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Volkan 500
User Manual
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Waste Spectrum Volkan 150, Volkan 200, Volkan 300, Volkan 400, Volkan 500 User Manual

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WASTE SPECTRUM INCINERATOR MANUAL
Read this manual before installing or using the incinerator
WASTE SPECTRUM
WORLD STANDARD VERSION INCINERATORS
Waste Spectrum incinerator Models Covered:
This document covers both Gas and Oil burner types.
Waste Spectrum Environmental Limited Spectrum House Checketts Lane Industrial Estate Worcester WR3 7JW England
Tel +44 (0) 1905 362100 Fax +44 (0) 1905 362101
Email sales@wastespectrum.com Web www.wastespectrum.com
File 2012 Volkan 150, 200, 300, 400, 500 & 1000 WORLD STANDARD Manual v1.0.doc Printed 16/02/2012 10:59:00
United Kingdom Health & Safety at Work Act 1974 Section 6 (a) of this Act requires manufacturers to advise their customers on the safety
and handling precautions to be observed when installing, operating, maintaining and servicing their products.
The user‟s attention is therefore drawn to the following:
The appropriate sections of this manual must be read carefully before installation Suitably trained personnel only, must carry out installation, operation and
maintenance
Normal safety precautions must be taken and appropriate procedures observed to
avoid accidents
Refer to the equipment suppliers, name and address below, for any technical advice or
Waste Spectrum Environmental Incinerator Manual
Page 2
CONTENTS
1 GENERAL SAFETY WARNINGS .................................................................................... 3
2 RECEIVING YOUR INCINERATOR ................................................................................. 5
2.1 Taking delivery by lorry-mounted crane ........................................................................ 5
2.2 Taking delivery by flat-bed lorry (for you to unload) .................................................... 5
2.3 Exterior Rust ................................................................................................................... 5
2.4 Storage before use .......................................................................................................... 5
3 LOCATING THE INCINERATOR ..................................................................................... 6
3.1 Preparing a Concrete Plinth ............................................................................................ 6
3.2 Distance from adjacent structures ................................................................................... 6
3.3 Installing the Incinerator Inside a Shelter or Building ................................................... 6
4 POWER & FUEL SUPPLIES ............................................................................................. 6
4.1 Mains Power ................................................................................................................... 7
4.2 Fuel Supply ..................................................................................................................... 8
5 INSTALLING YOUR INCINERATOR ............................................................................... 9
5.1 Locate the Received Items .............................................................................................. 9
5.2 Assemble the chimney stack......................................................................................... 11
5.3 Connect the Fuel Supply............................................................................................... 13
5.4 Connect the Electricity Supply ..................................................................................... 13
6 COMMISSIONING ............................................................................................................. 13
7 STANDARD OPERATING PLAN ................................................................................... 14
8 OPERATION ...................................................................................................................... 15
8.1 Warning ........................................................................................................................ 15
8.2 Volkan 150, 200, 300, 400, 500, 1000 ......................................................................... 15
8.3 Hot Loading .................................................................................................................. 16
8.4 Manual and Mechanical Loading ................................................................................. 17
8.5 Emergency Stop when running..................................................................................... 17
9 FAULT CONDITIONS ....................................................................................................... 18
9.1 CONTROL PANEL – Volkan 150, 200, 300, 400, 500, 1000 ..................................... 18
9.2 CONTROL PANEL – General ..................................................................................... 18
9.3 INCINERATOR – General .......................................................................................... 19
9.4 BURNERS – Gas.......................................................................................................... 19
9.5 BURNERS – Liquid ..................................................................................................... 19
9.6 Lockout Procedure ........................................................................................................ 20
9.7 Incinerator Cracks ......................................................................................................... 21
10 ROUTINE MAINTENANCE.......................................................................................... 22
10.1 De-Ashing ..................................................................................................................... 22
10.2 Burner Cleaning ............................................................................................................ 23
10.3 Annual Service ............................................................................................................. 23
10.4 Replacement Parts ........................................................................................................ 23
11 GENERAL DESCRIPTION .......................................................................................... 24
11.1 Incinerator Body ........................................................................................................... 24
11.2 Controller ...................................................................................................................... 27
12 TEST CERTIFICATES .................................................................................................. 27
Waste Spectrum Environmental Incinerator Manual
Page 3
1 GENERAL SAFETY WARNINGS
WARNING
To reduce the risk of injury, all users of the incinerator much read and understand the Incinerator manual before use.
WARNING
Failure to follow all safety instructions may result in serious personal injury.
WARNING
Wear only suitable clothing for high temperature usage.
IMPORTANT
Servicing of incinerators requires care and knowledge of incinerators and burners. Servicing should only be performed by qualified personnel. Use only approved spares. These are available from Waste Spectrum Environmental Limited.
IMPORTANT
Use your incinerator only for the purpose for which it is designed and authorised. This is animal carcass incineration. Incineration of other items is outside of the design specifications. It will also invalidate your warranty. Incineration of items such as plastics and acid containing items will cause severe and very obvious damage to the incinerator.
