Groth 8391B User Manual

Installation, Operation and Maintenance Manual for

Model 8391B Waste Gas Burner

IOM-8391B

©2008 Groth Corporation

Ref. ID: 95600

TABLE OF CONTENTS:

INTRODUCTION 2
TABLE 1: MAIN ASSEMBLIES 2
INSTALLATION 3
SYSTEM CHECKOUT 3
SAFETY PRECAUTIONS 4
OPERATION INSTRUCTIONS 4
INSPECTION AND MAINTENANCE 5

-AUTOMATIC IGNITION CONTROL 5

-TABLE 2: LAMP INDICATOR 6

-PILOT FUEL SYSTEM 6

-FIGURE 1: AIR INJECTION ASSEMBLY 6

-PILOT FLAME SENSOR 6

-ELECTRODE MAINTENANCE 7
TABLE 3: MAINTENANCE SCHEDULE 7
TROUBLESHOOTING 8
TABLE 4: BOLT TORQUE - MAIN BURNER FLANGE 8
TABLE 5: RECOMMENDED SPARE PARTS 8
BURNER INSPECTION CHECKLIST 9
PRODUCT LIMITED WARRANTY 10
DRAWING 87532: GROTH WASTE GAS BURNER W/ FLANGE MOUNT 11
DRAWING 87533: GROTH WASTE GAS BURNER W/ ANCHOR PLATE 12
DRAWING 94750: AUTO CONTROL PANEL SCHEMATIC 13
DRAWING 87463: AUTO PANEL WIRING DIAGRAM 14
DRAWING 84458: PILOT FUEL MANIFOLD 15
DRAWING 94961: IGNITION ELECTRODE ASSEMBLY 16
DRAWING 84652: MODEL 7622 FLAME CHECK 17

1

INTRODUCTION:

This manual is intended to provide recommended procedures and practices for installation, operation, and
maintenance of the Groth Model 8391B W aste Gas Burner. Any standard procedures and practices developed in a
specific plant or process should supersede this manual. Although this manual cannot cover all possible
contingencies, following these guidelines should provide safe, reliable Waste Gas Burner performance.

For information not contained in this manual, please contact:

Groth Corporation

13650 Promenade Blvd.

Stafford. TX, 77477

Phone: [phone]

Fax: [phone]

The 8391B Waste Gas Burner with Thermocouple Pilot Flame Sensor consists of seven sub-assemblies, each with a
specific function.

TABLE 1

MAIN ASSEMBLIES

SUB-ASSY FUNCTION

Control Panel

Pilot Fuel

Supply

Manifold

Main Burner/

Windshield

Ignition

Electrode

Thermocouple

Flame Sensor

Pilot Burner

Assembly

Ignition

Transformer

Assembly

Provide remote control over

ignition and pilot fuel system.

Control fuel supply to pilot

burner.

Deliver gas to the discharge

nozzle and protect pilot flame

from wind conditions.

Provide high voltage spark to

ignite pilot gas.

Senses that pilot flame is

established.

Deliver a combustible mixture of

pilot fuel to the ignitor, flame

sensor and waste gas discharge

nozzle.

Provide a high voltage source for

the ignition electrode.

2

INSTALLATION:

Mount the flare stack vertically by bolting to a standard ANSI 150# pipe flange with a suitable gasket, or mount the
anchor plate with studs in a foundation. Tighten bolts alternately and uniformly. If anchor plate is used, the stack
should be leveled and grouted in place. [See Bolt Torque Table 4 pg. 8]

Mount control panel on wall or suitable support structure at the specified minimum distance from the waste gas
burner; see drawing C-87532, Page 10 or C-87533, Page 11. The pilot gas line should be a minimum 1/2" ID pipe or
tubing.

Connect control panel to ignition transformer box as shown on drawing A-87463, Page 13. The transformer box is
grounded to the flare stack. The pilot gas line should be hydrostatically tested according to local codes. At a
minimum, the test pressure should be maintained for at least 30 minutes at 1.5 times unregulated supply gas
pressure.

The complete piping system must be bubble tight. Inspect the inspirating venturi and gas line to ensure that is free
of contaminants such as dirt, insects, nests, etc. prior to installation.

Connect 115/60/1 VAC [or other optional power supply as specified on purchase order] to the control panel following
both the National Electric Code and local code guidelines.

