1. Confirm Process & Design Parameters

Before any installation or adjustment, clearly define:

• 🔥 Required heat input (kW / kcal / BTU)

• 🌡️ Operating temperature range

• ⚙️ Furnace/kiln type (rotary kiln, tunnel kiln, furnace, dryer, boiler)

• ⛽ Gas type (natural gas, LPG, propane, biogas)

• 📈 Gas supply pressure & flow

• 🌬️ Combustion air source (natural draft or forced draft)

• 🔄 Control mode (ON/OFF, high–low, proportional)

These parameters determine burner size, control valves, and safety devices.

2. Install the Gas Train (According to Standards)

A typical industrial gas train includes (upstream → downstream):

1. Manual shut-off valve

2. Gas filter

3. Pressure regulator

4. Pressure switches (low & high)

5. Safety solenoid valves (double block & bleed recommended)

6. Flow control valve or proportional valve

7. Burner inlet connection

⚠️ Follow EN 746 / EN 676 / NFPA 54 / local codes strictly.

3. Install the Burner & Combustion Air System

• Mount the burner axially and securely

• Ensure correct flame shape and length for the furnace chamber

• Install:

  • Combustion air blower (if forced draft)

  • Air damper or air control valve

  • Air pressure switch

• Seal all flanges to prevent air leakage

4. Electrical & Control Wiring

Connect the following to the burner management system (BMS):

• Ignition transformer / spark igniter

• Flame detector (UV, IR, or ionization probe)

• Gas solenoid valves

• Air pressure switch

• Gas pressure switches

• Temperature controller / PLC

• Emergency stop circuit

✔️ Interlocks must ensure:

• No gas without air

• No ignition without correct pressure

• Automatic shutdown on flame failure

5. Pre-Commissioning Safety Checks

Before first ignition:

• ✅ Leak test all gas connections

• ✅ Verify correct gas pressure

• ✅ Check blower rotation direction

• ✅ Confirm air & gas pressure switch setpoints

• ✅ Ensure exhaust/flue path is clear

• ✅ Verify flame detector alignment

6. Ignition & Start-Up Procedure

1. Start combustion air blower

2. Pre-purge furnace (typically 30–60 seconds)

3. Open pilot gas valve (if equipped)

4. Ignite pilot flame

5. Prove flame signal

6. Open main gas valve

7. Ramp to low fire position

🔥 Flame must be stable, blue, and well-anchored.

7. Air–Gas Ratio Adjustment (Critical Step)

• Start at low fire

• Adjust air damper for clean combustion

• Increase to high fire

• Fine-tune gas and air valves

• Measure with flue gas analyzer:

  • O₂: 2–5%

  • CO: < 50 ppm (typical target)

• Avoid yellow flames or flame lift-off

8. Set Safety & Operating Parameters

• Low / high gas pressure switch settings

• Flame failure response time

• High-temperature limit

• Burner modulation limits

• Emergency shutdown logic

9. Trial Operation & Documentation

• Run system at different loads

• Observe flame stability & temperature uniformity

• Record:

  • Gas pressure

  • Air pressure

  • O₂ / CO readings

  • Control settings

📄 Keep commissioning records for maintenance and audits.

10. Operator Training & Maintenance Plan

• Train operators on:

  • Start/stop procedures

  • Emergency shutdown

  • Abnormal flame detection

• Schedule:

  • Burner cleaning

  • Filter inspection

  • Flame sensor cleaning

  • Annual safety inspection

⚠️ Important Safety Note

Industrial gas combustion systems must be commissioned by qualified personnel. Incorrect setup can cause fire, explosion, or equipment damage.