ensure no gas / oil build up in the vessel or chamber. Ensure the burner is tied down to avoid blow out if back pressure is present. Try if possible to light the burner outside the vessel / furnace prior to p l ac e me n t th is will a vo id g as bu i ld up in th e c h a mb er . If unsure contact the supplier.
Always use Stork Cooperheat spares and Accessories.
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15. Parts List Gas System
Your Gas system should comprise of the following components.
Item
Description
Manufacturer
Rating
Size
Qty
1 2 3 4 5 6 7 8
N/A N/A N/A N/A Saunders Saunders
N/A N/A 200 PSI 200 PSI 350 psi 350 psi 10 bar 360 mbar
¾” 2” 2” 2” ¾” 2” ¾” 2”
SET SET 1 1 1 1 2 1
NO NO NO NO YES Yes Yes Yes
9
Piping ¾” Piping 2” Camlock Fittings male Camlock Fittings fmale Diaphragm Valve Diaphragm Valve Solenoid shut off valve Slow Open Actuator Valve – Fast Close Safety shut off valve
10 11 11 a 11b 11c 11d 11e 11f 11g 11h
Electrogas
Data Sheet attached
360 mbar
2”
1
Yes
Pressure Gauge Control Box Control Box Panel Neon LED Relay 110 v Push Button Emergency Stop Milliamp meter Cable glands Flame relay
Krom Schroeder na
15 psi
2”
1
NO
na NA Fuji / tele na na na na Honeywell
IP 54 110 v 110 v 110 v 110 v 50 milamp na 110v
400mm 19mm 30 Amp 19mm 19 mm 1” na na
1 5 5 3 1 1 5 1
NO NO NO NO NO NO NO Yes
12 13
U.V Sensor Ignition Coil
Honeywell Brahms
na 110 v
na box
1
Yes NO
14 15
Burner Combustion Air Fan
Cooperheat Prtn/ coop
8 mill btu 11KW
6” o/t 15Hp
1 1
Cert of conformance No
25
List of Parts – Duel Fuel System Item
Description
Manufacturer
Rating
Size
Qty
1 2 3 4 5 6 7 8
N/A N/A N/A N/A Saunders Saunders
N/A N/A 200 PSI 200 PSI 350 psi 350 psi 10 bar 360 mbar
¾” 2” 2” 2” ¾” 2” ¾” 2”
SET SET 1 1 1 1 2 1
NO NO NO NO YES Yes Yes Yes
9
Piping ¾” Piping 2” Camlock Fittings male Camlock Fittings female Diaphragm Valve Diaphragm Valve Solenoid shut off valve Slow Open Actuator Valve – Fast Close Safety shut off valve
360 mbar
2”
1
Yes
10
Pressure Gauge
15 psi
2”
1
NO
na na na na
na 10 bar 100 psi 100 psi 300 psi 100 psi
¾” ¾” ¾” ¾” ¾” 2”
2 2 1 1 4 2
NO NO NO NO NO NO
na NA Fuji / tele na na na na Honeywell na Honeywell Brahms
IP 54 110 v 110 v 110 v 110 v 50 milamp na 110v 110 v na 110 v
400mm 19mm 30 Amp 19mm 19 mm 1” na na na na box
1 5 5 3 1 1 7 1 1 1 1
NO NO NO NO NO NO NO Yes na Yes NO
Cooperheat Prtn/ coop Cooperheat
8 mill btu 11KW na
6” o/t 15Hp na
1 1
Cert of conformance No NO
11 11 a 11b 11c 11d 11e 11f 11g 11h 11i 12 13 14 15 16
¾” piping Solenoid valves Oil regulator Air regulator Hydraulic fittings Pressure Gauge s/s Control Box Control Box Panel Neon LED Relay 110 v Push Button Emergency Stop Milliamp meter Cable glands Flame relay Selector switch U.V Sensor Ignition Coil Burner Combustion Air Fan Diesel Lance with Atomiser
Electrogas Krom Schroeder na na
Data Sheet attached
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List Of Parts – Diesel System Item
Description
Manufacturer
Rating
Size
Qty
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Needle valve ¾” piping Solenoid valves Oil regulator Air regulator Hydraulic fittings Pressure Gauge s/s Control Box Control Box Panel Neon LED Relay 110 v Push Button Emergency Stop Milliamp meter Cable glands Flame relay
na na na na na na
na na 10 bar 100 psi 100 psi 300 psi 100 psi
¾” ¾” ¾” ¾” ¾” ¾” 2”
1 2 2 1 1 4 2
NO NO NO NO NO NO NO
na NA Fuji / tele na na na na Honeywell
IP 54 110 v 110 v 110 v 110 v 50 milamp na 110v
400mm 19mm 30 Amp 19mm 19 mm 1” na na
1 3 4 3 1 1 4 1
NO NO NO NO NO NO NO Yes
12 13
U.V Sensor Ignition Coil
Honeywell Brahms
na 110 v
na box
1 1
Yes NO
Cooperheat Prtn/ coop Cooperheat
8 mill btu 11KW na
6” o/t 15Hp na
1 1
Cert of conformance No NO
14 15 16
Burner Combustion Air Fan Diesel Lance with Atomiser
Data Sheet attached
27
