Incinerator

Make : SUNFLAME
Type: OSV
Incinerator
 Operation
Preparation:
• Drain the layered water from waste oil (sludge) in
the tank before burning. Contaminations in oil may
cause some clog or trouble to valves and pumps
• Heat waste oil (sludge) before and while burning
• Agitate waste oil (sludge) before and while burning
(if fitted with agitator)
• Make sure strainers are clean
• Turn valves to correct set positions for a running
 Operation

VALVE SETTING
FOR WARMING UP
 Operation
Preparation:
• Make sure the powers of electricity and air to
the unit
• Solid wastes can be charged through the
single door before running. Close and bolt the
door steadily after every charging
• Set the burner and all doors in their running
position
 OPERATION

VALVE SETTING
FOR WASTE OIL
BURNING
 Operation
Running:
• Preset switches for start
• Turn ‘FUEL FOR MAIN BNR.’ switch to ‘D.O’
• Turn ‘DILUTION” switch to ‘AUTO’. (in case of automatic dilution
control)
• Close the furnace air damper and open the dilution damper to
decrease air into the combust ion chamber, then the warming up will
be quickened. Narrowing the gap of the burner air damper may effect
better. The dilution damper will be automatically operated as
described below in case of automatic dilution control
• Set valves for warming up by diesel oil
• Turn ‘RUNNING’ switch to ‘START’, and the exhaust fan and the main
burner will be driven. The pump assembled in the main burner is also
driven
 Operation
Running:
• Preset switches for start
• Turn ‘FUEL FOR MAIN BNR.’ switch to ‘D.O’
• Turn ‘DILUTION” switch to ‘AUTO’. (in case of automatic dilution
control)
• Close the furnace air damper and open the dilution damper to
decrease air into the combust ion chamber, then the warming up will
be quickened. Narrowing the gap of the burner air damper may effect
better. The dilution damper will be automatically operated as
described below in case of automatic dilution control
• Set valves for warming up by diesel oil
• Turn ‘RUNNING’ switch to ‘START’, and the exhaust fan and the main
burner will be driven. The pump assembled in the main burner is also
driven
 Operation
Running:
• Preset switches for start
• Turn ‘FUEL FOR MAIN BNR.’ switch to ‘D.O’
• Turn ‘DILUTION” switch to ‘AUTO’. (in case of automatic dilution
control)
• Close the furnace air damper and open the dilution damper to
decrease air into the combust ion chamber, then the warming up will
be quickened. Narrowing the gap of the burner air damper may effect
better. The dilution damper will be automatically operated as
described below in case of automatic dilution control
• Set valves for warming up by diesel oil
• Turn ‘RUNNING’ switch to ‘START’, and the exhaust fan and the main
burner will be driven. The pump assembled in the main burner is also
driven
 Operation
Running:
• The dilution damper will automatically open to quicken
warming up of the furnace in case of automatic dilution control.

After a proper purging, the ignition burner will be supplied with

diesel oil to atomize while the electrodes give a spark to the oil
mist at the same time
• The main burner will be supplied with diesel oil to burn in 10
seconds
• The ignition burner will stop in 10 seconds
• The fluid to the atomizer of the igniter will be replaced with air
by the atomizer cooling valve while the igniter stopping in order
to protect the atomizer from heat in a hot furnace
 Operation
Running: Waste oil (sludge) burning
• waste oil (sludge) has interlock to shut off with a lower
temperature than the low limit point in the combustion chamber
• Set valves for the wasted oil combustion after furnace
temperature becoming 650 or more
• change ‘FUEL FOR MAIN BNR. ‘ switch to wasted oil after ‘WASTE
OIL BURNING POSSIBLE’ lamp lights.
Adjust the burning rate and the dampers’ opening so that the
temperature is settled at about
1050 after the chamber warmed. To close the dilution damper can
control the temperature rising of the combustion chamber in case
of manual dilution control. Adjust the burner air damper
depending on the burning rate of oil.
 Operation
Running: Waste oil (sludge) burning
• Adjust the furnace air damper depending on the burning
condition of solid wastes
• When the chamber is heated up to the upper set point (1, l00) ,
fuel is automatically
shut off. when it is cooled back to the lower set point (1,000°C),
the igniter will start again
• When the exhaust gas is heated up to the upper set point (320).
fuels will be automatically
shut off. When it is cooled back to the lower set point, the
igniter will start again
• purging will be automatically carried out for 30 seconds or
longer after every shut off of fuels
 Operation
• Stopping:
• Stop agitation and heating of the waste oil if not
necessary
• Turn “FUEL FOR MAIN BNR” switch to D O
• 3 Way valve returning diesel oil from the burner
is shifted into the waste oil tank (sludge tank) on
this stage. Keeping at this position for long time
may cause an over filling of the tank
• Turn the switch to OFF after a few min so as to
clear the WO line and fill the line with DO
 OPERATION

