CURS ARZATOARE Net PDF

Combustion Seminar
425 Fifth Avenue • P.O. Box 431 • New Rochelle • NY 10802

Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com
©2004 FLYNNBURNER CORP.
FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com
Combustion Seminar
I Introduction...................................................................... 5
II Burner Technology ..................................................... 19
III Air Gas Mixers ..............................................................33
IV Gas Flow & Control ....................................................45
V Ignition............................................................................53
VI Combustion Air Blowers . ........................................59
VII Air Control Valves . ....................................................63
VIII Temperature Contro................................................69
IX Oven Efficiency . .........................................................77

INTRODUCTION

Overview
During the last 25 years, we have had the opportunity of visiting many bakery
facilities. As we discussed these visits, a common thread appeared. There was
a general lack of understanding on how the various components of the oven
combustion system interacted.
About this time one of the major bakery companies asked us to produce
a seminar for their key bakery employees which would provide the basic
information on the design and proper operation of the oven combustion
system. In the following pages we have tried to do just that.
As you can see from the outline, we will review each of the major
combustion system components and also some related topics such as
safety, efficiency and a brief overview of the OSHA code. This seminar is
our attempt to present to you how the combustion system components work
together to provide a reliable, controllable, safe baking environment.
This illustration is intended to provide you with an overview of the

essential components in your oven. It is important that you understand
that each item is interrelated and how the function of one interacts with
the others. Obviously, sizing is important so that each component of the
system is compatible with the other. When you look at your oven, we want
you to see it as series of components that have been engineered to provide
a system for you.

MAJOR COMPONENTS OF
A COMBUSTION SYSTEM
This illustration is intended to provide you with an overview of the

essential components in your oven. It is important that you understand
that each item is interrelated and how the function of one interacts with
the others. Obviously, sizing is important so that each component of the
system is compatible with the other. When you look at your oven, we
want you to see it as series of components that have been engineered to
provide a system for you.
The engineering art of

combining a series of
interrelated components
to produce a combustion
system.

BASIC TERMS &
DEFINITIONS
Let’s look at a couple of basic definitions which are involved in our discussion today.
HEAT - is defined as molecular activity or agitation. It is a form of

energy. We measure heat as a QUANTITY and express it in a familiar
term - BTUs/ per HR.
TEMPERATURE - is the result of the applied heat energy.

It reflects the QUALITY of heat, and we express this in degrees,
FAHRENHEIT or CENTIGRADE.
In any given process involving heat, there is a temperature profile to follow. For
example, in the process of baking food products, there is a specific temperature
curve or heat profile for each type of bread, cake rolls, cookies, chips, pretzels,
tortillas, etc. In most of these products, the variable is in the QUANTITY of heat, the
BTU’S/HR., depending on the volume and speed of the process. The temperature
required or the QUALITY of heat is the same, whether your wife is baking a loaf of
bread at home, or if you have a modern high speed oven. So to repeat:
HEAT = BTU\HR= QUANTITY
TEMPERATURE = Fo / Co = QUALITY
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The manufacture of crackers, cookies, biscuits, muffins, bread, rolls, cakes, snack
foods such as pretzels, tortillas, etc., involves the term known as BAKING. By
definition, baking is a series of chemical reactions, primarily activated by the
application of a controlled source of heat. Nearly all baked products are leavened,
that is, expanded by gases developed inside the dough.
Time-Temperature
Experience has taught us that the time-temperature relationship for a specific

product is quite narrow; thus, the control of the applied heat is a very significant
factor. Too much, too soon, too little, too late makes a product that ends up in the
scrap bin.
The movement of the heat from its source to the product is called HEAT TRANSFER.
This is accomplished in three ways as follows:
CONDUCTION: The transfer of heat by molecular contact such as

direct flame.
CONVECTION: The transfer of heat by hot air, usually augmented by

mechanical agitation such as fans, blowers, etc.
RADIATION: The transfer of heat by heat waves through the air

such as the rays of the sun heating the earth.
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In a typical baking oven, regardless of the product being produced, all three
methods of heat transfer are involved.
Heat from the conveyor, the steel band, or the pans, is conducted by actual contact
of the product to the band, as illustrated in Figure 1.
CONDUCTION
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DIRECT HEAT FROM CONVEYOR TO DOUGH
In longer ovens, the band is

often preheated to minimize
the heat loss in the first zone
as the fresh dough is placed on
the band.

