Design Considerations for Pipe Burner Heating Systems

Rev2.1

Thank you for purchasing a Burners, Inc. pipe burner. This burner has been built using exacting standards and manufacturing techniques in order to insure you a quality product which will give you many hours of worry-free service. It is our goal to give you a top quality product. In order to insure this, we have developed the following installation guidelines for you to reference. As every installation is a little different, these instructions represent a basic installation. If these instructions do not generally represent your installation requirements, please contact our technical support staff. We will be happy to offer additional assistance in your installation. General Installation The successful design of an oven or furnace burner system requires the appropriate design of four fundamental aspects of combustion: (1) Gas Supply, (2) Air Supply, (3) Head Space, and (4) Venting.

Basic Pipe Burner Diagram

1. Gas Supply In order for a burner to operate at full capacity, the gas supply piping must provide the burner with a sufficient volume of clean fuel at the correct operating pressure. As a rule of thumb, all propane operated pipe burners will operate at 11 water column (WC), and all natural gas pipe burners will operate at 8WC. It is important to remember that a burner which is designed for propane, can not be used with natural gas and a burner designed to operate on natural gas, can not be used with propane. You must also know the BTU rating for your burner. With this information, please refer to the chart in the back of this manual for proper gas supply line sizing. 2. Air Supply All pipe burners require sufficient amounts of both primary and secondary air for safe and efficient combustion. If your system is lacking on either primary or secondary air volumes, your burner will not operate correctly, and my cause your system to act erratically. Primary air is the air which is pulled into the burners mixer (the mixer is located at the beginning of the pipe burner). The amount of primary air is controlled by the air shutters (located on the mixer). The air shutters can be adjusted by loosening the jam nut, re-locating the air shutters, and re-tightening the jam nut. Insufficient primary air results in low flame temperature and will eventually cause carbon build-up in your system. This carbon will act as an insulator, and will further decrease the efficiency of your system. Insufficient primary air is evidenced by candle-yellow type flames present on the burner. Simply opening the air shutters will usually provide adequate primary air. If the gas orifice is over-sized, it may be impossible to correctly adjust the primary air shutters to allow for sufficient primary air to enter the pipe burner.

Secondary air is the air which is pulled into the final combustion (flame) from around the pipe burner. There are no adjustments on the burner to control the amount of secondary air. The burner will only use enough secondary air to complete proper combustion. However, if the pipe burner is located in an area which restricts the amount of secondary air the burner can use, the pipe burner will begin to act erratically (for example - there is not enough fresh air inlet openings underneath the burner). Lack of secondary air will also result in carbon build-up. Also, a lack of secondary air is evidenced by a lazy, undefined, bluish flame which will often be visible away from the burner. When designing your system, consider the pipe burner placement. It is not recommended that the burner be located directly near floors or walls of the system. It is also recommended that you allow for sufficient amounts of secondary air to enter into the system. Please remember, that even with careful planning, it is sometimes necessary to enlarge or add secondary air openings. 3. Head Space Head space is the distance between the top of the burner and the bottom of the surface being heated. Proper head space allows for room to complete the flame combustion. Adequate head space allows for all burner flames to be visible and well-defined. The inner cone of the flame should not strike the surface being heated. If this is allow to occur, it may result in incomplete combustion and/or the presence of gas odor in the exhaust of the system. As a rule of thumb, a single pipe burner should have a head space equal to approximately two time the diameter of the burner. Add 1/2 for every additional burner added to the system. Insufficient head space can be extremely dangerous, as it often results in incomplete combustion and the release of un-burned gas into the work environment. This problem must be resolved immediately. 4. Venting Once hot gasses and the products of combustion have heated the work, they must be properly vented from the system. As a rule of thumb, figure on a minimum of one square inch of flue venting for every 6,500 BTUs of burner output along the entire length of the burner. We always recommend rounding up for safety. In addition to providing a sufficient area, all venting must be un-obstructed. There must be a natural flow upward and outward for proper venting to occur. Once vented, all products of combustion must be collected in a vent hood or canopy and vented out of the building. The build-up of combustion gasses in an occupied work environment is extremely dangerous and can cause death. At no time should vented exhaust gas be allowed to occupy a work environment. This problem must be corrected immediately prior to operating the system. It is also important to mention that it may be necessary to contact your local municipal building department in order to determine if special installation considerations must be made, or special installation or operating permits must first be obtained. In the lack of any local building codes or requirements, you must always follow the standards of installation, outlined by NFPA 86 Standards for Ovens & Furnaces, as well as, ANSI Standards Z21.30 - Installation of Gas Appliances and Gas Piping.

