Service maintained

Nu-Way, boiler, burner
Problem prevention — Leigh Bryan.

Lack of attention to maintenance will inevitably lead to loss of efficiency and, even, loss of heating. Leigh Bryan discusses how to avoid problems during the heating season with careful planning to ensure an uninterrupted and trouble-free winter period.

With the 2012 heating season now at its height, the importance of correct burner maintenance is something that can't be forgotten about until the Spring, and some of the more careless among us may already be experiencing problems. Maintenance and service planning will ensure early pick up of any potential problems and, in turn, prevent last minute panics and distress purchases.

However, with so much emphasis being placed on minimising costs, skipping servicing and maintenance on boiler and burner equipment could be a tempting route to take. Aside from the effect on the performance of the efficiency of the burner, the safety of combustion equipment must always come first. In commercial and industrial applications, health-and-safety requirements must take priority as in the event of any problems caused by gas leaks, insurance can be invalidated if correct maintenance hasn’t been carried out at proper intervals.

When a burner functions correctly it operates at optimum efficiency. This will reduce costs as well as avoiding heating downtime.

As with most situations, prevention is better than cure, and a proactive maintenance programme will reduce the need for reactive steps to be taken. Types of service generally fall into two categories (major and minor) and normally depend on the time frame since the previous procedure was carried out.

A major service procedure would normally start with an inspection of the overall installation to ensure that it meets with current requirements and that the equipment is working at the optimum level.

Main equipment to be included in such an inspection procedure includes the boiler refractory, tubes/sections and the burner flame tube. Any damage to seals is something that needs careful examination so that they can be replaced if necessary.

Close inspection of the burner head is vital to ensure any problems can be rapidly repaired and prevent the inconvenience of costly downtime. Cleaning the fan and air intake will make a significant contribution to maintaining integrity of the combustion process. Where applicable, the UV cell should also be removed and fully cleaned.

A major service check list should also include ensuring electrical connections are secure as well as the safety interlocks covering low gas pressure, low air pressure and flame failure. Main fuel recording burner settings cover gas inlet pressure and the gas head pressure plus flame signal strength, as well as providing combustion analysis.

If a secondary fuel is included, the combustion will need to be checked, along with burner settings, and the resulting analysis properly recorded. All burner/boiler control functions should be considered to make sure thermostats and any modulation controllers are all working at optimum levels.

Nu-Way, boiler, burner
Combining practical and theoretical training is the key to maximising burner reliability and minimising costs.

A minor service procedure would involve a basic check of the UV cell, safety interlocks, fuel recording burner settings, combustion analysis and the boiler/burner control functions.

Treating regular maintenance and servicing as a priority will, in turn, assist fast and efficient fault finding. As an aid to this, electronic burner programmers enable a full fault history to be obtained, as well as offering improved diagnostics. This enables the engineer to carry out any repairs more easily and efficiently, so downtime periods should be reduced and eventually eradicated.

To ensure burner service and maintenance is carried out to the highest standard, it is important to keep up to date with training. Maintenance executed by the untrained and unqualified is something to be avoided at all costs as, while it may save a few pounds, it could mean the equipment ends up with inefficient or even dangerous operation.

Most leading manufacturers offer in-house training. When selecting training courses, it is best to ensure that both theory and hands-on practical sessions are included on topics such as commissioning, inspection and maintenance, fault finding, dismantling and reassembly. Taking part in training will pay dividends with energy efficiency and keeping poor emissions to a minimum through safe and efficient burner operation for energy conservation and reliable usage.

Getting the correct background knowledge for working with burner equipment from both the theoretical and practical perspective is vital, and something those who are involved with burners as part of their day to day roles will find invaluable.

When looking to minimise fuel bills and carbon emissions, sourcing burners with higher efficiency and the latest technology should be the most important consideration. Ensuring this efficiency is maintained will require regular and skilled servicing. Working with equipment manufacturers which can help will be a major benefit to those looking to keep their costs down.

Leigh Bryan is technical support manager with Nu-way

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