Manual Horno Jon Zink

DOCUMENTATION
Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

Customer: Nestradé Chile LINE 1 & LINE 2 Rev. 0
Purchase order: 4511139908
JZ KEU project: AHM000215 Seite 1 von 82
OPERATING INSTRUCTION
MOUNTING INSTRUCTION
and
FUNCTIONAL DESCRIPTION
PRIMARY AIR HEATER - VTT

with FUEL GAS - /
Light FUEL OIL – BURNER
ATTENTION !
Before
Start Up of the Primary Air Heater
please read this
Functional Description, Mounting and Operating Instruction
very accurate!
Page 1 (82)
DOCUMENTATION

INDEX
1 General .......................................................................................................................................................... 5
1.1 General plant description ..................................................................................................................... 5
1.2 Operating of the plant........................................................................................................................... 7
1.3 Suppliers ................................................................................................................................................ 8
1.3.1 Air heater unit .......................................................................................................................... 8
1.3.2 Burner unit................................................................................................................................ 8
1.4 Appropriate use of equipment.............................................................................................................. 8
1.5 Technical safety guidelines ................................................................................................................... 8
1.6 Requirements and qualifications: operating personnel ..................................................................... 9
2 Safety ........................................................................................................................................................... 10
2.1 Basic safety references ........................................................................................................................ 10
2.2 Obligation of the owner ...................................................................................................................... 10
2.3 Obligation of the personnel ................................................................................................................ 11
2.4 Risks in operating the plant................................................................................................................ 11
2.5 Guarantee and liability ....................................................................................................................... 11
2.6 Safety guidelines .................................................................................................................................. 12
2.6.1 Safety Chain (interlock system) .......................................................................................... 12
2.6.2 Inspection of flame................................................................................................................ 13
2.6.3 Elongation of heater.............................................................................................................. 14
2.6.4 Safety measures ................................................................................................................... 15
2.6.5 Instruction of the personnel ................................................................................................. 15
2.6.6 Plant control ........................................................................................................................... 15
2.6.7 Safety measures for normal operation conditions ............................................................ 15
2.6.8 Dangers due to electrical energy ........................................................................................ 16
2.6.9 Exceptional dangers ............................................................................................................. 16
2.6.10 Leakage of explosive gases and combustible liquids ................................................. 16
2.6.11 Noise / hearing protection ............................................................................................... 17
2.6.12 Structural changes at the air heater plant ..................................................................... 17
2.6.13 Maintenance and service, elimination of malfunction ................................................. 17
2.6.14 Cleaning of the plant and disposal ................................................................................. 18
2.6.15 Copyright ........................................................................................................................... 18
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3 Technical data ........................................................................................................................................... 19

3.1 Process and design data ...................................................................................................................... 19
3.1.1 Air heater with heat exchanger fuel gas mode ................................................................. 19
3.1.2 Air heater with heat exchanger in Light fuel oil mode ...................................................... 20
3.2 Burner data.......................................................................................................................................... 21
4 Description ................................................................................................................................................. 22
4.1 Structure of the air heater equipment ............................................................................................... 22
4.2 Structure of the burner equipment .................................................................................................... 25
5 Transport and storage ............................................................................................................................. 26
6 Mounting ..................................................................................................................................................... 27
6.1 Mounting instructions air heater and heat exchanger ..................................................................... 27
6.2 Mounting instructions burner ............................................................................................................ 29
7 Commissioning and operation .............................................................................................................. 31
8 Description of the burner control ......................................................................................................... 32
8.1 Description of the Interface ................................................................................................................ 33
8.2 Operation from CUSTOMERS plant control ................................................................................... 33
8.3 Operation from LOCAL air heater control cabinet......................................................................... 34
8.4 Commissioning..................................................................................................................................... 36
8.5 Start-up ................................................................................................................................................ 38
8.5.1 FIRST START- UP and DRYING - OUT during commissioning ............................... 38
8.5.2 Instructions for FIRST HEATING UP after DRYING - OUT ........................................ 42
8.6 Operating Instructions........................................................................................................................ 43
8.6.1 START- UP ............................................................................................................................ 43
8.6.2 NORMAL- MODE ................................................................................................................. 46
8.6.3 SHUT- DOWN ....................................................................................................................... 53
9 Maintenance ............................................................................................................................................... 55
9.1 General checks and measures during productions ........................................................................... 55
9.2 Maintenance and inspection plan ...................................................................................................... 56
9.2.1 In principle ............................................................................................................................ 56
9.2.2 Weekly ................................................................................................................................... 57
9.2.3 Monthly.................................................................................................................................. 58
9.2.4 Every 6 weeks ...................................................................................................................... 59
9.2.5 Every 6 months ................................................................................................................... 65
9.2.6 Every year ............................................................................................................................. 65
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9.3 Trouble shooting and fault finding guide .......................................................................................... 66

9.3.1 EMERGENCY- STOP- SWITCH at Burner Control Cabinet (HS V1S1) .................. 66
9.3.2 EMERGENCY- STOP- SWITCH at Burner Control Cabinet (PB 06.30) .................. 66
9.3.3 Flame failure (BFS 01.01) before the ignition transformer is activated ................ 66
9.3.4 Burner does not ignite....................................................................................................... 67
9.3.5 Burner only burns for a short time period ................................................................... 67
9.3.6 Symptom: Burner does not start but no alarm present ............................................ 68
9.3.7 Flame failure (BFS 01.01) during operation ................................................................. 68
9.3.8 CLOSED Burner flange limit switch (ZSL 01.02) not closed .................................... 68
9.3.9 OPEN Limit switch at flue gas damper (ZSH 07.15) not closed (Option) ............. 68
9.3.10 Primary air pressure (PSH 07.12) above high ......................................................... 69
9.3.11 Primary air flow (PDSL 07.08) below low ................................................................. 69
9.3.12 Combustion air flow (PDSL 01.07) above low ........................................................ 69
9.3.13 Temperature flue gas (TSH 07.06) above high ....................................................... 70
9.3.14 Temperature primary air (TSH 07.04) above high .................................................. 70
9.3.15 Fuel gas pressure (PSL 01.14) below low ................................................................ 70
9.3.16 Fuel gas pressure (PSH 01.15) above high ............................................................ 71
9.3.17 Fuel gas fittings tightness control unit (PSL 01.16) .............................................. 71
9.3.18 OPEN Fuel oil fitting limit switch (ZSH 01.65) not closed.................................... 71
9.3.19 OPEN Fuel oil fitting limit switch (ZSH 01.29) not closed.................................... 71
9.3.20 Fuel oil pressure (PSH 01.27) above high................................................................ 72
9.3.21 Fuel oil pressure (PSL 01.01.26) below low ............................................................ 72
9.3.22 Level control oil sump (LSH 01.37) above high (Customers Equipment) ....... 72
9.3.23 FUEL GAS BURNER does not operate; Start program does not run................ 73
9.3.24 Light FUEL OIL BURNER does not operate; Start program does not run....... 73
10 Spare parts and maintenance service ................................................................................................. 74
11 Drawings and data sheets ...................................................................................................................... 75
11.1 Drawings ............................................................................................................................................... 75
11.2 Technical data sheets ........................................................................................................................... 75
12 Documentation - Burner unit - ............................................................................................................... 76
13 Documentation - Spare parts and wear and tear elements-........................................................... 77
14 Documentation - Electronic equipment - ............................................................................................ 78
15 Documentation - Fabric compensators - ............................................................................................ 79
16 Documentation - Fabrication certificates - ......................................................................................... 80
17 Documentation - EG -Declaration of conformity - ............................................................................ 81
18 Documentation - Refractory lining / insulation - ............................................................................... 82
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1 General
1.1 General plant description
The primary air plant consists of following major equipment and components:
 Air heater recovery exchanger or economizer

 Burner system with control panel
 Primary air fan (by customer)
 Primary air ducting from fan to the heat exchanger (by customer)
 Primary air ducting to the air heater
 Primary air ducting from air heater to EGRON and to hot air stack (by customer)
 Flue gas ducting to heat exchanger
 Flue gas ducting from heat exchanger to the stack (by customer)
 Instrumentation and safety devices at the air heater
The primary air is supplied from the primary air fan to the air inlet socket of the heat ex-
changer with partial flow through the bypass ducting.
The mixture of the preheated and cold primary air is then led to the inlet socket of the air
heater.
Using the servo-motor-controlled primary air bypass flaps, the outlet flue gas temperature
from the heat recovery exchanger is controlled at set points as follows:
 Fuel gas firing (FG-mode): 80°C
 Light Fuel Oil firing (LFO-mode): 150°C (to prevent condensation and corrosion)
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Internal flow of primary air

In the air heater the air flow is divided into two streams
The first primary air stream cools the combustion chamber in parallel flow with the flue
gas.
The flue gas at the combustion chamber’s outlet is cooled down to approx. 800 till
850°C. At the end of the combustion chamber the flue gas flow is reversed and is
then led through the flue gas tubes, arranged cylindrically around the combustion
chamber. The flue gas leaves the air heater with max. 400°C.
The second primary air stream cools the flue gas tubes. Within the convection part
the flue gas is cooled down in co-current flow (to approx. 80°C at FG-mode, to ap-
prox. 150°C at LFO-mode) and supplied through the heat exchanger to the stack.
At the end of the air heater both primary air streams are mixed together and supplied to
the customers piping to the EGRON or to the customers hot air stack.
The flow in the air heater system is in horizontal direction.
Battery limits of the primary air heater system attend

