ENCON THERMAL ENGINEERS (P) LTD.

10.
9.
8.
7.
6.
5.
4.
3.
2.
1.
S.No.
LOCK NUT
OUTER TUBE
COLLAR CUM LOCK NUT
INNER TUBE
SPRAY GUN HOLDER
AIR TUBE
HANDLE FOR AIR ADJUSTER
AIR ADJUSTER
AIR RESISTER
DESCRIPTION
AIR SWIRLER

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

FOR “IIP-ENCON” FILM BURNERS
I. SELECTION OF BURNER
IIP ENCON ‘Film’ Burner are available in four different sizes. Due to its large ‘Turn Down Ratio’ of 7:1,
these four sizes of burners cover a wide range of application. The burners selection should be done,
keeping in mind the oil firing rate required for the furnace. In a furnace it is better to use more burners
7A
6A
5A
4A
3A
2A
SIZE
BURNER

of smaller size (if space permits) than one burner of higher capacity. The different models of burners
and their oil firing rates are as under :
AIR PRESSURE
100
100
100
100
100
100
A

Burner 500 mm w.g. 600 mm w.g. 700 mm w.g. 900 mm w.g.

500
500
500
450
400
400
B

Size oil 1/hr. oil 1/hr. oil 1/hr. oil 1/hr.

Min. Max. Min. Max. Min. Max. Min. Max.
450
430
430
350
300
300
C

2A 1 7 2 14 3 20 4 24
500
450
450
350
300
300
D

3A 2 14 3 20 5 35 7 40
700 350
445 350
445 350
341 300
297 272
297 272

4A 7 40 9 65 12 75 15 85
H

5A 15 85 17 110 20 120 25 150

M

6A 25 150 30 180 35 190 40 200

10
10
10

X
6
4
4

7A 40 200 45 150 50 160 60 350

20
20
20
15
10
10
Y

II. INSTALLATION
The ‘Film’ Burner is supplied as complete assembly alongwith cast iron mounting plate, refractory block
and burner plate are separate units and are to be properly matched with the burner size. The burner
block and burner plate sizes have been given in figure on the back page.
(a) Installing the burner
The Burner should be mounted on the cast iron burner plate (fitted on the furnace shell) with the help
of four bolts as shown in the diagram.
Ensure that the furnace steel plate has been adequately reinforced from all sides with the help of
M.S. Channels.
The cast iron burner plate has got two holes on each side. Similar holes should be drilled on the
channels welded on to the furnace plate to accommodate the burner plate as shown in the figure.
Ensure that the burner block face is in touch with the cast iron burner plate surface and burner block
is not cracked, while fitting.
Enough care is taken at our end during inspection and while despatching, to avoid any cracking of
ENCON Thermal Engineers (P) Ltd. burner block. Any minor breakage of corners and chipping of the external surface of the burner block
does not affect the working of the burners.
Faridabad Office : Vadodara Office :
297, Sector - 21 B, 308, Race Course Towers, Race Course (b) Air connections
Faridabad - 121 001 (Haryana) Circle, Vadodara - 390 007, (Gujarat)
Ph. : +91 129 4047847, 2439458 Ph. : +91 265 2358774 Air pressure has been mentioned in the chart against the burner size. Ensure the correct pressure of
Fax : +91 129 4044355 Telefax : +91 265 2335161 air is available near the burner for getting the desired oil firing rate. For light distilate fuels, such as,
E-mail : [email protected] E-mail : [email protected]
[email protected] [email protected]
kerosene and light diesel oil, which do not require preheating, air pressure can be decressed by about
100 mm w.g. than what has been mentioned. For furnace oil and other residual fuels, the air pressure
w w w . e n c o n . c o . i n should not be less than 500 mm w.g.
 ENCON THERMAL ENGINEERS (P) LTD. ENCON THERMAL ENGINEERS (P) LTD.

