CONTINENTAL THERMAL ENGINEERS

Admn. & Off & Works: 477, SIDCO Industrial Estate, Ambattur, Chennai – 600 098, India.
Tel: 91-044-26254266, 26259988, 26257195, 26257239, 26257303 Fax: 26244366 E- mail: contitherm@vsnl.com

ERECTION AND COMMISSIONING INSTRUCTIONS FOR GAS TRAIN SYSTEM

1. Ensure that the Customers Gas pipe line is flushed thoroughly to remove dirt
and welding fluxes.

2. Ensure available Gas pressure from the client’s pipe line is well with in the
designed inlet pressure of the Gas Train.

3. Remove the Dummy Gaskets provided on the Gas Train Inlet & Outlet (which is
provided to avoid dirt getting into the Gas Train during Transportation).

4. Connect the Gas Train inlet to the Customers gas pipe line as per the arrow
shown.

5. Proper Support to be provided to the Gas Train in such a way that the load of
pipe line does not act on any of the Gas Train Components.

6. Make Sure that all the Shut Off Valves prior to Gas Train are kept open and
required gas pressure is supplied at the inlet.

7. Ensure that all the Gas Valves near the Burners are kept closed to avoid any
leakage of Gas in to the furnace.

8. Check the Control Panel wiring as per the drawing and connect power (Drawing kept
inside the Panel)

9. Open, the Manual Gas Shut Off valve slowly (Part No. 1) on the Gas Train and
check the pressure on the inlet Pressure Gauge ( Part No. 3)

10. Set the Low & High Gas Pressure switches (Part No. 7 & 8) to the required level. Switch
on the
Control Switch on the Panel.

11. Set the Auto / Manual Switch on Manual mode. Red indicator will glow.

12. Check that the impulse pipe line to slam Shut Off Valve is connected.

13. Reset the handle to ON position on the Manual Reset type Solenoid Valve
(Part No. 4)
14. Adjust the Gas Pressure Regulator (Part No. 6) to the required level (As per manual)
by checking the Outlet Pressure Gauge ( Part No. 9).At this time, the blue colour
indicating lamp will glow and red colour will be off.

15. After ensuring that the green lamb is glowing on the panel, change the auto / manual
switch to Auto position.

16. Set the over Pressure Safety Valve (Part No. 10) to open when the Outlet Gas Pressure is
approx 10 M. Bar more than the required pressure. For this purpose, the Gas Pressure
Regulator can be adjusted temporarily & after setting the Safety Relieve Valve bring it
back to originally set level.

Even after the over pressure safety relief Valve opens, if the Gas Pressure does not come
to the required level, the high Gas Pressure Switch (Part No. 8) will make the Manual
reset type Solenoid Valve (Part No. 4) to close and the yellow indicator will glow on the
Control Panel.

17. Now proceed to Ignition of Burner as per Burner manual.

18. To close Gas Train: Ensure all Burners are Shut Off as per Burner Manual and then
Main Control Switch on Gas Train Control Panel to be put off. Close main Manual Gas
Shut Off Valve (1).

In case there is an electric power Failure

In case of an electric power failure, the blower will shut down, and at the same time the Gas
Solenoid Valve (4) will switch off. After correcting the problem restart procedure from step
No. 11 onwards (except step 13,14 & 16).

In case there is failure in gas Flow:

In case of a gas flow failure, the Gas Solenoid Valve (4) will switch off gas flow. This is done
when the Low Pressure Switch (7) / High Pressure Switch (Item No. 8) located on Gas Train
detects a variation in gas pressure.

After correcting the Problem, restart procedure from step 11 onwards (except step 13,14 &
16).