P&I – Diagram, drawing no.: 05377215
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1.2 Operating of the plant
The primary air temperature is controlled by air heater PLC – controller. The primary air is
measured with a resistant thermometer provided in clients piping behind the VTT system.
Depending on this temperature the combustion air and the fuel control valve of the burner
will be opened or closed. The fuel control valve and the combustion air fitting are electron-
ically connected by the burner control manager.
The primary air MAX-temperature is watched by resistant thermometer provided in clients
piping behind the VTT heater and a temperature limiter inside the burner control cabinet.
When the maximum allowed temperature of (TSH 07.04) at heater outlet is increased the
burner will be shut off.
The flue gas MAX-temperature at air heater outlet to heat exchanger is watched by a fur-
ther resistance thermometer and a safety temperature limiter (TSH 07.06 and will also
shut off the burner in case of to high flue gas temperature.
The primary air MIN-flow through the VTT heater is watched by a differential pressure
switch connected between primary air inlet and outlet pipe. When the differential pressure
of switch (PDSL 07.08) is lower then MIN the burner will be shut off to prevent damages
of the system.
The differential pressure control as well as the temperature limiters will be adjusted during
commissioning.
For SET POINTS and ALARM SETTINGS look at Chapter 11.2.4
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1.3 Suppliers
1.3.1 Air heater unit
John Zink KEU GmbH

Hülser Straße 410
D – 47803 KREFELD
Phone: + 49 (0) 2151 / 899 0
Fax: + 49 (0) 2151 / 899 111
1.3.2 Burner unit
WEISHAUPT GmbH
1.4 Appropriate use of equipment
The air heater with burner unit is exclusively designed for heating of primary air according
to technical data specified in chapter 3. Any other use of the equipment is not permitted.
KEU is not liable for any damage arising from misuse.
It is strongly recommended to:
 observe all references of the operating instructions and
 carry out inspection and maintenance works as scheduled
1.5 Technical safety guidelines
This described plant is in conformity with:
 DIN EN 746 - 2 Industrial thermo processing equipment,

Safety requirements for combustion and fuel handling systems,
 DIN EN 676 Gas burner
 DIN EN 267 Fuel Oil burner
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 DIN EN 230 fuel oil burner control systems
 VGB4 BGVA3
 DIN EN 292 Safety of machines, units and plants.
For special Burner Guidelines attend the Declaration of conformity

in accordance with ISO / IEC Guide 22 in Chapter 17.
1.6 Requirements and qualifications: operating personnel
In case of unqualified engagements into the plant or if not following the warning refer-
ences specified in this documentation, severe body injuries or damage to property may
occur.
Only appropriately qualified personnel are allowed to carry out operation at the plant.
Qualified personnel acc. to the safety guidelines in this documentation are persons who
are:
 are either familiar with the safety devices and the operation of the plant
 are instructed as an operating personnel how to operate the air heater and know about
the operation as described in this documentation
 have an education which enables them to act as a personnel to put plants into opera-
tion or to maintain the plant
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2 Safety
2.1 Basic safety references
The references in the operating instruction have strictly to be observed.

Basic requirement for a safe and free of interferences operation of the air heater plant is
the knowledge of the basic safety references and safety regulations.
This operating instruction contains the most important references to operate the plant
safely.
This operating instruction especially the safety references must be observed by all per-
sons working on the air heater plant.
Beyond that the references and regulations for accident prevention valid for the operation
area must be observed.
Unqualified manipulations to the system or non-observance of the warnings mentioned in
this documentation may cause human insurances or material damages.
Therefore, only qualified personnel is allowed to operate and maintenance the system.
2.2 Obligation of the owner
The owner is obliged only to have persons working at the machine which are:
 familiar with the basic regulations about work safety and accident prevention and are
instructed in operating the plant
 have read, understood and signed the safety chapter and the warning references in
this operating instruction
The safe working of the personnel must be checked regularly. Regular safety au-
dits/reviews are recommended to ensure conformance to safety regulations and proce-
dures.
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2.3 Obligation of the personnel
Before starting work all persons who are working at the plant are obliged
 to observe the basic regulations on safe work and accident prevention
 to read the safety chapter and the warning references in this operating instruction
 to sign that they have understood the instructions
2.4 Risks in operating the plant
The primary air heater with the burner (Technical data’s look at chapter 3) is built accord-
ing to the state-of-the-art technology and the acknowledged technical safety regulations.
Nevertheless in dealing with the plant life-threatening dangers for the user as well as oth-
er persons or damages to the plant or other material assets respectively may arise when
operating the primary air heater.
The primary air heater plant is only to be used:
 as directed (see chapter 1.4)
 in a technical safe and perfect condition

Any disturbances that can endanger the safety must be removed immediately.
2.5 Guarantee and liability
Guarantee and liability claims in case of damage to persons and things are excluded if
they are due to one or several of the following causes:
 Inappropriate use of the plant.
 Improper mounting, putting into operation and maintenance of the plant.
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 Use of the plant even with defective safety devices or safety devices that are not
appropriately installed and / or by-passed.
 Failure to comply with the references in the operating instructions with regard to
transport, storage, mounting, putting into operation, operation and maintenance of the
air heater plant.
 Unauthorized structural changes within the air heater plant.
 Unauthorized changes in the burner adjusting data.
 Insufficient supervision of machine parts that are wearing out.
 Repairs that are carried out inappropriately.
 Catastrophes due to effects of foreign substances and supernatural power.
2.6 Safety guidelines
2.6.1 Safety Chain (interlock system)
 Before every start-up of the primary air heater system all safety devices must be
Installed and working properly.
 Safety devices must only be de-installed if the power of the burner switch cabinet is
Switched of by main switch and if it is secured against starting. (attend chapter 2.6.8)
The main safety chain consists of:
 Emergency-push-button HS V1S1 inactive

 Emergency-push-button PB 06.30 inactive
 Limit Switch at Burner Flange ZS S7 closed
 Primary air at air heater inlet Pressure PSH 07.12 below high
 Primary air flow min PDSL 07.08 above min
 Combustion air pressure min PDSL 01.07 above min
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 Flue gas temperature max at air heater outlet TSH 07.06

 Primary air at air heater outlet TSH 07.04
 Fuel gas pressure min PSL 01.14 above min
 Fuel gas pressure max PSH 01.15 below high
 Fuel gas double block safety shut-off valve tightness check Unit PSL 01.16
In case LFO is chosen as fuel, the safety chain must be advanced
 Limit Switch at Fuel Oil Fitting ZS 01.29

 MAX- Pressure Light Fuel Oil PSH 01.27
 MAX- Level Oil Sump LSH 01.37 customers equipment
 MIN- Pressure Light Fuel Oil (PSL 01.26)
If these signals are in good condition, the main safety chain can be unlocked / closed by pushing “reset safety
chain” on the Burner Control cabinet. A deviation of one of these signals leads to an immediately shutdown,
burner trip. The safety chain must be rearmed after coming back to good conditions. The operator gets a
message for example “main safety chain closed”.
2.6.2 Inspection of flame
ATTENTION!
Sight Glass / Flame Inspection Device!
Due to risk of damage, the sight glasses in the inspection device must in no case
be exposed continuously to high temperatures in the combustion chamber!
Observation for a short period only!
Make sure that the inspection device is shut tight after each use
to avoid soot build-up and leakage of hot gases.
Damaged sight glasses must be changed at once!
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 Check the burner flame pattern through the sight glasses (located at the back door) at least
once a day.
Sight glasses
 Check that the flame pattern is good and centred and not touching the combustion chamber wall
at any point.
 In such a case, switch off the burner at once to avoid serious damage to the combustion cham-
ber main drum and check condition of the burner nozzle / diffuser.
 Then check fire installation and readjust the flame.
 At the same time check the flue gas pipes for any soot deposits and clean them if required.
2.6.3 Elongation of heater
 During start-up, ensure gradual expansion of the unit by using lowest burner capacity (lowest
preset fuel volume) for about 30 minutes until elongation of air heater can be seen at the support
construction (observe the dilatation on the support rollers).
For start-up procedure, see chapter 8.4 and 8.5.
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2.6.4 Safety measures
 A copy of the Operating Instructions must be kept permanently within the air heater plant area,
easily accessible to operators / personnel.
 In addition to the operating instruction the universal as well as the local plant regulations for ac-
cident prevention and for pollution prevention must be available and observed.
 Company regulations for accident prevention must also be available.
 All safety and emergency procedures at the plant are to be kept and readily available.
2.6.5 Instruction of the personnel
 Only trained personnel that are introduced to the job are allowed to work at the plant.
 The competence of the personnel is to be clearly laid down for mounting, commissioning, oper-
ating, maintenance and repairing.
 Personnel under training are only allowed to work at that plant when supervised by an experi-
enced person.
2.6.6 Plant control
 Unauthorized alterations on the burner control are strictly prohibited!
 Only trained personnel are allowed to operate the control system!
2.6.7 Safety measures for normal operation conditions
 Only when all safety devices work properly the plant can be operated.
 Before turning on the burner plant it must be guaranteed that no person can be
endangered by the operating plant.
 At least once per shift the plant is to be checked for visible damages and perfect
functioning of the safety devices.
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2.6.8 Dangers due to electrical energy
 Works at the electrical supply must only be carried out by an electrical engineer.
 The electrical equipment of the plant must be checked regularly.
 Loose connections and damaged cables must be removed immediately.
 The control panel must always be locked.
 Only authorized personnel with a key are permitted to have access to the panel.
2.6.9 Exceptional dangers
 Hot surfaces in the area of the burner casing, flame tube and air heater body, especially the
back door.
► Danger of severe burns when contacting the hot surfaces ◄
 Access openings have to be closed by customer to prevent unauthorized admittance.
 When work is to be carried out on the burner unit, flame tube or inside the combustion chamber,
allow sufficient time for cooling down.
 Secure plant against unintentional / accidental start-up.
2.6.10 Leakage of explosive gases and combustible liquids
 Only personnel with special knowledge and experience in gas and fuel oil
installation are allowed to work at the equipment of the gas and fuel oil valve trains.
 Before start of any repair works, follow standard procedure in depressurization of lines
beforehand.
 Take care of sufficient ventilation, draining and inertisation.
 After completion of work always check the fuel pipes for tightness by using pressure
test or treat with leakage spray in case of gas fuel.
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2.6.11 Noise / hearing protection
 Noise exceeding safe levels which can cause damage or loss of hearing could potentially be
generated during the Air Heater operation.
 In this case the operating personnel must be equipped with appropriate protection equipment
(ear plugs or ear muffs).
2.6.12 Structural changes at the air heater plant
 Do not make any changes, extensions or modifications without permission of the