The air piping from the blower should have a minimum cross sectional area equal to blower discharge. d. After starting the air supply to the burners, open the micro valve and allow furnace oil supply to
It is preferred that a higher size of pipeline should be used. For example, if rectangular opening of the the burners. The micro valve should be opened very steadly and slowly to the minimum desired
blower has got a discharge area equal to 100 mm dia a pipeline of 150 mm dia may be used. This is level. Normally, the steady flame will be achieved at position three of the micro valve, kerosene
to ensure that there is a minimum pressure drop in the pipeline. soaked cloth should continue to the burn till the flame stabilises.
The pressure drop between blower and the farthest burner should not exceed 50 mm water gauge. e. Allow the combustion to continue at the minimum level for about 5 minutes and then slightly
There should be a minimum number of bends, elbows and valves in the pipeline to ensure that the increase the flow of oil to the desired level, keeping the supply of air full open.
pressure drop is kept at the lowest.
B. Shut down of the burner
No elbow or bend should be placed within four pipe diameters distance from the burner inlet in order a. Close the micro valve and stop the oil supply to the burner.
to ensure that the air enters the burner without any turbulence. The branch lines connected to the
burner should be of one size larger than the burner inlet and finally reducing its size near the burner. b. After about one minute, close the butterfly valve in the air line or stop the blower and close the
air ports of the burner.
Each burner should be fitted with a separate butterfly valve to control the air supply.
Insert the shield to protect the burner choking due to cracking of fuel oil left over in the burner by
Atomising air connections should be given to the burner with the help of flexible hose pipe by giving the furnace heat.
from the main air pipe, before butterfly valve, as indicated in the figure. The flow of atomising air should
not be controlled and it should always be full open. C. Restarting of burner
a. Remove the shield from the front of burner and keep the air sleeve open.
(c) Oil connections
b. Start the blower and allow the air to enter the burner with butterfly valve fully open.
The size of the pipeline from the line heater or from the heating & pumping unit should be of adequate
size to avoid pressure drop and the size should be reduced nearer to the burner inlet. The oil should c. If the furnace is already hot (min. 7000C) open the micro valve slowly. The oil will automatically
be pumped to the burners through a composite heating pumping unit. Oil pressure near the burner ignite and stable flame will be established.
should be between 1 kg/cm² to 1.5 kg/cm².
d. If the furnace is cold, follow the same procedure as mentioned above for starting the new burner.
ENCON ‘Film’ Burners are designed for furnace oil of viscosity of upto 200 seconds R.I. Furnace oil
of viscosity 1500 seconds R.I. at 380 C. (presently available in the country) needs preheating to a
temperature of about 90-1000C, for getting the desired viscosity at burner tip.
IV. BURNER CLEANING
a. Remove the primary air connection.
A ‘Y’ strainer of 15 mesh should be used just before the burners. If there are two or more numbers of
burners near each other, a common ‘Y’ strainer can be used. b. Open the four bolts of spray gun holder (5).
If the burner is to be used with heavy fuel oil requiring heating before atomisation, draining facilities c. Remove oil connection from the micro valve.
should be provided. This will help the draining of hot oil between the heater and burner, when the
furnace is not in use. Lights oils, such as LDO and HSD do not require such draining facility. d. Take out the oil spray gun assembly consisting of inner tube, outer tube and spray gun holder.

Micro valve should be fitted with each burner for the fine control of oil flow rate. ENCON micro valve e. Dismantle all the components, such as, lock nuts (7&9), inner tube (6), outer tube (8) and air
is designed for fitting directly on the burner oil inlet. swirler (10).
f. The inner tube (6), outer tube (8) and air swirler (10) should be kept immersed in kerosene for
III. OPERATION about 15 minutes.
Important : g. Clean all these components with the help of soft cloth and remove all the carbon deposit.
Keep doors & damper in open condition before firing burners, Ensure the furnace chamber is free of h. Reassemble the oil spray gun assembly and ensure that the distance ‘X’ is maintained as desired
combustible gases. and tighten the lock nuts.
A. Starting of a new burner i. Ensure that asbestos rope packing is provided before tightening the collar cum lock nut (7) to avoid
any oil leakage.
a. Before lighting up the burner, the burner block is to be heated by open flame, such as, kerosene
soaked cloth introduced through the air opening of the burner. The preheating of burner block j. Fix the oil spray gun assembly in the burner and tighten the bolts. Check that gasket in between
should be continued for 10-15 minutes. the oil spray gun holder and the air tube (4) is not damaged. Change the gasket if required.
b. Start the heating & pumping unit and allow the oil to circulate within ring main till furnace oil attains k. Reconnect the primary air hose and the micro valve assembly. Ensure that the micro valve is
a temperature of 900C - 1000C. cleaned by flushing with kerosene before it is fitted.
c. Start the blower and allow air to pass through the burner.