Combustion Service Calls

Combustion in an industrial furnace is produced by using a fossil fuel and air mixing at the burner which creates the fire required to heat the product in the furnace.

The burner itself is normally only a part of a complete combustion system.  Additional pipe train accessories and control components will be required for a complete system installation. Below is a sketch of a typical pipe train system.

Combustion Pipe Train

A simple combustion reaction is given for methane which is the major molecule found in natural gas. Chemically, this combustion process consists of a reaction between methane and oxygen in the air. When this reaction takes place, the result is carbon dioxide (CO2), water (H2O) and a great deal of energy or heat.

Combustion Reaction

TOP 4 CAUSES FOR SUBOPTIMAL COMBUSTION DUE TO BURNER FAILURE

DIRT AND DEBRIS

Clean fuel and air lines are essential to prevent blockage of pipe train components or burner gas ports.

Yearly, the inside of the burner, UV detector, burner pilot, pilot mixer, bleed orifices, and ratio regulator impulse lines must be cleaned.

COMPONENT FAILURE

Burner block and casting failure is frequently the result of external stresses and strains transmitted to the burner through the piping.  Flexible connections are recommended in all piping to reduce piping stresses and alignment/shifting problems caused by thermal expansion.

Other components may fail causing the burner not to light. Mechanical wear on the spindle guide of the pressure regulator will cause the regulator to not open and close properly.  The air/gas ratio control diaphragms may become brittle and hard. Normal wear may cause the failure of the flame sensor, ignitor/ignition transformer or flame amplifier.

AIR/GAS SETTINGS

Air/gas settings can be affected by many things.  For example, air pressure fluctuations caused by soiled air filters or pipelines.  Fluctuating combustion air temperature or density by drawing in combustion air from outside the building where atmospheric temperature changes from winter to summer. Gas pressure fluctuations if additional consumers in the combustion gas network are activated or deactivated. Furnace chamber pressure fluctuations by charging the furnace chamber and fans drawing in or pushing out air.

ELECTRICAL

Electrical faults occur for any number of reasons.  Components that burn out or wear out easily, such as fuses, relay contacts, light bulbs and mechanical switches are a major cause of malfunctions.  Connections may loosen causing higher resistance and leading to overheating.  Insulation on the wires may be damaged which can lead to short circuits. Defective or incorrect wiring is a prime source of faults.

Onex’s combustion technicians will help you troubleshoot the root cause of your burner not operating optimally, fix the problem and get you back online producing product quickly.

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