Convection
Convection occurs through the flow of air utilized to exhaust the products of
combustion and the moisture being removed. The scrubbing action of the air over
the product enhances the convection process, as illustrated in figure #2. Convection
primarily affects the exposed areas of the product. In bread ovens, the convective
effect is often enhanced using mechanical agitation (coloraiders)
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Radiation
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Figure #3 shows the process of heat transfer by Radiation coming from the burner
flame, oven walls, the ceiling and, in some cases, from radiant type burners. Most
product color comes from radiation. Radiation is also a function of the absorptive
capacity of the product being baked.
In the Technical section at the end of this publication, there is a list of definitions
for key words utilized in the combustion process. These will be helpful in your
understanding as we go through this discussion

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17
BURNER TECHNOLOGY

HISTORY
There are a wide variety of heating sources for industrial heating processes
involving ovens, including electricity, oil, gas, kerosene, etc., as well as different
methods of heat utilization such as direct fired, indirect fired and convection. There
are also many types of burners available today. They range from simple on-off
atmospheric to sophisticated dual fuel, totally automatic, computer controlled process
burners. Our discussion will involve primarily ribbon burners, but we will look at
atmospheric and premix, as well as the gun type variety.
In the interest of providing some perspective on the evolvement of the burner, a

little background will be helpful. The gas industry had its beginning in this country in
the early 1800’s, but use of gas dates back much further.
The Chinese are said to be the first to utilize natural gas by using bamboo pipes
from wells as deep as 2000 feet. Manufactured gas was discovered in the early 1600’s
but progress was slow because of the superstition which surrounded it. Interestingly
enough, it was an engineer named William Murdock who worked for James Watt
(developer of the steam engine) who devoted himself to the task of producing
manufactured gas from coal and in 1792 successfully lighted his house with gas
lanterns.
Similar activity took place in England and France. In 1812, the British Parliament
granted a charter to the “Westminster Gas Light & Coke Company” establishing the
first known gas company. On December 31, 1813, the famous Westminster Bridge was
lighted by gas to the amazement of Londoners.

Following this spectacular success, the use of gas spread to Paris and to the United
States, where in Baltimore and Newport, the streets were lighted with gas.
Natural gas, as we know it, was not discovered commercially until the 1820’s. A well
27 feet deep was drilled in upstate New York and in 1821, the local hotel used the gas
to cook meals. This is the first reported use of natural gas for commercial purposes.
In 1840, a well was drilled to a depth of 700 feet and the gas utilized to evaporate
water to produce salt in large evaporation pans. By 1872, gas was being utilized in the
pottery industry and by 1891, gas was being transported by high pressure pipelines
from the wells in northern Indiana to Chicago.
The availability of natural gas spread quickly to the industrial field and the
development of burners was the key ingredient in the utilization. Robert William Von
Bunsen produced the famous Bunsen Burner.
BUNSEN BURNER
Bunsen introduced the concept of

monitoring the flow of gas into a tube
through an orifice, depending on the
velocity of the gas to entrain some of
the air prior to ignition and proved that
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ATMOSPHERIC BURNERS
An atmospheric gas burner is the type in which part of the air required for
combustion is premixed with the gas prior to the point of ignition. The air premixed
with gas is defined as Primary Air. The balance is called Secondary Air and is drawn
from surrounding atmosphere at atmospheric pressure, hence the name atmospheric
burner. In order to deliver the air-gas mixture to the burner head, the principles
developed by Venturi & Bunsen were utilized. This is illustrated in figure #5.
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Delivering gas through an orifice (1) at a pressure ranging from 3-11 inches would
produce about 40% of the primary air (2) required. As long as sufficient secondary air
(3) was present, proper combustion could take place. The Venturi mixer (4) coupled
with a burner nozzle (5) or head became the mainstay of early gas applications. Many
varieties exist today.