Do not attempt to light the pilot until performing the system check-out.

WARNING:

The solenoid valve can freeze in either the open or closed position if exposed to temperatures below 32oF.
The valve must either be installed in a protected environment or heat traced and insulated.

SYSTEM CHECK-OUT:

Before a waste gas burner is placed into operation, the complete system must be checked carefully. The check list
below may include items that are not included in your system.

Note: Some of these checks have been performed at the factory. However, since a long time period may have

occurred between shipment of the equipment and start-up, it is recommended to check all applicable items.

1. Pressure test the pilot gas line.

2. Pressure switch function - isolate switch and raise pressure checking that NO terminal contacts are closed. If
control panel is equipped with automatic mode option, check that PILOT GAS ON lamp is illuminated when
pressure switch is energized.

3. Solenoid valve function. Supply power and confirm that valve opens; disconnect power to check shut-off.

4. Back-Pressure Regulator [if applicable]. Isolate regulator from system and confirm that regulator opens at
desired set pressure.

5. Check Valve - ensure that it is installed in correct flow direction.

6. Connect power supply to control panel. With pilot gas supply closed, check ignition cycle by switching the
Control Panel to manual or providing signal from the remote switch. Observe both spark and duration of "spark
on" - "spark off" cycles. Refer to operation instructions on page 4.

7. The air injector has been adjusted to the specified gas supply pressure. However, it may be necessary to adjust
the air intake plate to optimize the pilot flame. Do NOT remove the Flame Check, drawing C-84652, page 16,
which is installed in the gas supply port of the injector.

3

SAFETY PRECAUTIONS:

1. When burner is operating, all personnel should maintain a safe distance from the unit.

2. The ignition electrode provides a HIGH VOLTAGE DISCHARGE which can cause severe bodily injury or
death. DO NOT attempt to service the electrode without first disconnecting and locking out the power
supply to the control panel and transformer box.

3.

All components on the main burner can be VERY HOT; DO NOT attempt to service any part of the

ignition system or pilot assembly until it has cooled. Failure to observe this precaution can cause
severe burns.

4. DO NOT SMOKE or use any equipment that could spark while working in the vicinity of the main burner.

5. ALWAYS shut off the gas supply to both the main burner and pilot line before attempting to do any
repairs on the system.

6. DO NOT remove or modify the flame check at the pilot gas supply port of the burner, drawing C-84652,
page 17.

7. Wiring of the burner must be done according to both National Electric Code and all relevant state and
local codes.

PERATING INSTRUCTION:

O

The pilot operation is controlled by a MANUAL/OFF/AUTO switch. When the control switch is in the MANUAL
position, the pilot control sequence is initiated instantly, and the pilot is ignited and maintained. When the
AUTOMATIC position is selected, the pilot control functions on demand and is controlled by a remote switch. A
pressure switch is typically provided unless specified otherwise.

Manual: When the "MANUAL" position is selected, pilot fuel is turned on and the ignition electrode begins sparking.

The ignition cycle consists of 10 seconds on and 3 seconds off, with pilot fuel remaining on throughout the
cycle.

The ignition cycle is repeated until a pilot flame is established. The pilot flame is maintained regardless of
flow to the waste gas burner. The ‘Pilot Gas On’ and ‘Pilot Flame On’ lights will verify a successful pilot
flame.

Automatic: When the "AUTO" position is selected, the pilot control sequence will begin when the remote switch is

closed. Normally this is a pressure switch which is installed in the main burner supply line, upstream of the
back pressure regulator. It should be set approximately 0.5" - 1" W C below the regulator setting to ensure
that the pilot flame will be ignited before gas flows to the main burner. The pilot control is the same as in the
manual mode. The burner will continue to operate until the switch condition is interrupted.

Note: The pilot control will respond to the actual supply of waste gas. When the gas pressure drops [due to
increased consumption or decreased production], the pressure switch will open and shut off the pilot control.
The burner will stay in a "stand-by" mode until gas pressure rises and the pressure switch contact closes
which resumes the pilot control sequence.

