INSTRUCTIONS OPERATING MANUAL FOR FULLY AUTOMATIC LPG / CNG BURNER

Transcription

1 INSTRUCTIONS & OPERATING MANUAL FOR FULLY AUTOMATIC LPG / CNG BURNER 1/6, Gabrie Gomes, Opp. Nutan Nagar, Kanjur Marg (E), Mumbai Te : (022) / Fax : (022) e-mai: [email protected]

2 INDEX 1. LPG FACT SHEET PROPANE FACTS THE POINTS FOR ATTENDENT INSTALLATION PROCEDURE ELECTRICAL CONNECTIONS TO BE DONE PRECAUTIONS DURING INSTALLATION DO S & DONT S FAULTS & REMEDIES BURNER LAYOUT DRAWING TYPICAL LPG CYLINDER INSTALLATION BURNER WITH DILIGENT BSC W/O TC BURNER WITH DILIGENT BSC WITH TC BURNER WITH HEATGEN BSC W/O TC BURNER WITH HEATGEN BSC WITH TC

3 LPG FACT SHEET Liquefied Petroeum Gas (LPG) is a generic name for commercia propane and butane and is made from crude oi and wet gas. LPG has the specia property of becoming iquid at atmospheric temperature if moderatey compressed and is stored and transported in containers as iquid but is generay drawn out and used as a gas by reducing the pressure. LPG in gaseous state is neary twice as heavy as air. Any eakage of LPG therefore tends to sette down at foor eve. Liquid LPG is amost haf as heavy as water, thus when iquid LPG is converted to a gaseous state it expands by about 250 times. The eakage of iquid LPG is therefore very dangerous due to the voume of gas created. LPG in a natura state is non-toxic and invisibe but can dispace the air necessary to sustain ife. Commerciay avaiabe LPG by aw has an odorant added to faciitate eak detection. Its sme is detectabe in air at concentration down to one fifth of the ower exposive imit. Escape of even sma quantities of the iquefied gas can give rise to arge voumes of vapour/air mixture, the mixture of LPG and air, in certain proportions, wi expode if ignited. In its gaseous state LPG presents a fire and exposion hazard. The ower infammabiity imit for LPG is 2% and the higher imit is around 10%. However over rich mixtures can aso become hazardous when diuted with air. The combustion of LPG produces carbon dioxide and water vapour but sufficient air must be avaiabe. Inadequate appiance fueing and/or ventiation or poor air/gas e.g. due to ack of servicing can resut in the production of carbon monoxide, which is extremey hazardous. LPG vapour is denser than air and consequenty vapour may fow aong the ground and into drains sinking to the owest eve of the surroundings and be ignited at a considerabe distance from the source of eakage. A naked fame shoud never be used to search for a eak. A container that has hed LPG and is empty may sti contain LPG in vapour form and is thus potentiay dangerous. If a vave is eaking or eft open air can diffuse into the container forming a fammabe mixture and creating a risk of exposion, aternativey LPG can diffuse to the atmosphere.

4 In the event of a gas eak : Turn off the gas suppy at the emergency gas contro and turn off a appiances. Open doors and windows to disperse the gas. Extinguish a naked fames and isoate the other sources of ignition. Get further hep by using the emergency teephone number provided by the suppier. Do not turn on the gas suppy again unti the instaation has been inspected, repaired if necessary and passed safe for use by approved engineers. In the event of a fire : Turn off the gas suppy at the emergency gas contro and turn off a appiances. Ca the fire brigade. Evacuate the buiding. Get further hep by using the emergency teephone number provided by the suppier. PROPANE FACTS Propane is the iquid petroeum gas (LPG) used to fue hot air baoons. When handed propery it is a safe and efficient fue. It is sometimes suppied in a mixture with other gases such as butane, butyene and propyene. Genera Properties of Propane 1. Propane is a coouress, odouress and non-toxic gas. It is suppied commerciay with an added odorant to assist detection by sme. 2. Propane bois at -42 degrees Cesius. At 15 degrees Cesius it has a storage pressure of 635 kpa. 3. Propane is stored as a iquid under pressure and wi expand approximatey 270 times to a vapour at norma temperatures and pressure when reeased. 4. When the propane changes to a vapour it is possibe to see the initia eak by the cooing effect of the eak, which causes condensation, and even freezing of the water vapour in the air. Not being abe to see the effects of the eak after a short distance does not mean that the gas is not present in a potentiay exposive mixture. 5. Propane is heavier than air, and may fow aong the ground or through drains and wi sink to the owest eve of the surroundings. 6. The fammabiity range of the gas is 1.6% to 9.5% by voume in air. A sma proportion of the gas can therefore give rise to a fammabe mixture. 7. Propane and other LPG gases are exceent sovents of petroeum and rubber products. 8. Propane and other LPG gases are generay non-corrosive to stee and copper aoys. Precautions against corrosion may be necessary if auminium or auminium aoys are used.