In the late 1920’s, the following criteria was established for burner systems by the
American Gas Association:
• Be controllable over a range of turndown without flashback or

outage.
• Provide uniform flame distribution.
• Be capable of completely burning the gas.
• No lifting of flames away from ports.
• Provide ready ignition with flame traveling from port to port over
the entire burner rapidly and positively.
• Substantial construction to withstand heating and cooling.
• These requirements must be met under a wide variety of

conditions.
• Differences in gas composition and changes in pressure and
specific gravity should not prevent satisfactory operation.

Along with other industries, there was a desire to increase productivity, resulting
in the corresponding need to distribute the flame in a wider pattern. It seemed only
natural to take a pipe and drill holes in it to produce a drilled pipe burner as illustrated
in Figure #6.
These worked, but were limited to low BTU capacities per lineal inch. This
limitation exist today, eventhough there are many of these burners in daily operation,
particularly in small batch type ovens in neighborhood bakeries. This limited capacity
precluded their use in high production facilities.

PORT AREA & IGNITION
In their attempts to increase capacities by enlarging individual burner ports,

researchers soon discovered a relationship between:
A. Port diameter,
B. Port depth
C. Velocity of the air-gas mixture.
Once ignition of flame has been established, the flame front actually burns back
toward the source of the air-gas mixture.
The flame front will be stable only when the velocity matches the rate at which the
mixture burns. If the velocity is too high, the flame will lift off or blow off the ports.
Figure #7 illustrates this phenomenon.
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If the velocity is too low, the flame speed burning back towards the source of the air-
gas mixture will cause a burn-back, or quenching action.
Research established a maximum port size of a #30 drill. The ignition temperature
also is important. It takes approximately 1170°F to ignite natural gas, but only about
900° to ignite propane. The cool metal surrounding a port will quench the flame
provided it has sufficient mass to absorb the heat. Thus, there is the need for a certain
port depth.

NOZZLE BURNERS
Many attempts were made to improve the flame stability and BTU capacity of
burners. Researchers soon realized that the key was to lower the velocity of a portion
of the air-gas mixture or else limit the capacity of the burners far below the ability of
the mixers to deliver air-gas mixture. Gun-type nozzles were developed as illustrated
in Figure #8.
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As you can see, a portion of the air-gas mixture is diverted into a small protected
area (1). The velocity of this portion of the mixture is reduced to a point where the
piloting will provide continuous ignition to the main air-gas stream emitting from the
large center port (2).

FLAME RETENTION
Now it was possible to increase the rate of mixture velocity out of the
nozzle, increasing the BTU output substantially. This phenomena is known as
FLAME RETENTION and it is an inherent feature in all power burners. As a rule,
atmospheric burners do not require the flame retention feature as long as the
gas supply pressure does not exceed eleven inches.
This is a key point of this presentation, and I cannot over-emphasize its
importance to the performance of burners. The ability to build FLAME
RETENTION in combustion equipment has been a major factor in the
development of the wide variety of gas burners available today. If you leave here
with the understanding of this process, you’ll have a significant grasp on how to
maximize the performance of any piece of gas equipment.
Flame Retention is the process

of reducing a portion of the
velocity of the air-gas mixture
into a protected area to provide
a continuous source of ignition
to the main air-gas stream
The Key is Flame Retention

DRILLED PORT BURNERS
The
next step was to take the principle of Flame Retention and apply it to line burners,
such as drilled pipe burners. A single row of ports was drilled down the center,
and following the pattern of the flame retention nozzle, rows of small holes were
drilled on each side. Deflectors or ignition rails were placed over the two rows of
piloting holes as shown on Figure #9.
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This worked reasonably well except that the deflectors warped, burned up and
fell off. Metalurgical advances in high temperature materials for the deflectors
helped, but never completely solved the problem.