manufacturer. This applies as well for welding at supporting parts and structure.
 All modifications need to be confirmed in writing by the manufacturer.
 Replace machine parts that are not in perfect condition immediately.
 Only use original spare and wearing parts.
 When using non-original spare parts of other dealers it is not guaranteed that they are
designed and manufactured according to respective safety regulations and specifica-
tions.
2.6.13 Maintenance and service, elimination of malfunction
 Follow specified instructions for SHUT-DOWN of the Air Heater Plant according to this
Functional Description before carrying out any work
 Furthermore the POWER SUPPLY has to be SWITCHED OFF / CUT OFF with the
main switch at the LOCAL BURNER CONTROL CABINET.
 Attached a label to the switch board reading:
C A U T I O N!
- MAINTENANCE WORKS-
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 Inform operating personnel before maintaining and repairing works.
 Recommended maintenance, adjustments and inspection works must be carried out

within the period stipulated (attend chapter 9).
 Secure attachment of large components to lifting gear carefully when changing them.
 Check screws for looseness and tighten accordingly.
 After each maintenance work, check the safety devices for perfect functioning.
 After working on the fuel pipe check the respective pipe sections for tightness by using
pressure test or treat with leakage spray in case of gas fuel.
2.6.14 Cleaning of the plant and disposal
 The used materials are to be handled adequate and be disposed, in particular if sol-
vents are used for the cleaning.
2.6.15 Copyright
 The copyright of this functional description remains at the manufacturers of the air
heater plant.
 This documentation is intended only for the owner and his personnel.
 It contains
Instructions and references that must not be completely or partially copied, distributed
or informed in any other way to a third party.
 Contravention can lead to criminal prosecution.
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3 Technical data
3.1 Process and design data
3.1.1 Air heater with heat exchanger fuel gas mode

Fuel NG
Heat output, net kW 2100
Heat output air heater kW 1880
Heat output heat exchanger kW 220
Primary air mass flow kg/h 19000
Primary air Inlet temperature heat exchanger °C 10
Primary air Outlet temperature air heater °C 393
Fuel gas consumption m3/h 235
Excess air NG λ 1, 2
Flue gas mass flow kg/h 3650
Flue gas outlet temperature air heater °C 350
Flue gas outlet temperature heat exchanger °C 80
Pressure loss air heater primary air side mbar 30
Pressure loss air heater flue gas side mbar 4,5
Pressure loss heat exchanger primary air side mbar 5
Pressure loss heat exchanger flue gas side mbar 3,5
Total pressure loss primary air side mbar 35
Thermal efficiency air heater with heat exchanger % 90,5
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3.1.2 Air heater with heat exchanger in Light fuel oil mode
Fuel: LFO
Heat output, net kW 2100
Heat output air heater kW 1880
Heat output heat exchanger kW 220
Primary air mass flow kg/h 19000
Primary air Inlet temperature heat exchanger °C 10
Primary air Outlet temperature air heater °C 393
LFO consumption kg/h 235
Excess air LFO λ 1, 25
Flue gas mass flow kg/h 3750
Flue gas outlet temperature air heater °C 350
Flue gas outlet temperature heat exchanger °C 120
Pressure loss air heater primary air side mbar 30
Pressure loss air heater flue gas side mbar 5
Pressure loss heat exchanger air side mbar 3
Pressure loss heat exchanger flue gas side mbar 4
Total pressure loss primary air side mbar 33
Thermal efficiency air heater with heat exchanger % 89
The performance data in chapter 3.1.1 and chapter 3.1.2 are based on clean heating sur-
faces.
The heat efficiency and the fuel consumption are calculated with a tolerance of ± 5%.
The pressure losses are calculated with a tolerance of ± 10%.
The tolerances are based on the design values.
For more PROCESS and DESIGN DATA look at the P&ID and at the MEDIA LIST
they are part of this documentation in chapter 11.1.2 and chapter 11.2.6.
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3.2 Burner data
Manufacturer WEISHAUPT
Burner type: WM-GL30/3-A
Total heat capacity: 5700 kW
Fuel gas: Natural Gas
Calorific value (LHV): 9,86 kwh/m³
Fuel gas pressure: 200 mbar g
3 3
Fuel consumption: min 0 mN / h … max 235 mN / h
Fuel oil: LFO
Calorific Value (LHV): 11,86 kWh/ kg
Fuel Oil Inlet Pressure: 400 mbar g
Fuel Consumption: min 0 kg / h … max 198 kg / h
Combustion Air: Ambient Air
Combustion Air Volume: min 4000 kg / h … max 4100 kg / h
Excess Air: 1, 2 to 1,25(λ)
Flue Gas Temperature: from 0°C … + 850°C
Pressure Combustion Chamber: 0 … + 13 mbar
Normal Voltage: 400 V 50 Hz (3P + T + N)
Control Voltage: 230 V 50 Hz
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4 Description
4.1 Structure of the air heater equipment
Air heater plant with VTT heater and WT economizer
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Air heater VTT with opened combustion chamber door
Flue gas tubes
Combustion chamber
Combustion Section of VTT heater

chamber door Burner insert
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Double shell around combustion chamber with swirl vanes
Tube bundle
Flue gas inlet

Cleaning door
Section of economizer
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4.2 Structure of the burner equipment
The burner is a modular designed, nozzle-mixed dual fuel compact burner unit.
The burner unit includes within its casting connections for the main fuel gas, the pilot fuel
gas, the heavy fuel oil, the ignition electrode and the flame sensor. The combustion air
fan is also part of the burner unit.
The burner unit is mounted into the combustion chamber insert of the heater. All required
devices for fuel, air supply and control of the burner are mounted to the heater unit.
The burner can be drawn out of the combustion chamber for maintenance and inspection
works.
The primary air differential pressure over the air heater unit will be approx. 47 mbar at de-
signed maximum primary air flow.
Compressed air, supplied by the primary air plant, is needed for cooling / purging of the
combustion chamber sight / inspection glasses.
The pressure air has to be dry and free of any oil.
The flame sensor is cooled by the combustion air of the burner.
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5 Transport and storage

All units must only be lifted from the supplied transport eyes / lifting lugs.
The units of the air heater as well as the fittings and the switchboard must be protected
against outside stresses.
The switchboard and all electrical units must be protected against rain and from the ele-
ments.
When the unit is expected to be stored for a prolonged period, it must be packed acc. to
the storage conditions and kept dry and warm.
A brand-new air heater should not be exposed to ambient temperatures lower than + 4°C
due the risk of damaging the refractory.
Rotating parts (e.g. fan shaft) must be manually rotated from time to time to prevent stor-
age damages.
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6 Mounting
The air heater and the heat exchanger are separate completely assembled in our works.
For shipping dates look at separate data sheet.
At site they have to be assembled in accordance with our arrangement drawing no

05377115.
The heat exchanger framework is part of customer delivery.
For foundation attend our drawing no. 15377116
6.1 Mounting instructions air heater and heat exchanger
For mounting the primary air heater the drawing no. 15377116 is binding.
Before positioning of the heater the foundation has to be prepared very carefully. The
base for that is the above mentioned drawing no.
After finishing the preparatory work the primary air heater can be installed by using a
crane.
The crane ropes only are allowed to be fastened at the provided eyes at the heater.
The important mounting tips at the drawing no. 15377116 are to be attended.
The most important assembly works are:
Mounting / installation of the heater to the foundation is in the responsibility of the cus-
tomer.
As shown at the construction drawing, the heater has to be anchored to one base support
point only. The foundation bolts including nuts required for this are to be provided by the
customer.
The support located on the door side must be able to slide without restriction so that the
heater can expand longitudinally when in operation.
For this reason it is necessary to provide foundation plates underneath the support as
shown on the foundation plan and the arrangement drawing.
The rollers (50 mm round bars) included in KEU supply must be positioned on the loose
supports (door side).
The pressure screw is located underneath the combustion chamber lid fixture and serves
to support the weight of the door.
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DOCUMENTATION