5 I The points a service engineer/attendant must know w 1. Oven/furnace overa specifications and eectrica rating. w 2. Operating temperature, Maximum Temperature and detais of air circuation arrangement. w 3. Oven/furnace working space dimensions, detais of baffe space and wa/insuation thickness. Specifications of instaation and supporting materia parts. w 4. Specifications and type of temperature sensor. w 5. Appication of the oven/furnace to the customer. w 6. Detais of previous change carried out on the oven/furnace. II Instaation Procedure w 1. Check for a the instaation instruments, incuding supporting parts and burner parts to be ready for the instaation. w 2. Before carrying out any modifications or rework, confirm the oven/furnace specifications (existing) and the modifications/renovations to be carried out. w 3. Ensure the pace of burner instaation by taking in account the oven/furnace specifications as per the temperature requirement and uniformity of temperature. w 4. Ensure the LPG pipeine and overa arrangement is done according to the standards burner instaation point. w 5. Ensure the pace of temperature sensing arrangement to maintain the required temperature uniformity. w 6. Fix up the position of burner contro pane(s), according to the no. Of burner and controing systems. Aso fix up the perfect position of ow pressure reguator and the hiow system/soenoid vaves. w 7. Take the cutouts for burner fow tube insertion and combustion chamberfixing, stricty according to the required dimensions.

6 w 8. Fix-up the burner mounting bracket/support pate/fange to the oven/furnace body according to the requirement. w 9. Once again check the inside parts of burner mounted propery at their required positions. (fame sensor rod, ignition rod, nozze-diffuser pate arrangement) w w 10. Mount the burner on the fange/support pate/bracket and tight up the bots firmy. 11. Mount the ow pressure reguator and soenoid vave assemby in their prescribed horizonta position and arrange a LPG pigtai from burner to hi-ow system. w 12 Mount the contro pane (s) in its predefined position, ensuring easy accessibiity. w 13. Mount the temperature sensor at its prefixed position and take out the termna contact wires to the contro pane. Ensuring a the assemby and mounting work being competed, move towards the wiring/eectrica connections for the oven and controing system. III Eectrica connections to be done * w w First of a check the existing eectrica and contro system in the oven/furnace. Foowing are the eectrica connections at the particuar points with LPG firing system. A]. ON THE BURNER CONNECTOR (To the burner side) w 1. Ph and N wires for burner bower. w 2. Ph and N wires for Ignition Transformer. w 3. Earthing from Ignition Transformer connected to body. w 4. Fame sensor rod cabe going inside the burner to the fame sensor rod. w 5. Ignition cabe from ignition transformer going inside the burner to ignition rod.

7 *B]. WIRES COMING IN TO THE CONTROL PANEL : w 1. Ph and N from main switch going inside connector for a further eectrica connections. w 2. Cabe from fame sensing rod (via burner connector) going inside connetor and then to sequence controer. w 3. The thermocoupe termina extension wires going to the temperature controer. *C]. WIRES COMMING OUT FROM THE CONTROL PANEL : w 1. The inter connecting wires, in case of more than one burner and contro panes. w 2. Ph and N for burner bower going to burner connector. w 3. Ph for Ignition transformer going to burner connector. w 4. Signa wires for hooter/arm. W 5. Signa wires for Hi-ow system/soenoid vaves. W * Carry out a the eectrica connections with above information considering the specific IV appication and requirement of the system which differs from oven to oven (furnace to furnace) PRECAUTIONS TO BE TAKEN DURING INSTALLATION, ELECTRICAL CONNECTIONS & TRIALS* W 1 After making suitabe arrangement go for checking & giving power suppy w 2 Checkfor a the specifications of the existing system and the burner system to be instaed. w 3 Ensure troube-free operation of materia handing system, materia oading\system and door-openings. w 4 Ensure easy accessibiity of burner, contro pane, LPG shut-off vave & Eectrica switch.