Figure #10 illustrates a cross section of a typical drilled port line burner which is
widely used in the industry today.
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RIBBON BURNERS
The problem with the deflectors was one which came to Harold Flynn’s attention
during his days as chief engineer for Reynolds Metals in New York. If a way could
be developed to control the air-gas mixture flow INTERNALLY prior to the point of
ignition, no EXTERNAL means of flame retention would be required.
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Working in conjunction with the Con Edison Laboratory, and applying the principles
of flame retention, he took stainless steel ribbon, corrugated it and produced varying
ribbon patterns.

This illustration shows a typical ribbon burner. A suitable slot is milled in a pipe or
casting and the ribbon pattern inserted. Introducing an air-gas mixture at a given
pressure into the burner cavity confirmed Mr. Flynn’s calculations. Two pressure drops
occurred which had exactly the desired effect; the velocity of a portion of the air-gas
mixture was reduced - establishing piloting along each side of the rows of main ports
which were produced by the ribbon configuration. Air gas mix flows thru the entire
ribbon stack. The rate of flow thru the meshing sections is reduced ow slowed down
to provide flame retention and a source of ignition to the main ports
This eliminated any external deflectors or rails and was a key factor in utilizing
ribbon line burners in the baking industry. Further refinements of ribbon type line
burners has made it possible to manufacture various slot widths and various ribbon
configurations to produce practically any flame pattern required. The flame stability
and overall performance of these type of burners was such that they soon became
standard in industry.
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AIR GAS MIXERS

AIR GAS MIXERS
Along with the development of nozzles, flame ports etc., came the evolvement of
air-gas mixers. With the discovery of flame retention, higher gas pressures could be
utilized in the Venturi. Gas pressures up to 25 psig are still used in applications such as
brick kilns and grain dryers. There are many oven installations throughout the world
using high pressure inspirators and gas in the range of 5-7 psig, which provides an
effective, simple combustion system totally compatible with the baking industry.
As the use of gas spread, the availability of high pressure gas has been limited for
various reasons, primarily because utilities are reluctant to supply high pressure gas
inside your building. This limitation of gas pressure was a factor in developing the
proportional mixer, still utilizing the Venturi principle and Bunsen concept.
By reversing the accepted practice of injecting the gas through the orifice and
instead, injecting the combustion air through the orifice, ample suction is created to
entrain all the gas necessary.

UNIMIXER
For all practical purposes, 100% of the primary air can be delivered by a
combustion air blower through the orifice as illustrated in Figure #13. This type of
air-gas mixer is designated as a proportional mixer.
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With this development, gas

combustion systems could now
be designed on the air handling
capacity. While all the burner
manufacturers, including us, rate
our burners in BTU’s/hr., in reality,
the capacity is actually based on
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can handle. This applies to both
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systems as well as low pressure (two
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Air is delivered under pressure

thru an orifice (Bunsen’s
concept) into a venturi tube

COMBUSTION AIR
Since combustion is a process involving air and gas, we need to take a look at
combustion air requirements. As a general rule, you need 10 cubic feet of combustion
air for each 1000 BTU. Another formula is as follows:
BTU/HR
REQUIRED CFH/AIR
= = CFM/AIR
100 60
The requirements of 10 cubic feet of air for each 1000 BTU is true for all
commercially available gaseous fuels. Let’s look at an example:
Combustion Air Requirements
BTU/HOUR = CU.FT. HR OF AIR

100
Example:REQ’D - 1,000,000 BTU/HR
1,000,000 = 10,000 CFH-AIR

100 per
1,000,000 BTU/HR

or
10,000 ÷ 60 = 165 CFM AIR

It is very important that you realize that for each 1,000,000 BTU/hr., you need
10,000 CFH or 165 CFM of air on a continuous non stop basis. In reality, the need
for a constant supply of air is often overlooked in the proper performance of any
combustion system.
In a typical oven, let’s assume it is rated at 3,000,000 BTU/hr. If we use our formula:
3,000,000 ÷ 100 = 30,000 CFH ÷�

