Industrial burner is a key component in the industrial combustion system, and common faults may affect the combustion efficiency, safety or equipment life. The following are the common fault types, causes, and solutions:

1, the flame is unstable or flameout

Possible reasons: gas pressure fluctuation (too high or too low), imbalance of air and fuel ratio (improper adjustment of air valve), carbon deposition or blockage of burner head, deviation or aging of ignition electrode position, poor fuel quality (such as water, impurities).

Solution: check the gas supply pressure, adjust the pressure relief valve; recalibrate the air-fuel ratio (through the flowmeter or control system); clean the nozzle and ignition electrode; replace the damaged electrode or adjust the clearance (usually 3-5mm).

2. Ignition failed

Possible causes: ignition electrode damage or poor insulation, the gas valve is not open or the solenoid valve failure, control circuit failure (e. g. relay, PLC signal problem), flame detector fault (misjudged no fire).

Solution: check the electrode discharge, replace the fracture electrode; test the valve action, repair the circuit or replace the solenoid valve; calibrate the flame detector (ie, UV probe, ion probe).

Burn efficiency decreased

Performance: increased energy consumption, high smoke exhaust temperature, and exceeding the standard of CO emission.

Possible causes: abnormal air-fuel ratio (excess air or excess fuel), wear or deformation of the burner nozzle, ash accumulation or blockage of the heat exchanger.

Solution: use the flue gas analyzer to optimize the air-fuel ratio (O ₂ content within a reasonable range); replace the damaged nozzle parts; clean the flue or heat transfer surface.

The burner is overheated or ablated

Possible causes: cooling system failure (such as air-cooled burner fan stop, water-cooled burner is not smooth circulation), long-term flame tempering leads to local high temperature, insufficient material temperature resistance grade.

Solution: check the cooling fan, water pump or water valve; adjust the flame shape to avoid tempering; replace the high temperature resistant material burner (such as ceramic head).

5. Abnormal noise (deflagration, howling)

Possible reasons: high gas pressure leads to excessive combustion speed, combustion chamber resonance (structural design problem), uneven air inhalation (air duct blockage).

Solution: reduce the gas pressure or increase the silencer; check the sealing and structural fasteners of the combustion chamber.

6. Fuel leakage

Danger: It may lead to an explosion or a fire.

Possible reasons: aging pipe or valve seals, loose burner joints.

Solution: stop immediately, use the leak detector (such as soapy water) to find the leakage point; replace the sealing ring or tighten the interface.

7. Control the system failure

Performance: the burning mouth can not start, no feedback signal.

Possible reasons: wrong PLC procedure or faulty sensor (pressure / temperature switch), poor cable contact.

Solution: check the PLC alarm code, reset or reprogram; test the sensor signal and replace the damaged parts.

Preventive maintenance recommendations

1. Regular cleaning: remove carbon deposition or dust from the nozzle, electrode and flame detector.

2. Calibration inspection: quarterly detection of air-fuel ratio, gas pressure and valve response.

3. Replace vulnerable parts: such as electrodes, sealing rings, filters (according to the manufacturer's recommended cycle).

4. Record operation data: track combustion efficiency and emission indicators, and find abnormalities in advance.

Safety tips

Cut off the gas source and power supply before maintenance