It can take a lot to install a fully-fledged combustion heating burner. A scheduled date, a team of skilled and qualified engineers, the right tools for the job. But that’s almost the easy bit – getting a process heating system designed, planned and assembled is arguably the most complex part of what we do and involves many more people, teams and types of expertise.
Once we’ve completed a site survey, information is passed on to our Technical team. It’s at this stage that a detailed package is pulled together. This planning phase is designed both to confirm with our customer the specification of the burner system and provide our factory team with drawings to then take into production.
Burner Planning
Technical team planning will commonly cover two main areas:
Standard Sub-Assemblies
The sub-assembly comprises the core elements of the combustion heating system. This includes:
- Burner wind box, which houses the burner
- Combustion air fan, which feeds in air
- Gas valve train, responsible for supplying and controlling gas
- Control panel assembly – the brains of the system.
Burner Customisations
Whilst we offer a range of set base models, such as our TX tank heating burners, there might be many cases where specific aspects of an installation need non-standard designs, adjustments or considerations. These can include:
- Accommodations for 24-hour operation
- Remote control panels, or control panels removed from their standard position
- Burner placement configurations, including mounting plates
- Fan speed control inverters
- Heat exchanger variations, such as length, pitch and orientation
Burner Assembly
With all planning aspects now taken care of, our Technical team can now pass the build onto our factory for full assembly.
Our factory workshops operate five main production processes:
- FD/TX burners
- DB/FD burners
- Gas valve trains
- Control panels
- Testing and quality control
Each one of our burners has a gas train, a control panel, a fan and a burner section.
Parts picking
Firstly, all the necessary parts required for the assembly are picked from our factory stores. Components and other materials are kept in a process-efficient way, grouped together based on similar model types to reduce picking time and minimise back-and-forth from stores to factory bays.
Awaiting assembly bay
After parts have been picked, they are deliver to an ‘awaiting assembly bay’ ready for the assembler. The designated assembler then collect the parts from this bay and takes them to another station for assembly.
Burner assembly
Our skilled and qualified workshop hands then carefully piece the burner together. Some take an hour or so, such as building our popular burner models like the FD and TX burners, whereas FDB and DB burners typically take an additional couple of hours.
Standard gas trains might need an hour and a half up to a day if more complex, while the more intricate task of completing a control panel assembly can take anything from half a day to a full week depending on the requirements.
Testing bay
Once our operations team complete the burner or component build, it’s then moved on to the testing bay. Here, a test inspection record completed, involving several rigorous tests and quality control checks.
In order to be able to carry out this role, each team member must receive the correct training and be certified for running QC checks in the testing bay.
Packing bay
Once the burner has been fully tested, it is then moved on to the awaiting packing bay. Here, a team member will collect the assembly, move it to the packing bay and carefully pack the item to ensure its safe onward journey after shipping – whether elsewhere in the Midlands or on the other side of the world.
We usually aim to have testing, packing and shipping completed in the same working day, to ensure smooth running of our schedule.
From initial survey to design, planning and then the extensive process of assembly, producing a burner is no small undertaking. Thankfully, with decades of experience it’s a process we’ve been able to fine tune, allowing us to deliver a high quality, reliable process heating solution to a wealth of industry sectors.
If you’re looking to have a combustion burner installed, or are considering an upgrade to help with performance, efficiency and reliability, get in touch with our team today.
T: +44 (0) 24 7635 2000
E: sales@lanemark.com