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500 CFM
500 CFM of Combustion Air is required. Where does this air come from?
A great deal of consideration needs to be given to the source of combustion and

process air for proper oven performance and to meet existing code requirements.
The National Fuel Code for air requirements are as follows:
General: The air requirements of the gas equipment to be

installed and the air supply in the building in which the equipment
is to be installed shall be checked to determine that sufficient make-
up air shall be supplied to prevent any possibility of crating a partial
vacuum in the building.
NOTE: Suitable precautions should be taken to assure that the

air supply will be clean. When necessary, make-up air should be
heated.
Combustion Air: Complete combustion of gas requires

approximately one cubic foot of air, at standard conditions, for
each 100 BTU of fuel burned, but additional air for proper burner
operation (Atmospheric burner) may be required. When the
building space in which gas equipment is installed does not have
adequate air infiltration to assure proper combustion, one or
more permanent openings to the outdoors or to spaces freely
communicating with the outdoors shall be required. Such openings
shall have a minimum free area of one square inch for every 5,000
BTU per hour for equipment , an opening or openings having a
minimum free area of 0.5 square foot per 1,000,000 BTU per hour
should be provided.

GAS REQUIREMENTS
Factores requeridos para obtener 10,000,000 BTU-Hora
HEATING
VALUE CU.FT.HR. COMBUSTION
OR SPECIFIC CFH = AIR AIR-GAS
CALORIFIC GRAVITY BTU REQ’D = RATIO
VALUE (AIR=1.0) HTG.VALUE CFH
(BTU/FT’)
NATURAL 1,000 .62 1,000 10,000 10:1
PROPANE 2,500 1.52 400 10,000 25.1
BUTANE 3,200 1.90 310 10,000 31.1
Note: For a given BTU/HR requirement, combustion air volume is constant

regardless of fuel type used.
Variable is in the CFH of gas

AIR/GAS MIXER CAPACITY
This graph illustrates a capacity curve for a Flynn #6 Unimixer with a ¾” air inlet.
Note that the mixer has a window of operation, depending primarily on the size of the
air orifice and the air pressure available. With a #8 jet and 16 ounces of air pressure,
the capacity is approximately 40,000 BTU/HR. With the same mixer, a #11 jet, and 16
ounces of air, the capacity doubles to approximately 80,000.
Note also the need to increase both the air and gas supplies accordingly. If you
don’t have a mixer capacity chart available, you can calculate the theoretical capacity
of the mixer using the following formula:
CAPACITY (BTU/HR) = (168) (AIR PRESSURE IN OUNCES) ½ (JET SIZE)²
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AERATION
One of the key design criteria for combustion systems is that a constant ratio of gas
and air be maintained at all firing rates.
This ratio of air and gas is defined as a percentage of theoretical air required for the
gas fuel.
We call this the percentage of aeration. Thus the amount of primary air in the air-
gas mixture and is expressed as a total of the theoretical air required. Atmospheric
burners normally have a 40% to 50% aeration. Power burners and high pressure
systems usually have a minimum 80-85% aeration percentage.
The percentage of aeration determines the flame characteristics. The lower the
percentage of primary air, the longer and softer the flame.

Flynn Uni-mix systems in Band Ovens
How to adjust the heat in a band oven
Correct Burner Flame Adjustment
1 With header air set at maximum pressure

2 With ignition “on”
3 Gas ratio valve full open
4 Remove cap in center of gas ratio valve handle
5 Back out “ratio screw” (turning left until a greenish color flame is produced)
6 Turn in on “ratio screw” slowly (to right until a silvery blue color colored flame is
obtained without long flame tails)
Correct Burner Flame
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Incorrect Burner Flame
You will note from the sketches below, that with an incorrect
burner flame, that is the air-gas mixture set to provide long flame tails, the flame
wipes over the burner body causing the burner body to overheat and will cause flash-
back (on burners with such flames) when burners are turned down to their minimum
output.
Also, fast deteriotation of the burner body casting will result; and in a short time you
will require replacement by a new burner.
Incorrect Burner Flame