Options: The Groth Waste Gas Burner has several options from the factory. Please contact the factory for

ordering information. The following is a short description of commonly requested options:

Bio-Gas Soleniod Valve: This option is physically connected to a Groth Model 8400A Pressure Relief and

Flame Trap Assembly and function is controlled by the Groth Waste Gas Burner Control Panel. The
Bio-Gas Solenoid Valve keeps the Model 8400A closed as to not vent bio-gas until the thermocouple
senses a proper pilot flame.

Dual Thermocouple (Waste Gas Sensing): A dual thermocouple setup on the Groth Waste Gas Burner

provides the ability to sense the pilot flame and the bio-gas flame. The advantage of sensing the bio­gas flame is that when verified, the Control Panel will shut off the pilot gas saving the factory money
spent on maintaining a pilot flame via natural gas, propane, etc.

Temperature Controls: The thermocouple [T/C] is in direct contact with the deflector plate. The PILOT T/C

OK indicator comes on when the "sensed" temperature exceeds the T/C relay lower switch point
[ambient temperature]. This verifies that both thermocouple and monitor are functioning. When the
temperature exceeds the T/C relay upper switch point [approx. 800° F.], the PILOT FLAME ON
indicator comes on, the ignition cycle is stopped and the pilot continues to burn.

4

Note: The maximum thermocouple temperature that the pilot flame can achieve is dependent on various
factors; pilot fuel, fuel pressure, ambient temperature and wind conditions. The purpose of the thermocouple
is not to measure the flame temperature, but to determine if a flame exists. Therefore the upper switchpoint
can be adjusted to any temperature which meets the following criteria:

1. Lower than the temperature achieved by a constant pilot flame under the worst gas and wind
conditions.

2. Greater than the temperature that can be achieved by ambient conditions or a weak, intermittent or
otherwise inadequate pilot.

The lower switchpoint should be set at approximately ambient temperature.

Burners equipped with a thermocouple [T/C] flame sensor normally take less than 3 minutes, but in some
cases may take 10 - 20 minutes to reach the upper switch point. Until that temperature is attained, the
ignition cycle will continue. Once established, the pilot will continue to burn, as long as the remote pressure
switch energizes the pilot control and power is supplied to the panel. The PILOT GAS ON indicator is
illuminated as long as the gas solenoid valve is open.

After a successful ignition, if the pilot flame is extinguished for any reason, the ignition electrode will begin
sparking when the "sensed" temperature drops below the upper switch point. Ignition will be attempted as
described above.

When ignition is initiated, either manually or automatically, an adjustable time interval begins, typically 10
minutes. If the time interval ends before a pilot flame is established, a flame failure indicator is illuminated on
the panel, however the ignition cycle continues. Additional contacts are provided for a remote alarm signal if
desired.

The flame failure interval should be set to provide the normal T/C heat-up time plus 20% to avoid nuisance
alarm signals.

If the Auto Shut Down / Manual Reset option is chosen, the ignition system will shut down after a pilot flame
failure indication. The system is manually reset at the control panel by turning the selector switch to OFF and
then returning it to AUTO or MANUAL. This option is enabled by removing the internal jumper between
terminals 5 and 8.

INSPECTION AND MAINTENANCE:

To ensure safe operation of your complete burner system, the following items need to be inspected periodically. See
table 3, page 7 for suggested maintenance intervals. Follow your own plant safety guidelines before performing the
inspection. W e recommend the following:

MINIMUM SAFETY PROCEDURES

1. Disconnect and lock-out electric power to the control panel.

2. Shut off the supply of gas to the pilot line and lock-out.

3. Allow burner to cool to ambient temperatures or take precautions to deal with metal parts that are
exposed to the pilot and main burner flames.

AUTOMATIC IGNITION CONTROL

1. Open the ignition control panel enclosure door and check the condition of wiring, relays, switches, and the

flame monitor equipment. Look for evidence of loose wires at connections, burned components, loose
enclosures on relays, moisture, dirt or foreign materials, etc. Make sure that the proper range is selected
on all time delay relays. 1TR should be set for 10 seconds on and 3 seconds off. 2TR is typically set for 5­10 minutes but may be longer [see operating instruction].

2. Open the transformer enclosure door and make sure the high voltage lug connection on the transformer is

tight. Check for loose wires, moisture, dirt or foreign materials, etc.

3. Remove the junction box cover from the electrode and disconnect the ignition wire and flexible conduit.

Remove [2] U-bolts and remove the electrode from the burner [see electrode maintenance]. Handle the

5