WARNING This incinerator is VERY HOT when operating and afterwards when cooling down.
WARNING The exhaust from the top of the stack will be VERY HOT. It is possible that the exhaust gas temperature could be well in excess of 1000oC.
Waste Spectrum Environmental Incinerator Manual
Page 4
WARNING The main (primary) chamber where the waste is loaded is designed to operate at a temperature that incinerates waste. It is possible that the inside contact surfaces could be well in excess of 500oC.
When the door is open, it is possible that the air exhausting from the chamber could be well in excess of 500oC.
WARNING The outside body of the incinerator will be VERY HOT. It is possible that the outside body surface temperature could be well in excess of 100oC.
WARNING When operating and when cooling down, it is possible that the stack outside surface temperature could be well in excess of 1000oC.
IMPORTANT
The incinerator and the ash will take time to cool down. Ensure that both are cool before de-ashing the incinerator.
WARNING
De-ashing hot ash could result in the ash igniting and causing a fire.
Waste Spectrum Environmental Incinerator Manual
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2 RECEIVING YOUR INCINERATOR
Note that Waste Spectrum Environmental Limited does not carry out installations or erect the chimney sections; we supply and deliver the incinerator and equipment for others to install.
Please also refer to the PRE-DELIVERY HANDBOOK supplied to you when you confirmed your order. This handbook gives incinerator weights & dimensions, and detailed the preparations required prior to delivery.
Where we are delivering to you, there must be good firm access for a standard heavy goods vehicle, with clear headroom. Trees, power lines or other overhead obstacles can prevent offloading or cause damage to the incinerator while in transit - such damage will not be covered by warranty.
Take particular care to handle the incinerator gently, avoiding shock. Refractory concrete blocks can be damaged or dislodged by incorrect handling - such damage will not be covered by warranty.
2.1 Taking delivery by lorry-mounted crane
We must be able to position the vehicle adjacent to the concrete plinth, with no overhead obstacles that will interfere with the unloading operation. The driver will carry the necessary slings and chains to place the incinerator in position but will not unwrap or install the incinerator.
2.2 Taking delivery by flat-bed lorry (for you to unload)
We must be able to position the vehicle adjacent to the concrete plinth, with no overhead obstacles that will interfere with the unloading operation. You must provide appropriate and adequate lifting equipment, including slings and chains.
2.3 Exterior Rust
The exterior body of your incinerator is coated with a heat-resistant paint, which requires high temperatures (achieved when incinerator is in use) to cure. Some rusting will become evident before the paint has cured. This rust should be removed, and the areas re-painted with the spare incinerator paint which we supply.
2.4 Storage before use
The incinerator will be shipped to you ready for installation - it will not be prepared suitable for storage therefore storage should be avoided.
If storage is unavoidable then you must remove all loose items (including burners) for safe dry storage and protect the incinerator and controls from excesses of weather. Damage caused by or during storage will not be covered under warranty.
Waste Spectrum Environmental Incinerator Manual
Page 6
3 LOCATING THE INCINERATOR
3.1 Preparing a Concrete Plinth
The incinerator must be mounted on a level concrete plinth of sufficient strength and size for the model selected. Note – this plinth should be completed before we can deliver the incinerator.
Please refer to the Typical Layout diagram on the reverse page of the sales literature, as this includes a suggested plinth size.
It is extremely important that the incinerator is level to ensure that stresses are not induced in the main body when hot, and to reduce the risk of hot flammable liquids leaking from the ash door.
3.2 Distance from adjacent structures
Air must be allowed to flow naturally around the incinerator, providing oxygen to the combustion process, and allowing external cooling of the incinerator, burners and other external parts.
It is suggested that a minimum clearance of 3.0m is maintained between the incinerator and adjacent structures to reduce the risk of overheating or igniting these structures.
The area around the incinerator should provide sufficient clear space to allow:
Safe loading of the incinerator without risk of mechanical damage Cleaning and de-ashing of the incinerator and surrounding area Access to remove and service burners and other components
3.3 Installing the Incinerator Inside a Shelter or Building
DEFRA recommend that low capacity incinerators are housed in a simple building to protect from rain. Waste Spectrum Environmental Ltd. can supply a simple metal shelter for some applications; please apply to our Sales Consultant for prices and availability.
Note that where the incinerator is installed inside a building, care must be taken to ensure adequate airflow for combustion and cooling, and eliminating the risk of either overheating or igniting adjacent structures.
If you are supplying your own shelter or building, then before installing your incinerator you should consult a suitably qualified structural engineer for advice on materials, methods of construction, sizing and how to protect the roof structure from heat damage or ignition.
The chimney is supplied in three connecting sections, and will reach temperatures far in excess of 850 degrees Celsius. Care must be taken to eliminate the risk of either overheating or igniting adjacent structures.