GAS FLOW AND CONTROL

BALANCED ZERO REGULATORS
Air/gas flow control is an important function for proper combustion. In a two pipe
system, using a proportional type air-gas mixer such as the Flynn Unimixer, gas flow
volume is controlled by a Balanced Zero Regulator, as illustrated on the opposite
page. The regulator must be mounted in the upright position. The operation is as
follows:
1. With no combustion air or gas supply, the pressure at all

points are atmospheric. The regulator is in the closed
position. The weight of the valve stem and seat is precisely
balanced by the spring.
2. When a gas supply is introduced at “A”, the downward

pressure on the valve is balanced by the upward pressure on
the small diaphragm. The valve stays closed.
3. As combustion air is introduced through the orifice in the

unimixer, a Venturi suction is created at “F”. This suction
decreases the pressure at “B”, which in turn decreases the
pressure at “C” via the impulse hole “E”. The pressure
differential across the diaphragm opens the valve, just
enough to a pressure slightly less than the pressure at “D”,
which is “ZERO” or atmospheric pressure. The amount of gas
flowing is determined by the gas ratio screw and the amount
of suction at “F”.
4. As the combustion air flow increases, the suction at “F”, and

gas flow across the ratio screw increases proportionally. The
regulator valve opens to maintain pressure at “D”
5. The gas ratio screw is set initially to establish the proper air-
gas ratio.
No further adjustment is required.

Ratio Adjustment
Adjust the high fire air /gas ratio by slowly turning the air valve to high fire position
while adjusting the gas ratio cock to the desired air/gas ratio. Be sure to replace the
ratio cock cover.
Trouble Shooting
SYMPTOM:
At high fire, outlet pressure goes negative or Flame goes lean.
CAUSES:
1. Insufficient supply pressure or supply line is undersized.
2. Regulator is Undersized.
3. Leak around lower diaphragm.
4. Hole in large diaphragm.
SYMPTOM:
Fire goes Rich at “Low”
CAUSES:
1. Balancing spring has been adjusted, this spring should NEVER be
adjusted.
2. Hole in small diaphragm.
3. Gas Ratio Cock adjusted beyond normal to compensate for any
conditions under “A”.
4. Valve hanging open because of dirt or damage.
5. Vent in Regulator is plugged.
SYMPTOM:
Fire goes Lean at “Low”
CAUSES:
1. Balancing spring has been adjusted, this spring should NEVER be
adjusted.
2. Vent in Regulator is plugged.
GAS PRESSURE REGULATOR
A pressure reducing Regulator is used upstream of a Zero Gas Regulator to drop

the supply pressure below the pressure rating of the Zero Regulator and maintain a
constant inlet pressure to the Zero Regulator at all flow rates. A basic spring pressure
regulator is illustrated here:
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The downstream (Regulated) pressure acts on one side of the diaphragm while
an adjustable spring is balanced against it on the other side of the diaphragm. The
valve will remain open as long as the downstream pressure is too low to balance the
constant force of the spring. The upper chamber of a gas pressure regulator MUST be
vented to outdoors in case of a diaphragm rupture.
DIFFERENCES BETWEEN ZERO GAS AND GAS PRESSURE REGULATORS

1. Have an adjusting spring to set required pressure. Different outlets spring
ranges are available.
2. Have changeable orifice to accommodate different gaseous fuels and
varying inlet pressures.
3. Are field adjustable. Zero gas regulators should NEVER be field adjusted.

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IGNITION

IGNITION TRANSFORMER

The biggest single problem area in most baking ovens today is ignition. The
purpose of the ignition electrode is obviously to light the burner, but also to provide a
continuous spark in the event of a burner malfunction.
Most field complaints center around the inability to adjust the electrode from the
outside. In most cases it is necessary to remove the electrode and make adjustments
to regain the spark.
Things you can do to help
1. Check to ascertain that your ignition transformers are properly grounded.

(see sketch on opposite page).
2. Be sure your electrodes are uniform - all alike.
3. Check to be sure the ceramic is not in the flame.
4. Check your burners to see if “lube” is dripping - usually falls near electrode.