Support combustion chamber door
Prior to opening the combustion chamber door this screw must be unscrewed to such an
extent that the base plate firmly rests on the foundation.
After closing of the combustion chamber door the base plate must be lifted the foundation
by one rotation of the pressure screw due to heat expansion during operation.
When connecting the primary air pipes with the double flap and flue gas pipes to the heat
exchanger and the heater, please note that the customer has to provide supports for
these and provide them with the necessary expansion compensation / flexible joints.
Flange connections between heater, heat exchanger, primary air double flap with ducting
and connecting duct pieces.
The selection and the arrangement of the sealing / gaskets for flange connections, vide
the arrangement drawing.
The sealing / gasket material is to be selected acc. to the highest operating temperature
and the combustion chamber pressure.
The sealing glued to one flange only, namely sealing rope and FIBERFRAX square tress
rope with PATTEX.
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DOCUMENTATION

The customer should make sure that the primary air ducts of the complete system
and the flue gas ducts up to the flue gas stack can be purged freely.
The burner unit incl. the accessories and all connection to the air heater plant must
be protected against outside stresses.
Observe zero potential / stress - free assembly of all connections.
6.2 Mounting instructions burner
The burner unit is supplied pre-mounted and consists of:
 Fuel gas pipe trains for main and for pilot gas,
 Fuel oil circulation unit,
 Fuel oil shut off fitting unit,
 Burner unit including fuel oil pump unit, combustion air fan and mounting flange,
 Burner control cabinet,
 Thermocouple and resistance thermometer,
Mounting of the burner unit by customer comprehends following works:
 Piping and assembling of the equipment belonging to the fuel lines, to the customers
supply lines and to the burner as shown at the P&ID drawing no. 05375735.
 Connection of the fuel supply lines (fuel gas and fuel oil) to the burner fittings station.
 Oil sump with level control is also part of customer delivery.
 After assembling every fuel line has to be checked that they are absolutely tight.
Before pressure test it has to be approved that the line instruments are save against
the test pressure. That means maybe the pressure gauge valves have to be closed
or some instruments have to be dismounted during the test period.
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DOCUMENTATION

 Installation and wiring of the field equipment to the burner switchboard according to
the P&ID in chapter 11.1.2, the WEISHAUPT wiring diagram in chapter 11.1.3 and
the air heater arrangement drawing in chapter 11.1.5.
 Voltage supply connection 400V 50Hz to the burner cabinet.
 UPS - voltage supply connection 230V 50Hz to the burner cabinet.
 Signal cabling from the burner cabinet to customers control system.
Improper use of burner, fittings and other accessories of the heater equipment
(e. g. as “ladder or platform”) is not allowed.
Observe zero potential assembling of all connections.
ATTENTION!
The burner and the attached accessories have to be protected

from external loading influences.
It is not allowed to climb onto the burner, fittings and other accessories.
Take care during mounting that the control panel as well as all other electrical
parts
are protected from rain and other weather conditions.
The documents of the burner in Chapter 11 and 12 are binding for

Burner assembly
Burner wiring
Burner operation
and
Burner maintenance
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DOCUMENTATION

7 Commissioning and operation

For control Philosophy of air heater plant operation during start- up,
shutdown and hot air temperature / pressure adjustments in relation to
the boiler house and Egron control system attend the
NESTLÈ – User Requirement Specifications” Rev. 2.4
as part of this Functional Description. (Attend Chapter 20)
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8 Description of the burner control

The burner can be operated either from the external customer plant control (EGRON
DCS) or local from the HMI which is mounted in the door of the air-heater control cabinet.
This cabinet is to be located near to the primary air heater plant.
The operation of the burner is monitored by a hardwired burner control unit with a digital
combustion manager suitable for continuous operation, start sequence control, flame
monitoring and valve proving for fuel gas valves. The digital combustion manager is a part
of the Air heater control cabinet.
The burner control unit is linked to a MOD-Bus master witch is connected to Allan Bradley
PLC mounted inside the burner control cabinet. Via Ethernet the local control panel HMI
communicates with the Air heater PLC.
The Air Heater PLC communicates with CLIENTS DCS ( Egron control) via Ethernet net
and with the CLIENTS primary air fan MCC also via Ethernet.
Exchanged ANALOGUE SIGNALS are 4 … 20 mA.
Exchanged BINÄR SIGNALS (hardwired) potential-free.
Following MANUAL CONTROL ELEMENTS are at the LOCAL CONTROL PANEL and
BURNER CONTROL CABINET:
LOCAL CONTROL PANEL (FIELD)
- BUTTON – EMERGENCY – STOP HS (V1S1)

- BUTTON – ALARM RESET (PLC FAULT) (V1S5)
- SWITCH – BURNER CONTROL ON / OFF (R1S1)
- SIGNAL LAMP – “PLC FAULT” (flashing light “collecting fault signal”) (A10)
- SIGNAL HORN – “PLC FAULT” (buzzer “colleting fault signal”) (A10)
- SIGNAL LAMP – “BURNER CONTROL ON” (burner “running on”) (R1S1)
- SIGNAL LAMP – “BURNER ON” (R1A10)
- TOUCH PANEL – “Panel VIEW PLUS 1000” (B10CAD1)
- SWITCH – MAIN POWER 400 V 50 Hz (A1Q1)
- SWITCH – UPS POWER (on cabinets mounting plate) 230 V 50 Hz (S1)
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8.1 Description of the Interface
Look also at Wiring diagram WEISHAUPT burner in chapter 11.1.3.

Normally Primary Air Heater Plant is executed with 1 Primary Air Fan 06.12.
For detail BURNER CONTROL information’s look at

Chapter 11.1.3 WIRING DIAGRAM and
8.2 Operation from CUSTOMERS plant control
 Put the PRE-SELCTION at LOCAL TOUCH PANEL into “REMOTE - MODE”.
 Fuel PRE-SELCTION at LOCAL TOUCH PANEL “FG - / HFO - MODE”.
 The air heater can be started by the EGRON PLC signal „BURNER START”.
 Now the PRIMARY AIR FAN, the COMBUSTION AIR FAN and the FUEL OIL SUPPLY
PUMP automatically will be set in operation by BURNER CONTROL PLC.
Only when primary air fan, the combustion air fan and fuel oil supply pump are running
the whole unit can be started and pre-purged.
ATTENTION!
Start of FUEL OIL SUPPLY PUMP only if LFO-MODE was selected.
Power control of primary air fan and fuel oil supply pump are realised in CLIENTS
MCC.
 All external interlocks must be released.
 The burner control with its purging-time-relays can only be activated if the primary air
fan and the combustion air fan have been started properly.
 Sufficient combustion air flow is monitored by the pressure switch (PDSL 01.07).
 Sufficient primary air flow is monitored by the pressure switch (PDSL 07.08).
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ATTENTION!
The operator of the plant has to ensure that the entire combustion system from
the burner to the stack can be purged without any flow obstruction.
(For PURGING attend START- UP Chapter 8.5.1)
 After the checks of the safety chain have been passed properly the burner will be
started automatically by the burner management system.
 The burner now rests in operation as long as no fault shut-down arises.
 The burner shut-off will be executed if the Button “BURNER OFF” pushed is on the
HMI” or in case of a fault by one of the interlocks or preconditions.
 The fuel valves close and the Burner trip.
ATTENTION!
The primary air fan and the combustion air fan remain in service
for additional ventilation of the system for approx. 20 minutes.
(For SHUT- DOWN attend Chapter 8.5.3)
8.3 Operation from LOCAL air heater control cabinet
 Put the PRE-SELCTION at LOCAL TOUCH PANEL into “LOCAL - MODE”
 Fuel PRE-SELCTION at LOCAL TOUCH PANEL “FG - / HFO – MODE”.
 The air heater can be started by BUTTON at TOUCH PANEL „BURNER START”.
 Now the PRIMARY AIR FAN, the COMBUSTION AIR FAN and the FUEL OIL SUPPLY
PUMP automatically will be set in operation by Air Heater PLC.
Only when primary air fan, the combustion air fan and fuel oil supply pump are running
the whole unit can be started and pre-purged.
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DOCUMENTATION

