Installing and Commissioning Industrial Gas Burner; 10 Powerful Steps

Industrial gas burners are essential devices in heating systems of buildings and industries. Correct installation and commissioning of these burners are crucial to ensure optimal efficiency, safety, and long lifespan. This article examines the various steps for installing and commissioning industrial gas burners and offers key tips for a successful process.

Pre-Installation Steps

Before beginning the installation process for gas burners, it is essential to carefully complete the preparatory steps, which require special attention and accuracy. These steps involve assessing requirements and technical specifications, as well as selecting an appropriate location for installation. Each of these steps will be explained in detail below.

1- Assessing Requirements and Technical Specifications

A precise evaluation of the requirements and technical specifications is important for the correct selection and installation of an industrial gas burner. This step includes the following:

• Determining the required heating capacity: To choose the appropriate burner, the heating capacity needed for the system must be determined first. This capacity is usually determined based on heating needs of the building or industrial process. The burner capacity should be selected in such a way that can meet the heating needs fully and efficiently.

• Selecting the type of gas: Industrial gas burners can operate using natural gas, LPG, hydrogen, or other types of gases‌. The gas type should be compatible with the existing gas supply network and the system’s requirements. Choosing the correct type of gas ensures both optimal operation and system safety.

  

• Evaluating the burner’s technical specifications: The technical specifications of the burner include combustion type, heating capacity, efficiency, and its dimensions. It’s necessary to ensure that the burner’s specifications match the system’s requirements and fit the installation space. Additionally, it’s important to consider compatibility with the boiler or other heating equipment.

• Checking local requirements and regulations: Different regions may have specific requirements and regulations for the installation of industrial gas burners. These include safety laws and regulations, building standards, and environmental requirements. Checking and following these regulations is crucial to avoid safety problems.

• Assessing quality features and warranty: Industrial gas burners should be of high quality and manufactured by reputable companies. Evaluating quality features, warranty, and after-sales services can help in selecting the right burner and preventing potential problems in the future.

2- Choosing an Appropriate Installation Location

Selecting the appropriate location for installing an industrial gas burner significantly influences its optimal operation and safety. In this step, the following factors should be considered:

• Environmental Conditions: The installation location should be chosen based on suitable environmental conditions. This includes assessing temperature, humidity, altitude, and adequate air for combustion.

• Access to Fuel and Ventilation Systems: The installation location should have easy access to fuel lines (such as gas pipes) and ventilation. This accessibility facilitates the installation and maintenance of the burner and helps to prevent potential problems in the future.

• Assessing the Installation Location: The installation location must provide sufficient space for both installation and maintenance. Additionally, the burner should not be put near flammable materials or other heating equipment to minimize potential hazards.

  

• Compliance with Safety Regulations: It is essential to ensure that the burner installation location complies with all safety regulations and requirements. This includes maintaining safe distances from walls, floors, and ceilings, as well as installing the burner in specified space.

• Assessing Electrical Requirements: Industrial gas burners may require to supply electricity for control and safety systems. Therefore, it’s important to ensure that the installation location is equipped with an appropriate electrical supply and necessary electrical facilities to meet the burner’s energy needs.

Industrial gas burner Installation Steps

The installation process for an industrial gas burner involves several important steps, each essential for ensuring the burner’s proper operation and safety. The following sections will provide detailed descriptions of each step:

1- Assembling the Burner Components

The installation of the industrial gas burner involves putting the burner in the determined location and mounting on the boiler or furnace. It is crucial to ensure that the burner is mounted securely and correctly without any leakage or fitting problems.

2- Supplying Combustion Air (Fan)

After installing the burner, it must be connected to the fuel systems and the ventilation system. This includes connecting the gas train to the burner and ensuring that the air supply system operates correctly. Additionally, it is important to check that the fuel system and combustion air supply systems are properly adjusted and that there are no gas leaks.

3- Installation of Safety and Control Systems

Safety and control systems involve the installation of sensors, controllers, and other safety devices that are essential for the optimal and safe operation of the burner. These systems must be installed and adjusted correctly to prevent potential hazards.

Steps for Commissioning an Industrial gas burner

The steps for starting an industrial gas burner include initial adjustments and operation test to ensure the proper operation and safety of the burner. Each of these steps is explained below:

1- Initial Adjustment

The initial adjustment of the industrial gas burner is an important step performed to ensure the proper operation and safety of the burner before long-term use. This step includes several key actions, which are mentioned as follows:

• Final checking of Connections: Before commissioning, all gas and electrical fittings must be precisely analyzed to ensure that the fittings are secure and there are no gas leaks.

• Checking the Mechanical Connections: The mechanical connections of the burner should also be examined to ensure that the connections and mechanisms within the burner are functioning correctly.

2- Adjusting the Pressure of Inlet Gas to Gas Train and Burner

The inlet gas pressure should be adjusted in accordance with the specifications of the burner. Incorrect adjustment of gas pressure can negatively influence burner operation and lead to issues such as incomplete combustion or insufficient burner capacity.

3- Adjusting the Control Systems

The burner settings must be checked and adjusted correctly. This includes adjusting the air dampers actuators, fuel valve, cams, timing cycles, and other control parameters that improve burner correct operation.