NEW DEVELOPMENTS
Due to the long standing problems with ignition, and also the inability of the oven
operator to really verify the status of the oven burners, we have developed a new
product which has proven very successful in many installations.
The Spark Monitor unit provides ignition and

flame sensing using a single electrode. The
system utilizes a gas solenoid valve switch, in
the event of burner shutdown, closes, shutting
off the flow of gas. Red and green indicating
lights, tell the operator, at a glance, which
burners are on or off.
This replaces the “FM” cock system. You will
still need a “ratio” cock. In addition, there is a
substantial reduction in electrical energy use,
the ignition transformers are eliminated and
it will provide you with much improved oven
control.
These can also be incorporated into a
programmable controller for multi-purpose oven.
Burners can be programmed to be selectively
turned on or off as required, which provides
true burner management.

OVEN IGNITION SEQUENCING
USING
SPARK MONITOR SYSTEM

58
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COMBUSTION AIR BLOWERS

CENTRIFUGAL BLOWER

The purpose of the Combustion Air Blower is to provide combustion air at a suitable
pressure and volume to ensure proper combustion.
Theoretically, blower capacity is determined by adding the maximum pressure
drops of all resistances in series along the highest resistance branch of the system
including burners, piping fittings, control valves, regulators, etc.
In practice, pressure of 16-24 oz. are normally sufficient for most bakery applications.
To determine volume, over manufacturers use empirical data based on the type of
product, e.g.: bread 450-500 BTU/lb. of finished product.
We often receive calls from bakeries complaining they can not get sufficient heat
from their ovens. If the original equipment supplied the proper bake, then check the
combustion air blower as follows:
There are a number of things to consider regarding the combustion air blowers in
your plant:
1. Check the rotation
2. Check the RPM
3. Be sure the filters are clean
4. Make a pressure test. Most Bakery blowers are sized to deliver 16 ounces of
air pressure. If the pressure is considerably below this you need to:
a. Clean or replace the air inlet filter
b. Clean or replace the impeller
c. Check the motor bearings
d. Replace or rebuild the entire blower

AIR CONTROL VALVES


AIR CONTROL VALVES
The volume of air which is delivered to the air-gas mixers from the combustion
air blower is controlled by a butterfly valve. Normally, this valve is actuated by an
electric or pneumatic control motor, which receives its signal from the temperature
controller.
It is important for you to understand the flow characteristics of these valves.

Notice on the flow chart that EACH size valve has a different flow characteristic. Let’s
consider how this effects the performance of the burner system.

BURNER
COMBUSTION
AIR BLOWER
PRESSURE GAUGE AIR GAS MIXER
BUTTERFLY AIR VALVE AIR HEADER
AIR CONTROL VALVE SIZING

VENT TO ATMOSPHERE
VENT VALVE (OPTIONAL)

LOW GAS PRESSURE SWITCH CHECK WITH INSURANCE
CARRIER IF REQ'D
SIZE ACCORDING TO CODE
TO
BURNERS
GAS SHUTOFF VALVE #2
TEST COCK GAS SHUTOFF VALVE #1

HIGH GAS PRESSURE SWITCH
GAS PRESSURE
TEST TAP COCK GAUGE
(FOR CHECKING LEAKAGE OF
GAS SHUTOFF VALVES)
MAIN SHUTOFF COCK
GAS SUPPLY

TYPICAL PIPING
MAIN GAS SHUTOFF VALVES
AS PER NFPA-86 (1990)
67
TEMPERATURE CONTROL

TEMPERATURE CONTROL
Temperature is probably the most widely controlled variable in industrial processes.

If the objective is to improve process efficiency, a good start is to select the righ
control system.
The first consideration in selecting a temperature controller is to define the

variable and application. As a rule, the temperature controller selected will become
more sophisticated as the need for accuracy increases.
A temperature control system is classified by the method of feedback from the

process zone. In order to achieve this, two components are required; a sensor and a
control device.
Temperature controllers are calibrated for a specific type sensor. Two basic
types of sensors are available; mechanical and electronic.
Mechanical sensors use moving parts or linkage to transmit the results of the
sensed temperature to the control devise. The most commonly used mechanical
sensor is the filled-thermal sensing bulb connected to the control device by a capillary
tube.

H-1
H-1
The most widely used electronic sensor is the thermocouple. A thermocouple

Thesmall
generates most widely
voltage used
signals electronic
in measuring sensor
loops is the thermocouple.
as a funcction difference betweenA
thermocouple
the temperature generates small
at the sensing voltagejunctions.
and reference signals in measuring loops as a
funcction difference between the temperature at the sensing and reference
junctions.