ATTENTION!
Start of FUEL OIL SUPPLY PUMP only if HFO-MODE was selected.
Power control of primary air fan and fuel oil supply pump are realised in CLIENTS
MCC.
 All external interlocks must be released.
 The burner control with its purging-time-relays can only be activated if the primary air
fan and the combustion air fan have been started properly.
 Sufficient combustion air flow is monitored by the pressure switch (PDSL 01.13).
 Sufficient primary air flow is monitored by the pressure switch (PDSL 07.08).
ATTENTION!
The operator of the plant has to ensure that the entire combustion system from
the burner to the stack can be purged without any flow obstruction.
(For PURGING attend START- UP Chapter 8.5.1)
 After the checks of the safety chain have been passed properly the burner will be
started automatically by the burner management system.
 The burner now rests in operation as long as no fault shut-down arises.
 The burner shut-off will be executed if the button “BURNER OFF” pushed on the HMI
or in case of a fault by one of the interlocks or preconditions.
 The fuel valves close and the burner trip.
ATTENTION!
The primary air fan and the combustion air fan remain in service
for additional ventilation of the system for approx. 20 minutes.
(For SHUT - DOWN attend Chapter 8.5.3)
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8.4 Commissioning
ATTENTION!
The commissioning of the burner must only be done by authorized and qualified
specialists who are familiar with the special plant conditions as well as with the
operation and safety devices.
Before the commissioning can be started please check if the burner parts have been en-
tirely supplied and if those parts are properly mounted and connected to the supply lines.
These measures will be the basis for the proper process of the continuing works.
In detail we suggest to proceed as follows:
 Compare the burner, fitting and accessory types with the received technical documentation.
 Check fittings to correct installation position.
 Check fuel lines to free flow. The lines have to be free of any dirtiness and impurity.
 Check fuel inlet pressure before opening the fuel fitting to the burner.
 Check electric units to correct energy connections.
 Check flame detector to suitability to the specific flame control system.
 New installed fuel lines are always air-filled and must be deaerated before start-up.
 The supply voltage of the burner control has to be released.
 The primary air fan has to be set in operation for testing the invigilators.
 At minimum air flow working of the primary air fan, the pressure switch (DPSAL 07.08)
has to be adjusted.
 Open main fuel fitting and check if the contacts of the safety devices are closed.
 The function of each control and safety device must be tested by simulating the differ-
ent alarms. The results have to be recorded in writing (attend chapter 2.6.1).
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 The flue gas damper has to be fixed in OPEN POSITION (ZSAH 07.16).
 Check signal exchange to superior control system.
 Fuel differential pressures at load case (MIN – NORM – MAX):

They have to be checked during start up and have maybe to be changed.
PD - Main fuel => combustion chamber 00 mbar

PD - Ignition fuel => combustion chamber 00 mbar
PD - Light fuel oil => combustion chamber 00 bar
PD - Primary air => heater system 00 mbar
 Now it must be checked that the drives at the control fittings work correct according to
the signal of the temperature regulator.
 The fuel control and the combustion air control fittings must be set to the minimum or
Start position. For Details look at WEISHAUPT – MANUAL in chapter 12.
 If all pre-conditions mentioned before are released, the combustion air blower is
started by the control system and if purging time is finished the burner start can be ex-
ecuted.
 The fuel / air - ratio has to be adjusted over the complete turndown range such that a
stable flame and good combustion quality can be guaranteed (flue gas testing re-
quired).
 After first heating up to process temperature all flange connections must be

retightened as far as possible by customer. This procedure has to be done again after
an operation time of 5 days. After 500 h operating time the flange connections must be
visually checked to tightness by customer.
Start - up settings look at Chapter 11.2.4 LIMIT AND SET POINT LIST.
Dates must be completed / changed if necessary at the end of the commissioning.
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8.5 Start-up
8.5.1 FIRST START- UP and DRYING - OUT during commissioning
Before first operation the concrete in the air heater has to be dried out according to the
following instructions.
The drying out procedure has to be done with the fuel gas burner only.
The heating up has to be executed accordingly to the attached temperature curve in this
chapter.
The measurement of the temperature will be done with thermocouple (TIT 07.14), mount-
ed at the backside of the air heater.
DRYING – OUT has to be finished at a primary air temperature of 400°C (TIT 07.03). The
flue gas temperature (TIT 07.05) at the end of DRYING – OUT should be about 800 till
900°C. This limit value has to be fixed during commissioning.
Measuring point
TT 07.14
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DOCUMENTATION

ATTENTION!
The Temperature Control with a TEMPERATURE RAMP for DRYING – OUT will be
adjusted during FIRST START UP under the supervision of a KEU TECHNICIAN.
The FIRST START UP PERSONNEL has to ensure to work accurately
with the requested temperature curve as shown in this chapter.
The variation from this temperature curve must not be more than
CURVE SECTION A) ± 15 K below 500°C (DRYING - OUT with 8 K/h = 40 HOURS)

CURVE SECTION B) MAINTAIN the TEMPERATURE 500°C for 12 HOURS
CURVE SECTION C) ± 25 K above 500°C (HEAT UP to SERVIVE TEMP. with 20 K/h)
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DOCUMENTATION

TEMPERATURE CURVE (TIT 07.14)

FIRST DRYING - OUT
(°C)
1000
900
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50 60 70 80 90 100
time ( h)
Temperature curve DRYING - OUT and COMMISIONING at FIRST START- UP
SECTION A) below 500°C (DRYING- OUT = 40 HOURS)

SECTION B) at 500°C (TEMPERATURE MAINTAINING = 12 HOURS)
SECTION C) above 500°C (HEATING UP to SERVICE TEMPERATURE)
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DOCUMENTATION

Look also at the GENERAL GUIDELINES for DRYING - OUT and PRESERVATION of
the REFRACTORY LINING part of this functional description and operating instruction.
attend chapter 18)
 After first heating up to process temperature all flange connections must be

retightened as far as possible by customer.
 After an operation time of 5 days this procedure has to be done again.
 After 500 h operating time the flange connections must be visually checked to
tightness by customer.
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8.5.2 Instructions for FIRST HEATING UP after DRYING - OUT

FIRST HEATING UP after DRYING - OUT
(°C)
1000
900
800
700
600
500
400
300
200
100
0
0 10 20 30 40 50 60 70 80 90 100
time ( h)
Temperature curve at FIRST START- UP after DRYING - OUT
SECTION A) below 500°C (HEATING UP with 70 K/h)

SECTION B) at 500°C (TEMPERATURE MAINTAINING = 6 HOURS)
SECTION C) above 500°C (HEATING UP to SERVICE TEMPERATURE with 20 K/h)
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ATTENTION!
The Temperature Control with a TEMPERATURE RAMP for FIRST HEATING UP after
DRYING OUT will be realised during FIRST START UP
under the supervision of a KEU TECHNICIAN.
8.6 Operating Instructions
8.6.1 START- UP
The burner plant is designed for automatic operation and can be started automatically by
external signal from the superior plant control.
 Before starting the burner make sure that no person can be endangered by
running the plant.
 Before start – up, at least once per shift the entire plant has to be checked for
any external damages and soiling at the inlet filter of the combustion air fan.
 Clean flame detector and spark ignitor.
 Open main fuel valves careful.
 Turn on main switch at the control panel.

 Starting of the plant can be executed EXTERN from EGRON CONTROL ROOM or
LOCAL at the air heater cabinet, if the interlocks are released and the following pre-
conditions are fulfilled. (Attend chapter 8.2 and 8.3)
During start-up the primary air has to be supplied to the heater system with a temperature
between (T-MIN = + 10°C and T-MAX = + 60°C).
The primary air controller (PIC 13.21) is already released during start-up with a pressure
set point presetting from the EGRON CONTROL ROOM.
At start-up and preheating of the air heater the primary air is switched to the HOT AIR
STACK by the EGRON CONTROL ROOM.
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ATTENTION!
It has to be ensured that the complete exhaust air system
(Combustion chamber with heat exchanger and the piping’s to the atmosphere)
is sufficiently purged 5 times of the complete fluegas volume of the plant before
burner start according to the regulations of EN 746-2.
The PURGING TIME (according to EN 746-2) of the Combustion chamber and

Heatexchanger outlet is 180 seconds (3 Minutes) is realised with a TIME RELAY
inside the Burner Control.
The PURGE VOLUME of the combustion air fan during this PURGING TIME consti-
tutes too 4100 m³/h COMBUSTION AIR.
The amount of the complete fluegas volume from Burner to end of stack (outlet)
has to be calculated by the customer
The burner can be started. The successful purge is reached when the purge-timer has
elapsed.
Start-up from and to process temperature attend the guideline
“COOLING - DOWN AND HEATING - UP GUIDELINES”
ATTENTION!
The TEMPERATURE CONTROL (TIC 07.03) with a Temperature RAMP for HEATING
- UP
is provided in the burner control system which is
PART of the AIR HEATER CONTROL SYSTEM.
The Controller (TIC 07.03) with the HEATING - UP RAMP has
to keep the temperature curves witch are shown at Chapter 8.5.2.3.2.
After burner is in operating mode the TEMPERATURE CONTROLLER (TIC 07.03) has to
be activated for HEATING UP the air heater according to the HEATING – UP RAMP as
shown in chapter 8.6.2.3.2.
Start-up with lowest burner capacity (lowest preset fuel volume)
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DOCUMENTATION