Basic Trouble Shooting Techniques

A) Does the pipe burner work? Is the burner getting any fuel - Is the fuel supply turner ON Is the burner getting the correct amount of fuel - refer to section 1) Gas Supply Are the ports in the top of the burner clogged - clean if necessary Are the air shutters loose - align and tighten Is there adequate fresh air inlet openings and vented exhaust - see sections 3) & 4) NOTE - Propane systems, low on fuel will not work correctly - use a full tank

B) Does pipe burner get hot enough? Is the burner getting the correct amount of fuel - refer to section 1) Gas Supply NOTE - Propane systems, low on fuel will not work correctly - use a full tank Check with the system manufacturer for proper operating limits Is there adequate fresh air inlet openings and vented exhaust - see sections 3) & 4) When re-locating the burner to a different elevation, it may be necessary to re-adjust the primary air shutters.

This publication is provided by Burners, Inc. as a general guideline for a safe and efficient design guideline. This information is not recommended to be an installation manual. For specific and particular information, please consult the system manufacturer. Burners, Inc. - P.O. Box 369 - Milford - Michigan - 48381 Telephone (248) 676-9141 - Fax (248) 684-4475

Gas Pipe Sizing Charts

PROPANE - 11 water column
Pipe Length 10 ft. 20 ft. 30 ft. 40 ft. 50 ft. 60 ft. 80 ft. 100 ft. 1/2 275,000 189,000 152,000 129,000 114,000 103,000 89,000 78,000 3/4 567,000 393,000 315,000 267,000 237,000 217,000 185,000 162,000 1 1,071,000 732,000 590,000 504,000 448,000 409,000 346,000 307,000 1-1/4 2,205,000 1,496,000 1,212,000 1,039,000 913,000 834,000 724,000 630,000 1-1/2 3,307,000 2,299,000 1,858,000 1,559,000 1,417,000 1,275,000 1,086,000 976,000

NATURAL GAS - 8 water column

Pipe Length 10 ft. 20 ft. 30 ft. 40 ft. 50 ft. 60 ft. 80 ft. 100 ft. 1/2 174,000 119,000 96,000 82,000 73,000 66,000 56,000 50,000 3/4 363,000 249,000 200,000 171,000 152,000 138,000 118,000 104,000 1 684,000 470,000 377,000 323,000 286,000 259,000 222,000 197,000 1-1/4 1,404,000 965,000 775,000 663,000 588,000 532,000 456,000 404,000 1-1/2 2,103,000 1,445,000 1,161,000 993,000 880,000 798,000 683,000 605,000

These charts are intended to be used a reference only. Any bends, elbows or other fittings will derate these btu capacities. Please consult your system installer for exact btu capacities.

PIPE BURNERS
Burners, Inc. pipe burners are manufactured for many commercial & industrial uses and fit a variety of applications. They are custom made to meet your specifications. We offer a wide selection of pipe diameters and your pipe burner can be made to any length. A Burners, Inc. technical support representative can assist you in determining the correct specifications for your application.

Pipe Size 1/2 1/2 1/2 3/4 3/4 3/4 3/4 1 1 1 1 1 1 1 1/4

Flame Lgth 12 16 20 12 18 24 30 18 24 30 36 42 48 24

Total Lgth 17 21 25 18 24 30 36 26 32 38 44 50 56 33

BTU / hr (x 1000) 6 7 8 9 10 11 13 11 14 17 19 20 21 15

Pipe Size 1 1/4 1 1/4 1 1/4 1 1/4 1 1/4 1 1/2 1 1/2 1 1/2 1 1/2 1 1/2

Flame Lgth 30 36 42 48 54 18 24 30 36 42

Total Lgth 39 45 51 57 63 29 35 41 47 53

BTU / hr (x 1000) 19 22 26 30 34 24 31 39 43 45

Pipe Size 1 1/2 1 1/2 2 2 2 2 2 2 2 2

Flame Lgth 48 54 36 42 48 54 60 66 72 84

Total Lgth 59 65 50 56 62 68 74 80 86 98

BTU / hr (x 1000) 47 51 61 65 67 71 73 76 79 82

All pipe burners come complete with valve, mixer, air shutter & engineered pipe. The standard inlet connection, for most burners is 9/16"-10 LH.

Cooker Burner Valve/Orifice Assemblies

We offer both a standard orifice assembly (CV series) and a combination Valve/Orifice Assembly (FV-11 style) for our CV series cooker burners and pipe burners. All of our orifices are made in our factory and can be ordered with a wide variety of inlet connections. Our standard inlet connections are 9/16-18LH hose inlet and 1/4 mpt pipe thread inlet. Please specify the burner model number and BTU rating at the time of ordering.

Orifice Assembly

CV series

Valve / Orifice Assembly

FV-11