H-2
H-2
This sketch illustrates a mechanical unit. Temperature control devices which
are considered to be mechanical act as a receiver of the moving parts from the filled
system sensor. Through a linkage arrangement, the mechanism is positioned to
“make” or “break” contact outputs. Mechanical or filled sensors are available for use
This sketch
with pneumatic processillustrates a to
signal outputs mechanical unit.
control valves Temperature control
or dampers.
devices which are considered to be mechanical act as a receiver of the
moving parts from the filled system sensor. Through a linkage
arrangement, the mechanism is positioned to "make" or "break" contact
outputs. Mechanical or filled sensors are available for use with
pneumatic process signal outputs to control valves or dampers.

H.3
H.3
This sketch illustrates an electronic system. In electronics or “solid state”
controllers, the set point is established by adjusting potentiomenters. Input to the
electronic controller is direct from a thermocouple or another type of electronic
sensor. Control acction occurs when the process pointer breaks a set point circuit.
Partlow
This sketch illustrates an electronic system. In electronics or "solid
state" controllers, the set point is established by adjusting
potentiomenters. Input to the electronic controller is direct from a
thermocouple or another type of electronic sensor. Control acction occurs
when the process pointer breaks a set point circuit.

OVEN EFFICIENCY

OVEN EFFICIENCY
Much has been written about oven efficiency. This subject is not nearly as complex
as it appears. When you put a certain amount of heat into the oven, obviously the
heat has to come out in various forms.
As you can see there is a formula involved. Thus, we are able to arrive at a heat
blance for the oven. What are the variables which can be controlled?
BTU IN = BTU OUT
PRODUCT = (SP.HT.PRODUCT)(WGHT./HR)(∆T)
BTU/HR. GAS INPUT= EXHAUST=(1.08)(C.F.M.)(∆T)
RADIATION=(.5 BTU./HR)(SURFACE AREA)(∆T)
BAND=(WEIGHT OF BAND)(SP.HT.STEEL)(∆T)


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Combustion Seminar

425 Fifth Avenue • P.O. Box 431 • New Rochelle • NY 10802

II Burner Technology ..................................................... 19

III Air Gas Mixers ..............................................................33

IV Gas Flow & Control ....................................................45

VI Combustion Air Blowers . ........................................59

VII Air Control Valves . ....................................................63

VIII Temperature Contro................................................69

IX Oven Efficiency . .........................................................77

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 

This illustration is intended to provide you with an overview of the

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 

This illustration is intended to provide you with an overview of the

The engineering art of

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HEAT - is defined as molecular activity or agitation. It is a form of

TEMPERATURE - is the result of the applied heat energy.

HEAT = BTU\HR= QUANTITY

10 FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com

Experience has taught us that the time-temperature relationship for a specific

CONDUCTION: The transfer of heat by molecular contact such as

CONVECTION: The transfer of heat by hot air, usually augmented by

RADIATION: The transfer of heat by heat waves through the air

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 11

DIRECT HEAT FROM CONVEYOR TO DOUGH

In longer ovens, the band is

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FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 13

14 FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com

FLYNN BURNER CORPORATION Tel 914-636-1320

Fax 914-636-3751 • www.flynnburner.com

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 19

In the interest of providing some perspective on the evolvement of the burner, a

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Bunsen introduced the concept of

This was the fore runner of the

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• Be controllable over a range of turndown without flashback or

• Provide uniform flame distribution.

• Be capable of completely burning the gas.

• No lifting of flames away from ports.

• Substantial construction to withstand heating and cooling.

• These requirements must be met under a wide variety of

24 FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com

FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com 25

In their attempts to increase capacities by enlarging individual burner ports,

².!452!, ²02/0!.% $)2%#4)/./&

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Flame Retention is the process

The Key is Flame Retention

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32 FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com

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FLYNN BURNER CORPORATION Tel 914-636-1320 Fax 914-636-3751 • www.flynnburner.com

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