At the end of HEATING UP the primary air behind air heater system will be heated to ap-
prox. 400°C by the controller (TIC 13.20).
If the conditions of the primary air are as estimated the primary air can be switched from
the HOT AIR STACK to the EGRON DRIER by EGRON CONTROL ROOM.
The maximum primary air temperature is limited at 420°C by (TSH 07.04).
For PRESSURE CONTROLLER - PRIMARY AIR (PIC 13.21) attend chapter 8.6.2.1.
For TEMPERATURE CONTROLLER - COMB. CHAMBER (TI 07.14) attend chapter
8.6.2.2.
For TEMPERATURE CONTROLLER - PRIMARY AIR (TIC 07.03) attend chapter 8.6.2.3.
For TEMPERATURE CONTROLLER - FLUE GAS (TIC 07.10) attend chapter 8.6.2.4.
To protect the air heater against overheating following safety equipment is provided:
1. Flue gas temperature (TSH 07.06) behind heater is limited by input of the nominal val-
ue in the burner management system.
2. Hot primary air temperature (TSH 07.04) at EGRON input is limited by input of the
nominal value in the burner management system.
3. Primary air MIN-flow is guaranteed and limited by differential pressure switch (PDSAL
07.08) by input of the nominal value in the burner management system. If the pri-
mary air volume decreases due to fan damages or other reasons resulting in lower dif-
ferential pressure over the air heater system the burner system is shut off by the dif-
ferential pressure switch.
If the primary air set temperature or pressure or volume or flue gas temperature or some
other safety limit of the burner management is exceeded an alarm is activated at the
PanelView 1000 and at the EGRON PLC and the burner system is shut off automatically.
Shortly – which means not more than 20 minutes – a maximum flue gas air heater outlet
temperature of 400°C at (TSH 07.06) is allowed.
The burner can be re-started when the air volume is increased and the differential pres-
sure is reached as listed in the LIMIT AND SET POINT LIST (see chapter 11.2.4).
Each safety shutdown caused by high temperatures requires a manual re-start of the
burner at side.
The flue gas from the burner leaves the combustion chamber with integrated air heater
and gets through the heat exchanger and the stack to atmosphere.
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DOCUMENTATION

Start-up mode:
Look also at operating instructions and functional description of the burner unit.
8.6.2 NORMAL- MODE
8.6.2.1 PLC – Controller Primary Air Pressure (PIC 13.21)
The Control of the Primary Air Pressure is executed with a controller inside the
BURNER CONTROL DCS.
The primary air pressure is measured in the hot air pipe to the spray drier (EGRON).
The speed of the primary air fan will be increased or decreased by the DCS-controller
output signal if the pressure of the primary air is increased respectively decreased from
the set point.
The set point range of the primary air pressure depends on the EGRON process values
and is between 000 and 000 mbar (Approval and fixing of these values at commission-
ing).
The actual set point is forced from EGRON CONTROL ROOM.
The DCS-controller part of the BURNER CONTROL is executed with external set point
guiding.
The controller (PIC 13.21) is active at EVERY AIR HEATER MODE.
At HEATING UP MODE the forced PRIMARY AIR VOLUME should be at MAXIMUM

flow at all times. The corresponding Pressure Set Point has to be selected accord-
ing to this volume.
Range of the Setting points look at LIMIT AND SET POINT LIST (see Chapter 11.2.4)
as part of this functional description and operating instruction.
Normal - Mode Burner:

See also WEISHAUPT operating instructions and functional description of the
burner system in Chapter 12.
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8.6.2.2 Control of Flue Gas Temperature Combustion Chamber (TIT 07.14)
(Part of KEU TECHNICIAN during DRYING OUT at FIRST START UP and at FIRST
HEATING DOWN and at HEATING UP after DRYING OUT)
The combustion chamber temperature is controlled by the KEU TECHNICIAN. The fuel
and the combustion air control valves are opened respectively closed when the tempera-
ture is increased respectively decreased from the set point ramp.
For set point ramp look at the curve diagram in Chapter 8.6.2.3.1
8.6.2.3 PLC – Controller Primary Air Temperature (TIT 07.03)
The Control of the Primary Air Temperature is executed with a controller inside the
BURNER CONTROL DCS.
The primary air temperature is measured in the hot air pipe to the spray dryer (EGRON).
The output signal of the controller (TIC 07.13) is conducted to the fuel and to the combus-
tion air control valves Flap 01.06 and CV 01.10 at FG - mode and to Flap 01.06 and CV
01.22 at LFO - mode.
The fuel and the combustion control valves are opened respectively closed by the PLC-
controller output signal if the temperature of the primary air is increased respectively de-
creased from the set point.
The set point range of the primary air temperature depending on the process values is 393°C.
The PLC-controller part of the BURNER CONTROL is executed with external set point
guiding.
The actual set point is forced from EGRON CONTROL ROOM.
The PLC controller is active at NORMAL HEATING UP – MODE and at NORMAL -

MODE.
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DOCUMENTATION

The TEMPERATURE SET POINT RAMP for HEATING UP has to be adjusted during
FIRST START UP by WEISHAUPT together with the KEU TECHNICIAN and has to real-
ise the combustion air temperature (TIT 07.14) nearly according to the GUIDELINES of
the REFRACTORY LINING.
For set point ramp look at the curve diagram in Chapter 8.6.2.3.2
The Air Heater at all times has to be heated up with the smallest possible Set Point / smallest
possible Fuel Volume.
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DOCUMENTATION

8.6.2.3.1 Temperature at Outlet Combustion Chamber (TIT 07.14)

NORMAL COOLING – DOWN and HEATING - UP
(°C)
1000
900
800
700
600
500
400
300
200
100
0
0 1 2 3 4 5 6 7 8 9 10
time ( h)
Temperature curve COOLING - DOWN and HEATING - UP
SECTION A) COOLING DOWN from SERVICE TEMPERATURE to approx. 300°C

(without BURNER) and
(with PRIMARY AIR FAN for 30 Minutes) and
(with COMBUSTION AIR FAN for 20 Minutes)
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DOCUMENTATION

SECTION B) COOLING DOWN to AMBIENT TEMPERATURE

(without BURNER and without FANS)
SECTION C) HEATING UP to SERVICE TEMPERATURE

(with BURNER for approx. 2 Hours)
The times for COOLING – DOWN and HEATING – UP shown at the Diagram
have to be controlled during START – UP.
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DOCUMENTATION

8.6.2.3.2 Temperature Primary Air behind the Air Heater (TIT 07.03/TIC13.20)

NORMAL COOLING – DOWN and HEATING – UP
(°C)
400
200
0
0 1 2 3 4 5 6 7 8 9 10
time ( h)
Temperature curve COOLING - DOWN and HEATING - UP
SECTION A) COOLING DOWN from SERVICE TEMPERATURE to approx. 200°C

(without BURNER) and
(with PRIMARY AIR FAN for 30 Minutes) and
(with COMBUSTION AIR FAN for 20 Minutes)
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DOCUMENTATION

SECTION B) COOLING DOWN to AMBIENT TEMPERATURE

(without BURNER and without FANS)
SECTION C) HEATING UP to SERVICE TEMPERATURE

(with BURNER for approx. 2 Hours)
The times for COOLING – DOWN and HEATING – UP shown at the Diagram
have to be controlled during START – UP.
8.6.2.4 PLC - Control Flue Gas Temperature (TIC 07.10)
The Control of the Flue Gas Temperature is executed with a controller inside the
BURNER CONTROL PLC.
The controller (TIC 07.10) is active at any air heater mode and is responsible for the flue
gas temperature control.
Set point of the flue gas temperature is 80°C at FG-mode.
Set point of the flue gas temperature is 120°C at LFO-mode.
The double flaps Flap 07.17 / FLAP 07.18 are controlled in such a position so that a cer-
tain part of primary air gets to the heat exchanger.
During standard operation the primary air is heated according to the fixed design load-
ings, according to the process parameters of the process data (see chapter 3.1).
For Range of the Setting points look at Chapter 11.2.4 LIMIT AND SET POINT LIST
which is part of this functional description and operating instruction.
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8.6.3 SHUT- DOWN
The air heater plant is automatic mode designed with the possibility to shut-down with signal from
EGRON CONTROL ROOM. (attend chapter 8.2 and 8.3)
 It is possible to STOP the plant from EGRON CONTROL ROOM or LOCAL from the
BURNER CONTROL CABINET at site.
 At SHUT DOWN MODE (COOLING DOWN MODE) the burner capacity will be re-
duced to minimum.
 For shut-down time temperature curve of the air heater look at the chapter 8.6.2.3.1
and the chapter 8.6.2.3.2.
 At the end of the burner shut-down time the burner will be shut off.
 The BURNER COMBUSTION AIR FAN REMAINS IN SERVICE for additional

ventilation of the air heater by using a time- lag relay inside the burner control.
The adjusted time at the relay is approx. 20 MINUTES and will be fixed during
commissioning.
 The PRIMARY AIR FAN also has to REMAIN IN SERVICE for approx. 30 MINUTES to
cool the primary air heater after BURNER has been SHUT- OFF. The cooling time
has to be adjusted with a second time relay inside the burner control and will be
fixed during commissioning.
 Only if the air heater is cooled down it is allowed to open the cleaning lid at the
combustion chamber.
 Only if the cooling times of the combustion air fan and the primary air fan are finished
it is allowed to switch off the power supply at the main switches of the burner
control cabinet and the CUSTOMERS primary air MCC.
Page 53 (82)
DOCUMENTATION

