Site surveys are a regular job for our engineers and an important preparatory step in the process of installing a a new burner system. Read on to learn about what a site survey, what it consists of and what the outcomes are.

What is a industrial burner site survey?

A site survey for a burner heating system involves a series of detailed checks, tests and protocols to determine the condition and function of the existing equipment. Through a site survey we can make sure that a new burner can be installed safely and then work effectively once in place.

There are several parts of a survey:

Gas inspection

When it comes to gas, there are a number of important tasks to carry out, especially around safety.

Gas supply check

Firstly, the overall condition of the gas supply is inspected. Depending on age or level of use, there may be issues to uncover that could affect installation or operation in future. A safe gas supply is crucial for safety, reliability and overall operational performance in the long run.

Gas purge

One the gas supply check is done, the existing system is purged of any residual gas that might hinder connection of a new burner installation.

Installation ready

Lastly, the engineer will carry out final checks and ultimately prepare the gas supply system so that it is fully prepared for the new install.

 

Electrical inspection

Alongside the series of gas checks is a thorough assessment of all burner system electricals. Once our engineer has confirmed that an electrical supply is present, tasks often include the following:

Control safety circuits

The first stop is to check the safety circuit is working as intended. This should follow a certain order.

1. Check for any trapped residual gas in the burner before new gas is fed in and ignited
2. Carry out the purge cycle, which ensures process air is coming thought the burner, combustion air is present and the flame sequence is working
3. Run the start sequence whereby controlled gas is introduced before ignition finally takes place

Temperature controller inspection

A pivotal component in the combustion heating process, the temperature constantly senses the process temperature, sending a signal to the burner whenever heat is required. As part of a site survey, we’ll check:

• what the current temperature control method is
• whether it needs to be changed
• what steps would be required to make changes

Police stat check

The police stat is a safety feature that sets a maximum possible temperature for the burner. This shuts the burner down in the case that it starts to exceed the maximum temperature, to save the burner from damage. In the case that the survey concerns a heating oven, electrical checks will also involve checking for a police stat.

If the site survey identifies that a police stat is old or faulty, we may recommend a replacement. If there isn’t a police stat present, our engineer will potentially suggest one is retrofitted.

Air pressure switch test

Our site survey will test the air pressure switch too. Similar to the police stat, if the air pressure switch senses no air flow then it will turn the burner off. Without air flow, the burner will start to distort and ultimately run the risk of needing expensive repairs. As with police stats, we usually recommend retrofitting an air pressure switch if there isn’t one present.

Further recommendations

Taking the time to survey a site also gives us the opportunity to suggest some changes to a burner system:

• Improve efficiency

If the existing burner works using a high-low heating process, we will often recommend changing to fully modulating gas and air. Gas and air modulation allows for tighter control around the set point compared to high-low – a couple of degrees rather than 5-10 degrees – thereby allowing for greater economy. This also involves changing the temperature controller to allow for a modulating signal.

Replace an obsolete or old burner with more a more modern unit (reliable, efficient (gas and air), easier to repair.

• Add a gas flow meter

Gas flow meters facilitate data readings remotely. These can also be added to a PLC. This allows for better forecast energy requirements and as a result further improved energy efficiency.

• Burner placement

A site survey will analyse burner access and serviceability. For example, if an FD burner air heating burner is on a wall at a high level, or above an oven without a platform, activities such as replacement, installation, servicing and repairs become much harder. If the job that the site survey involves is to replace a non-Lanemark burner, we will also check for the need for an adaptor mounting plate.

 

So there we have it – a site survey is a thorough process carried out by trained experts. It aims to determine the condition of a process burner system, prepare the ground for replacement or upgrade, and looking for ways to improve its performance, safety or reliability. To book a site survey in with our team of engineers, contact us today.

T: +44 (0) 24 7635 2000 

E: service@lanemark.com