2- Performance Testing and Adjustments

It is a critical step to ensure optimal operation and safety of the burner. This step involves evaluating the burner’s performance under operational conditions and making final adjustments to improve efficiency. The following paragraphs delve into details of these steps:

1- Initial commissioning of Burner

There are some important points to be taken into account here.

• Checking the Ignition of Burner: Try to start the burner slowly and monitor its operation carefully. Ensure that the burner ignites correctly and the flame is stable.

• Inspecting Safety Systems: Safety systems, such as flame sensors and pressure switches must operate correctly to prevent potential hazards.

2- Load Testing

Two points must be considered here. They will be explained as follows:

• Evaluating Performance in Operational Conditions: The burner should be tested under full load or real operational conditions. This includes assessing heating efficiency, gas consumption rates, and the performance of the combustion system.

• Final Adjustments: Final modifications in the adjustments may be necessary based on the test results. This includes setting the flame dimensions, adjusting gas pressure, and modifying other operational parameters.

  

3- Evaluating the Efficiency

The efficiency of the burner must be analyzed which is explained below:

• Checking the Efficiency: The burner efficiency should be analyzed and assessed to ensure it provides optimal performance. This includes evaluating energy consumption and heat output.

• Optimizing Operation: Based on the efficiency analysis, burner settings may need to be adjusted to achieve the best possible operation and efficiency.

Safety Considerations for Installation and Commissioning

Installing and starting up industrial gas burners requires special attention to safety parameters in order to prevent potential hazards and serious problems. Here are some key safety points:

1- Gas Safety Precautions

Working with gas, especially during the installation and startup of industrial gas burners, requires adherence to specific safety principles to prevent accidents and serious risks. The following paragraphs highlights the safety precautions for working with gas:

1- Gas Leak Detection

• After installing the burner, it is important to make sure that leak detection equipment is used for testing the probable leaks. Gas leaks can lead to explosion and poisoning.
• When checking for leaks, use specific chemicals (such as foaming liquid) that easily identify leaks. Additionally, keep away from flame and heat sources.

  

2- Ensuring Proper Ventilation

• Ensure that the area where the burner is installed is well-ventilated. Proper ventilation helps prevent the accumulation of hazardous gases and reduces the risk of fire.
• Ventilation pathways should not be blocked or restricted, and they should be regularly cleaned.

2- Safety Standards and Regulations

Adhering to safety standards, regulations, and paying attention to hazardous areas during the installation and commissioning of industrial gas burners is crucial for maintaining safety, efficiency, and increasing the lifespan of the system. Below are some key standards and regulations in detail:

1- Compliance with Local Regulations

• All local building and safety laws and regulations must be followed. These regulations may include installation standards, ventilation requirements, and safety regulations for gas systems.
• In some areas, installing an industrial gas burner may require specific permits. Ensure that all necessary permits and certificates are obtained before starting the installation.
• If the burner installation location is in a hazardous area, all electronic equipment for the burner must be obtained and installed in accordance with the necessary standards.

  

2- Compliance with International Standards

• Industrial gas burners must comply with international standards and those set by other reputable organizations. These standards contribute to the safety and efficiency of the equipment.
• The manufacturer’s instructions must always be followed carefully. These guidelines include details on the installation, settings, and maintenance of the burner.

3- Training and Awareness

• Staff should receive the necessary training on the installation, operation, and maintenance of industrial gas burners. This training helps reduce errors and improves safety.
• Everyone involved in the installation and operation process should be aware of potential hazards and safety protocols to prevent accidents.

  

Common Issues and Solutions

During the installation and operation of industrial gas burners, several issues may arise, each requiring proper diagnosis and solution. Some of the common problems and their solutions are explained below.

1- Installation Issues and Solutions

Common problems during the installation of industrial gas burners include gas leaks, component mismatches, and problems in connecting to fuel and air supply systems. In order to solve these problems, all connections should be checked carefully and high-quality standard equipment must be used. It may also be necessary to adjust or replace defective parts.

2- Operation and Adjustment Issues

Typical issues during burner operation include failure to ignite, flame instability, malfunctioning of safety systems, and improper burner settings. To resolve these issues, the burner’s settings must be checked and ensure that all sensors and controllers are functioning correctly. It may also be necessary to repair or readjust the burner for optimal operation.

Overview of Key Steps in Industrial gas burner Installation and Commissioning

In the installation and commissioning of industrial gas burners, it is important to pay attention to the details of each step. Selecting the appropriate burner, investigating technical specifications, and adhering to safety standards are essential. Additionally, proper assembly and connection to fuel and combustion air supply systems must be taken into account for the safe operation of the burner. Moreover, initial commissioning and testing help identify potential problems before regular use. Following safety principles and being aware of common problems and their solutions can prevent accidents and increase the burner lifespan.

Raadman Industrial Group is a leading company in this field, producing and installing high-quality heating equipment. Raadman offers its high-quality products to various industries by utilizing the latest technologies and adhering to safety standards. By prioritizing high efficiency, energy savings, and outstanding after-sales support, raadman has built a strong reputation and gained the trust of customers.