At the end of the Shut-down time:
 The voltage supply 400 VAC has to be switched off with the main switch at the
burner control cabinet.
 The fuel supply must be closed with the main fitting at the fuel line of the burner.
Shut- Down Burner:

See also operating instructions and functional description of the
WEISHAUPT burner in Chapter 12
Page 54 (82)
DOCUMENTATION

9 Maintenance
9.1 General checks and measures during productions
ATTENTION!
After first heating up to process temperature all flange connections
must be retightened as far as possible by the customer.
This procedure has to be done again after an operation time of 5 days.
After 500 h operating time the flange connections must be checked to tightness
by the customer.
 The plant has to be checked at least once per shift for external damages and proper
functioning of the safety devices.
 Check flame of the burner for irregularities like “LIFTING / PUMPING / PULSING”.
ATTENTION!
The glass of the inspection device must in no case be exposed to
constant temperature load of the combustion chamber.
Observation for a short time period only!
Damaged sight glasses must be changed at once!
 Pay attention to unusual noises and smell of fuel in the area of the burner.
For BURNER details look at WEISHAUPT documents as part of this documenta-

tion!
Page 55 (82)
DOCUMENTATION

9.2 Maintenance and inspection plan
9.2.1 In principle
 Keep the plant clean.
 Use only dry and oil-free compressed air for purging of the inspection glass. In this
plant primary air is used for purging the inspection glass.
ATTENTION!
Check the flame pattern through the inspection opening at least once a day.
Check that the flame is burning centrically and not touching the combustion
chamber wall at any point.
If the flame touches the combustion chamber, switch off the firing installation
at once to avoid serious damage to the combustion chamber cylinder.
Then check the firing installation and readjust the flame.
At the same time check the flue gas line for any soot deposits and clean them if
required.
 Maintenance and Inspection works as well as cleaning works must only be

executed, when the burner start is blocked in the EGRON CONTROL ROOM and
at the LOCAL BURNER CONTROL CABINET.
 The SUPPLY VOLTAGE 400 VAC has to be switched off with the main switch at
the LOCAL BURNER CONTROL CABINET.
 Attach label to the switchboard reading:
CAUTION
-MAINTENANCEWORKS-
Page 56 (82)
DOCUMENTATION

9.2.2 Weekly
 Check and clean combustion air inlet.
 Check linkage of the primary air control flaps FLAP07.17 / FLAP 07.18 and the fuel /
combustion air ratio control for tight connection, tighten connecting screws if neces-
sary.
Combustion air inlet Gas air ratio- control
Page 57 (82)
DOCUMENTATION

9.2.3 Monthly
 Clean fuel and air filters according to the instructions in the technical data sheets.
 Observe the information of the technical data sheets of the components.
 Check condition of burner nozzles. If necessary clean the nozzles.
 Pressure switch and temperature limiter function to be checked.

Adjusted values have to be regulated up respective down until control is activated.
Thereafter reset to original value and compare with the start-up set value.
(Look at SET POINT and LIMIT VALUE LIST in chapter 11.2.4)
 Check flame detector and clean it.

Demount flame detector and clean it as well
Handle with care flame sensor is fragile!
The flame detector should be exchanged even after cleaning it if during operation the
flame
signal drops significantly under the data measured at commissioning
( In chapter 12 the flame scanner is described in detail).
 Check tightness check for correct functioning.

Generate artificial leakage by opening the screws of the impulse lines between tight-
ness
control unit and gap between valves.
Start the control.
The leakage tester must give an alarm signal.
Exchange tightness control unit in case of missing alarm and repeat the test.
When test has been finished the screws have to be tightened and check with leakage
spray.
 Check condition of the spark ignitor. Exchange if necessary.
► Handle with care ceramic isolator is highly fragile ◄
Page 58 (82)
DOCUMENTATION

9.2.4 Every 6 weeks
 The actual state of the burner nozzles have to be checked.

 Clean the burner nozzles if required.
 Cleaning of measurement connection pipes to pressure switches, pressure transmitter
and pressure-reducing regulators by blowing through with instrument air.
Measurement connection pipes have to be removed completely.
 Cleaning Air Heater
 Cleaning works must only be executed, when the burner start is blocked in the
EGRON CONTROL ROOM and at the LOCAL BURNER CONTROL CABINET.
 Furthermore the POWER SUPPLY has to be SWITCHED OFF / CUT OFF with the
Main switch at the BURNER CONTROL CABINET.
 Attach a label to the switch board reading:
CAUTION!
- MAINTENANCE WORKS-
 The air heater should be cleaned approx. every 6 weeks. If not required, because
soiling is only less, the cleaning intervals maybe lowered.
 If cleaning the air heater the following cycle should be observed:
 Prior to opening the combustion chamber door the pressure screw must be unscrewed
to such a position that the base plate firmly rests on the foundation.
 Unscrew locks at the combustion chamber door and cleaning holes.
 Push cleaning brush through the flue gas tubes.
 Remove the soiling via the lower cleaning holes and blow compressed air through the
flue gas collector.
 Close combustion chamber door and cleaning holes and screw tightly.
Page 59 (82)
DOCUMENTATION

 After closing of the combustion chamber door the base plate must be lifted from the
foundation by rotation of the pressure screw due to heat expansion during operation.
Attend the pictures at sheet 60 till 65!
Locks for
door
Pressure
screw
Page 60 (82)
DOCUMENTATION

Cleaning opening
for combustion
chamber and
tubes
Cleaning opening for removal of

soot into flue gas tubes
Page 61 (82)
DOCUMENTATION

Cleaning openings for removal of soot into

flue gas tubes
Page 62 (82)
DOCUMENTATION

Cleaning door
economizer
Page 63 (82)
DOCUMENTATION

Inspection opening
for removal of soot
Page 64 (82)
DOCUMENTATION

9.2.5 Every 6 months
 Blow of impulse lines of pressure switches and controllers.

Screw impulse line completely and tight!
9.2.6 Every year
 The air heater plant has to be maintained completely by the service personnel of
the plant manufacturer.
Page 65 (82)
DOCUMENTATION

9.3 Trouble shooting and fault finding guide

Attend the “Operating instructions of the WEISHAUPT burner” (Chapter 12)
9.3.1 EMERGENCY- STOP- SWITCH at Burner Control Cabinet (HS V1S1)

Alarm present but local button not pushed
During FUEL GAS – MODE or Light FUEL OIL – MODE
Possible causes:
 Signal failure, check cabling at any connection point (junction box)
 Wiring connection failure
 Wiring broken
9.3.2 EMERGENCY- STOP- SWITCH at Burner Control Cabinet (PB 06.30)

Alarm present but local button not pushed
Possible causes:
 Signal failure, check cabling at any connection point (junction box)
 Wiring connection failure
 Wiring broken
9.3.3 Flame failure (BFS 01.01) before the ignition transformer is activated
Possible cause:
 Flame detector is outdated and reports a flame signal due to raised test voltage of the
burner control
 Flame detector must be exchanged.
Page 66 (82)
DOCUMENTATION

9.3.4 Burner does not ignite

Possible causes:
 Ignition transformer defective
 Spark ignitor damp or dirty
 Fractures in the insulation material or conducting insulator at spark ignitor
 Pilot valve(s) defective and do not open
 Fuel connecting pipe blocked
 Electric connection is loose
 Flame guard control device is defective
 Burner safety chain fails (look at chapter 9.5.23 and 9.5.24)
9.3.5 Burner only burns for a short time period

Possible causes:
 Flame detector signal is too weak due to soiled detector
 Flame detector signal is too weak as detector is obsolete
 Safety-shut-off-valves defective and do not open
 Minimum capacity of the main burner is too low
 Electric connection is loose
 Flame guard control device is defective
Page 67 (82)
DOCUMENTATION

9.3.6 Symptom: Burner does not start but no alarm present

Possible causes:
 Burner control unit inside control panel switched off due to faulty control circuit
 Start position of the control drive (fuel control fitting) not correct
 Remote start signal from customers control system not available
9.3.7 Flame failure (BFS 01.01) during operation

Possible causes:
 Flame detector signal is too weak as it is obsolete
 Minimum capacity of the main burner is too low
 Maximum burner capacity is too high  flame lift-off
9.3.8 CLOSED Burner flange limit switch (ZSL 01.02) not closed

Possible causes:
 Burner not fixed to the combustion chamber flange
 Limit switch blocked or broken
 Limit switch loose, not fixed in the correct position at the burner
9.3.9 OPEN Limit switch at flue gas damper (ZSH 07.15) not closed (Option)
During FUEL GAS – Light or LIGHT FUEL OIL – MODE
Possible causes:
 Damper bleed not fixed in the open position
 Limit switch loose, not fixed in the correct position at the damper
Page 68 (82)
DOCUMENTATION

9.3.10 Primary air pressure (PSH 07.12) above high

Possible causes:
 Primary air DCS pressure control loop fails
 Primary air fan with the VSD fails
 Limit value faulty
 MAX - pressure switch defective
 Measuring line to pressure switch blocked
9.3.11 Primary air flow (PDSL 07.08) below low

Possible causes:
 Primary air fan does not operate or blower filter at inlet is soiled
 Measuring lines to the air pressure switch blocked or broken
 Pressure switch defective
9.3.12 Combustion air flow (PDSL 01.07) above low