8 w 5. Ensure easy accessibiity of burner, supporting parts and contro pane for the service engineer. w 6. Ensure the correctness of cut-outs and fabrication work to be done. w 7. Ensure the perfect mounting of burner bracket supporting pate/fange and tightening of a the nuts and bots. w 8. Ensure the mounting of combustion chamber being done carefuy considering the bending / warping due to excess heat during the operation. w 9. Ensure the position of the thermocoupe to sense the overa temperature of the oven/furnace. w 10. Ensure the mounting of ow pressure reguator and soenoid vaves of hi-ow system in the horizonta position stricty. w 11. Ensure proper venting of the oven/furnace in order to take out the excess heat/hot gases/fumes formed during oven/furnace operation. w 12. Ensure the correctness of a eectrica connections before the trias. w 13. Ensure sheathing/shieding of the eectrica wires wherever required. w 14. Ensure to carry the eectrica wires separatey in pipes wherever required for specific appication. w 15. Ensure the instaation of LPG manifod and pipeine being done according to the standards and specific requirement. w 16. Aways carryout the eak test (soap test) on the LPG pipe ine & upto the burner point. w 17. Check a the parameters before switching ON the burner for trias. w 18. Set the parameters of the LPG firing system according to the appication requirement. w 19. Check the suppy votage whether it is 230v+5. w 20. Switch ON the system & necessary changes in the parameters (Air, Gas setting) according to the actua conditions. w 21. Take vigorous trias to satisfy the process requirement (No-oad, Haf-oad, Fuoad Trias) w 22. Take down a the data coected during trias for further reference. w 23. Understand the process carefuy and remove any probems faced during trias ony.

9 V DO S & DON TS FOR THE OPERATORS/ATTEDANTS* w 1. The oven/furnace burner operating system shoud be operated by trained persons ony. w 2. The specified no. of LPG cyinders shoud be attached to the manifod. w 3. The manifod and LPG cyinders shoud be kept open to atmosphere/ fresh air and away from eectrica connections/cabes. w 4. Make sure to ON a the contro vaves of the LPG pipeine. w 5. Carry out the eak test (soap test) once in 15 days and make necessary repairs for the same. w 6. The temperature setting on the temp. Controer shoud be done according to the process requirement ony. Excess temperature setting may cause hazards. w 7. In case of hazards switch OFF the contro system and LPG suppy quicky or aways shut off the LPG suppy by the nearest vave to the burner w 8. Do not change the setting of Main & ow pressure reguator, soenoid contro vaves, air damper on the burner-bower etc. unnecessariy. w 9. Keep the oven/furnace atmosphere free from heat, dust, high humidity, fumes etc. w 10 Ensure good working of soenoid vaves. w 11 Observe the fu indication of sequence controer on contro pane. In case of burner faiures, the trained person ony shoud examine the system to find out the fauts and shoud carry out the remedies for the same.

10 VI FALULTS AND REMEDIES* Foowing are the fauts occurring in the burner system and their causes & remedies mentioned beow them. *A]. BURNER DO NOT START AFTER SWITCHING ON NO. CAUSE REMEDIAL A C T I O N 1 No Eectrica suppy Check for surety. 2 Main switch shut-off Check and make it ON. 3 LPG togge switch shut-off Check and make it ON. 4 Burner ON switch faiure Check and repair/repace. 5 Temperature is set to ZERO Check and reset to the or ess than atmospheric (oven) required process temp. 6 Loose eectrica connections Check and correct the c o n n e c t i o n s to burner or contro pane *B]. BURNER START AND GOES TO LOCKOUT IMMEDIATELY NO. CAUSE REMEDIAL ACTION 1 No Suppy of LPG Check a contro vaves and assure LPG suppy to the burner. 2 Low pressure of LPG Check and add cyinders if needed. 3 Fame not estabishing.check Air and gas ratio and correct by tria & error. No ignition on rod-check for it. 4 No Ignition on Check for sequencing of sequence Ignition Rod. controer & repace if needed. Check connections to Ignition transformer & ignition rod and correct if needed. Ignition rod touching to diffuser pate/ burner body check and correct the gap. Excess carbon on ignition rod-check and cean it. Broken ignition rod-check and repace if needed. 5 Faiure of seq. Controer. Check and repace if needed. 6 No Activation of reays Check reay operation (by indicators) of Temp. Controer/and repace temp. controer if needed. No Reay signa to soenoid vaves. 7 Soenoid stucked up. Check & repair.

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