Where chimney sections are to pass through roof structures, the entire top section must be positioned above the roof.
Additional middle chimney sections are available to purchase separately if required. Each section will increase the stack height by 960mm.
4 POWER & FUEL SUPPLIES
Waste Spectrum Environmental Incinerator Manual
Page 7
4.1 Mains Power
The incinerator is provided with 5 metres of power cable connected to the control panel, with a standard type 3-pin 16 Amp Euro Blue plug* on the trailing end.
You must provide a suitable single-phase 230V 5Amp switched RCB protected socket* (Euro type socket), located within 3 metres of the incinerator control panel.
* 230v, 2P+E to BS4343 Industrial (IEC-EN60309-2)
We suggest that you also install lighting and a spare socket outlet in the vicinity of the incinerator, which will assist in operation and maintenance of both the equipment and the area.
Ensure these are suitable for the location.
Waste Spectrum Environmental Incinerator Manual
Page 8
4.2 Fuel Supply
Please note that your incinerator will have been delivered with burners set to run on the fuel specified at the time of order. If there is any doubt about the type of fuel being used, please discuss this with us before firing the burners. Damage caused by use of fuels other than that specified will not be covered by warranty.
4.2.1 GAS Incinerators - running on Propane or Natural Gas
Installation & connection of the gas supply must be made by a fully qualified CORGI gas installation engineer, in accordance with current regulations.
You must supply and install a suitable fixed gas pressure regulator (governor) between the gas supply and the burners, which must be set at the following values for running conditions:
NATURAL GAS: 20mb PROPANE: 39mb
Gas cocks, which drop to the closed position, must also be supplied and fitted in the appropriate locations. Your installer must connect the gas supply to each burner using a minimum 400mm length of
½” nominal bore flexible hose (not supplied) which must be suitable for the type of gas being
supplied. Each hose connects into a ½” BSP female thread located on the monoblock gas valve
assembly which is supplied with the burner.
NOTE IT IS STRONGLY RECOMMENDED THAT SUITABLE FLEXIBLE GAS PIPES
(HOSES) BE USED FOR THE LAST CONNECTION TO THE GAS BURNERS.
Flexible pipes allow removal of the burners for servicing without breaking joints and removing pipework.
Burners installed on rigid pipework make removal difficult for cleaning and servicing. Waste Spectrum Environmental engineers will not be able to service them for you.
4.2.2 DIESEL Incinerators - running on 35sec Gas Oil (Diesel) or Kerosene
The fuel supply is to be provided in accordance with OFTEK regulations, describing oil storage
and distribution. Connection to the incinerator‟s fuel train is to made by suitably qualified
persons in accordance with local regulations. The fuel tank and pipeline must be clean and free of any contamination, including previous fuel
residues. The tank is to be located between 3m (minimum) and 20m (maximum) from the incinerator, with a maximum suction lift of 3m from the level of the highest burner.
You must supply and install a 10mm bunded fuel supply line, and connect this to the 10mm olive and compression ring which we provide on the incinerator‟s fire valve.
Waste Spectrum Environmental Incinerator Manual
Page 9
5 INSTALLING YOUR INCINERATOR
5.1 Locate the Received Items
Upon receipt of your incinerator, you will find the following additional items on top or inside the machine. Please locate and identify these parts before commencing installation.
Volkan 300 & 500
1 off base section chimney (straight through cylinder) 1 off middle section chimney (is straight through with swaged bottom) 1 off top section chimney (with larger section at top) 2 off chimney section clamps 3 off stainless steel guy wires 6 off wire clamps 1 off control box key 1 off Thumbscrew for Fire Valve (Oil fired units only) Plus Burner tools, Operators manual and spare tin of paint (with Material Safety Data Sheet for paint)
Volkan 150
1 off base section chimney (straight through cylinder) 1 off middle section chimney (is straight through with swaged bottom) 1 off top section chimney (with larger section at top) 2 off chimney section clamps 1off chimney support assembly 1 off control box key 1 off Thumbscrew for Fire Valve (Oil fired units only) Plus Burner tools, Operators manual and spare tin of paint (with Material Safety Data Sheet for paint)
Volkan 200 & 400
1 off base section chimney (straight through cylinder) 1 off middle section chimney (is straight through with swaged bottom) 1 off top section chimney (with larger section at top) 2 off chimney section clamps 1off chimney support assembly 1 off Thumbscrew for Fire Valve (Oil fired units only) Plus Burner tools, Operators manual and spare tin of paint (with Material Safety Data Sheet for paint)
Volkan 1000
1 off Afterchamber 6 off Bolt and nut set (flange fixing) 1 off base section chimney (straight through cylinder) 1 off middle section chimney (is straight through with swaged bottom) 1 off top section chimney (with larger section at top) 2 off chimney section clamps 1off chimney support assembly 1 off Thumbscrew for Fire Valve (Oil fired units only) Plus Burner tools, Operators manual and spare tin of paint (with Material Safety Data Sheet for paint)
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