Possible causes:
 Combustion air blower does not operate
 Blower filter at inlet is soiled
 Measuring lines to the air pressure switch blocked or broken
 Pressure switch defective
 3/2-way-solenoid valve in the measuring line to the pressure switch defective
Page 69 (82)
DOCUMENTATION

9.3.13 Temperature flue gas (TSH 07.06) above high

Possible causes:
 DCS temperature control primary air (fuel control) not inside set point limit range
 DCS temperature control does not work perfectly
 Thermocouple defective
 MAX-thermostat defective or temperature adjustment not correct
 Not enough combustion air over the burner
9.3.14 Temperature primary air (TSH 07.04) above high

Possible causes:
 DCS temperature control primary air (fuel control) not inside set point limit range
 DCS temperature control does not work perfectly
 Thermocouple defective
 MAX-thermostat defective or temperature adjustment not correct
 Not enough combustion air over the burner
9.3.15 Fuel gas pressure (PSL 01.14) below low
During FUEL GAS – MODE

Possible causes:
 Fuel filter soiled
 MIN - fuel pressure switch defective
 Safety shut-off valve closed
 Measuring line to fuel pressure switch blocked or broken
Page 70 (82)
DOCUMENTATION

9.3.16 Fuel gas pressure (PSH 01.15) above high

Possible causes:
 Fuel pressure regulator defective or broken
 MAX - fuel pressure switch defective
 Measuring line to fuel pressure switch blocked
9.3.17 Fuel gas fittings tightness control unit (PSL 01.16)

Possible causes:
 Fuel fittings line polluted or defective
 Tightness control unit defective
 Tightness control unit adjustment not correct
9.3.18 OPEN Fuel oil fitting limit switch (ZSH 01.65) not closed
During Light FUEL OIL – MODE

Possible causes:
 Fitting not fixed to the Open position
 Limit switch loose, not fixed in the correct position at the fitting
9.3.19 OPEN Fuel oil fitting limit switch (ZSH 01.29) not closed

Possible causes:
 Fitting not fixed to the Open position
 Limit switch loose, not fixed in the correct position at the fitting
Page 71 (82)
DOCUMENTATION

9.3.20 Fuel oil pressure (PSH 01.27) above high

Possible causes:
 MAX - fuel pressure switch defective
9.3.21 Fuel oil pressure (PSL 01.01.26) below low

Possible causes:
 MIN - fuel pressure switch defective
9.3.22 Level control oil sump (LSH 01.37) above high (Customers Equipment)
During HEAVY FUEL OIL – MODE

Possible causes:
 Fuel Oil Line leaky
 Level Control blocked or broken
 Level Control loose, not fixed in the correct position at the Oil Sump
Page 72 (82)
DOCUMENTATION

9.3.23 FUEL GAS BURNER does not operate; Start program does not run
Possible causes:
 EMERGENCY - STOP switch (HS V1S1) at burner control panel pushed.
 EMERGENCY - STOP switch (PB 06.30) at primary air fan pushed.
 Flame detector signal (BFS 01.01) fails.
 Limit switch at burner flange (ZSL 01.02) not closed.
 Limit switch at flue gas damper (ZSH 07.15) not closed.
 MAX - pressure switch primary air heater inlet (PSH 07.12) above high.
 MIN - flow pressure switch primary air (PDSL 07.08) below low.
 MIN - flow pressure switch combustion air (PDSL 01.07) below low.
 MAX - temperature flue gas (TSH 07.06) above high.
 MAX - temperature primary air heater outlet (TSH 07.04) above high.
 MIN - pressure switch fuel gas (PSL 01.14) below low.
 MAX - pressure switch fuel gas (PSH 01.15) above high.
 Fuel gas fittings tightness control unit (PSL 01.16) leaky
9.3.24 Light FUEL OIL BURNER does not operate; Start program does not run
Possible causes:
 EMERGENCY - STOP switch (HS VS1) at burner control panel pushed.
 EMERGENCY - STOP switch (PB 06.30) at primary air fan pushed.
 Flame detector signal (BFS 01.01) fails.
 Limit switch at burner flange (ZSL 01.02) not closed.
 MAX - pressure switch primary air heater inlet (PSH 07.12) above high.
 MIN - flow pressure switch primary air (PDSL 07.08) below low.
 MIN - flow pressure switch combustion air (PDSL 01.13) below low
 OPEN limit switch at fuel oil fitting (ZSH 01.65) not closed
 OPEN limit switch at fuel oil fitting (ZSH 01.29) not closed
 MAX - pressure switch fuel oil (PSH 01.27) above high.
 MIN - pressure switch fuel oil (PSL 01.26) below low
 Level Oil Sump (LSH 01.37) above high
Page 73 (82)
DOCUMENTATION

10 Spare parts and maintenance service

Due to a high availability of the plant it is necessary that all recommended spare and wear
parts according to the spare parts list are on stock.
It cannot be guaranteed that any of these parts can be supplied shortly in case of need.
To keep a high availability of the system it is required to store all important spare parts
and wear and tear elements.
If you need our service, please contact us:
John Zink KEU GmbH

Energie- und
Umwelttechnik
Hülserstraße 410
D – 47803 KREFELD
Phone: +49 (0) 2151 / 899 – 0
Fax: +49 (0) 2151 / 899 – 111
E-mail: keu@johnzink.com
Page 74 (82)
DOCUMENTATION

11 Drawings and data sheets
11.1 Drawings
11.1.2 P&I - Diagram Drawing- No.: 05377215/6
11.1.3 Wiring Diagram Burner Control Drawing- No.: 75478 /020012
11.1.5 Arrangement Air Heater Drawing- No.: 05377115
11.1.6 Foundation Plan Drawing- No.: 15377116
11.1.8 Installation of Gaskets Type K68 KEU-Standard 650- 001
11.2 Technical data sheets
11.2.1 Field Instruments List ( 1 Sheets DIN A4 )

11.2.2 Measuring and control loop list ( 1 Sheet DIN A4 )
11.2.3 Technical Data Sheets ( 15 Sheets DIN A4 )
11.2.4 List of Set Points and Limit Values ( 1 Sheets DIN A4 )
11.2.5 Electrical Consumers List ( 1 Sheet DIN A4 )
11.2.6 Media List ( 9 Sheets DIN A4 )
Page 75 (82)
DOCUMENTATION

12 Documentation - Burner unit -
Page 76 (82)
DOCUMENTATION

13 Documentation - Spare parts and wear and tear elements-
Page 77 (82)
DOCUMENTATION

14 Documentation - Electronic equipment -
Page 78 (82)
DOCUMENTATION

15 Documentation - Fabric compensators -
Page 79 (82)
DOCUMENTATION

16 Documentation - Fabrication certificates -
Page 80 (82)
DOCUMENTATION

17 Documentation - EG -Declaration of conformity -
Page 81 (82)
DOCUMENTATION

18 Documentation - Refractory lining / insulation -
Page 82 (82)

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DOCUMENTATION

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

PRIMARY AIR HEATER - VTT

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

3 Technical data ........................................................................................................................................... 19

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

9.3 Trouble shooting and fault finding guide .......................................................................................... 66

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

 Air heater recovery exchanger or economizer

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

Internal flow of primary air

Battery limits of the primary air heater system attend

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

1.2 Operating of the plant

For SET POINTS and ALARM SETTINGS look at Chapter 11.2.4

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

1.3.1 Air heater unit

John Zink KEU GmbH

1.3.2 Burner unit

1.4 Appropriate use of equipment

It is strongly recommended to:

 observe all references of the operating instructions and

 carry out inspection and maintenance works as scheduled

1.5 Technical safety guidelines

This described plant is in conformity with:

 DIN EN 746 - 2 Industrial thermo processing equipment,

 DIN EN 676 Gas burner

 DIN EN 267 Fuel Oil burner

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

 DIN EN 230 fuel oil burner control systems

 DIN EN 292 Safety of machines, units and plants.

For special Burner Guidelines attend the Declaration of conformity

1.6 Requirements and qualifications: operating personnel

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

The references in the operating instruction have strictly to be observed.

2.2 Obligation of the owner

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

2.3 Obligation of the personnel

 to observe the basic regulations on safe work and accident prevention

 to sign that they have understood the instructions

2.4 Risks in operating the plant

The primary air heater plant is only to be used:

 as directed (see chapter 1.4)

 in a technical safe and perfect condition

2.5 Guarantee and liability

 Inappropriate use of the plant.

 Improper mounting, putting into operation and maintenance of the plant.

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

 Unauthorized structural changes within the air heater plant.

 Unauthorized changes in the burner adjusting data.

 Insufficient supervision of machine parts that are wearing out.

 Repairs that are carried out inappropriately.

 Catastrophes due to effects of foreign substances and supernatural power.

2.6 Safety guidelines

2.6.1 Safety Chain (interlock system)

 Emergency-push-button HS V1S1 inactive

Plant: Primary Air Heater VTT XIII ISSUE: 18.06.15

 Flue gas temperature max at air heater outlet TSH 07.06

In case LFO is chosen as fuel, the safety chain must be advanced

 Limit Switch at Fuel Oil Fitting ZS 01.29

2.6.2 Inspection of flame

Sight Glass / Flame Inspection Device!