VALVE SETTING
FOR PIPE
CLEARING
 Operation
• Stopping:
• Stop agitation and heating of the waste oil if not necessary
• Turn “FUEL FOR MAIN BNR” switch to D O
• 3 Way valve returning diesel oil from the burner is shifted into the waste oil tank
(sludge tank) on this stage. Keeping at this position for long time may cause an over
filling of the tank
• Turn the switch to OFF after a few min so as to clear the WO line and fill the line with
DO
Quenching stage :
• Turn “RUNNG” switch to “STOP” after the thermometer of waste oil (sludge) equals to
the diesel oil temperature (which confirms DO in the sludge line)
• Fuels will be shut off and the burner will stop immediately, and the combustion
chamber will be cooled by the exhaust fan. Close the dilution damper for quickening
of cooling of the combustion chamber
• The fan will stop after quenching the chamber to the finish point
• Check the inside of the furnace soon after the fan stopped. If it is not enough cooled
or some ember remains in, drive the fan soon again
 Operation
After Stopping and quenching:
• Remove oil, soot or carbon froth every exposed part soon after
quenching.
Clean the furnace wall by a brush or a chisel, the atomizing cup by
rag or a sheet of sand paper, the flame eye by rag, the sight glass by
rag and the electrodes of the ignition burner by a brush or a sheet
of sand paper
• Emergency stop stage :
• Two methods for emergency stop are prepared locally and/or
remotely as follows;
• “RUNNG” switch (to “ STOP”) on the local panel and EMERGENCY
STOP” switch extended
remotely (if installed for the general emergency stop) is provided for
the purpose.
 Operation
After Stopping and quenching:
• Remove oil, soot or carbon froth every exposed part soon after
quenching.
Clean the furnace wall by a brush or a chisel, the atomizing cup by
rag or a sheet of sand paper, the flame eye by rag, the sight glass by
rag and the electrodes of the ignition burner by a brush or a sheet
of sand paper
• Emergency stop stage :
• Two methods for emergency stop are prepared locally and/or
remotely as follows;
• “RUNNG” switch (to “ STOP”) on the local panel and EMERGENCY
STOP” switch extended
remotely (if installed for the general emergency stop) is provided for
the purpose.
 Operation
After Stopping and quenching:
• Remove oil, soot or carbon froth every exposed part soon after
quenching.
Clean the furnace wall by a brush or a chisel, the atomizing cup by
rag or a sheet of sand paper, the flame eye by rag, the sight glass by
rag and the electrodes of the ignition burner by a brush or a sheet
of sand paper
• Emergency stop stage :
• Two methods for emergency stop are prepared locally and/or
remotely as follows;
• “RUNNG” switch (to “ STOP”) on the local panel and EMERGENCY
STOP” switch extended
remotely (if installed for the general emergency stop) is provided for
the purpose.
 Operation
Incineration of solid wastes :
• It should be considered that a hot chamber and a good
ventilation are necessary for substances to burn well with
neither smoke nor unburned residue.
• Ensure that the garbage loaded in he incinerator is dry
• Cut large substances into pieces and divide them into charging
lots depending on their combustibility. Small divisions/amount
will make combustion better controlling a rapid firing.
• Take a special care against overcharge for incineration
• Put muddy, granular or thin materials on the flat floor through
the single door while the combustion chamber is safe and cool
without any firing
 Operation
Incineration of solid wastes :
• Keep the combustion chamber hot enough for a complete
incineration with the burner assisting, while an
incineration goes on the main burner can be supplied with
either waste oil (sludge) or diesel oil
• For simultaneous burning of oil from the main burner and
solid substances, decrease the oil rate by the flow control
valve to prevent some overheat trouble
• After the completion, please ensure that the exhaust fan
runs continuously to reduce the temperature below 60
deg centigrade
 Operation
Incineration of solid wastes :
Solid wastes which are prohibited to burn
• Annex I, II and III cargo residues and related contaminated
packing materials
• Poly—chlorinated biphenyls (PCBs)
• Garbage as defined in Annex V of the Convention, containing
more than traces of heavy metals
• Refined petroleum products containing halogen compound
• Explosive or pressurized cans
• material with low flash point in a cardboard or in any other
containers
 Operation
Incineration of solid wastes :
• system has interlocking and locking devices for
safe charging. Please open them and charge
disposals while CHARGEABLE lamp lit and the
incinerator stops
 Trouble Shooting
• All the machines and devices including fuel
supplying ones are interlocked with the
exhaust fan
• Trouble: The alarm means the fan cannot
establish a normal pressure to gas flow
• Remedy: A reset button is mounted on the
magnetic switch of the motor. Push the but
ton to reset after restoring
 Trouble Shooting
• All the machines and devices including fuel supplying ones are interlocked with
the exhaust fan
• Trouble: The alarm means the fan cannot establish a normal pressure to gas flow
• Remedy: A reset button is mounted on the magnetic switch of the motor. Push
the but ton to reset after checking the following.
1.Check the driving belts and change torn one. & Check the pressure conducting
tube to the pressure switch and remove any clogging.
2. Check and fasten the cable connections of the switch.
3. Test the switching function while the fan runs, and change broken one.
4. Check the surface temperature of the motor.

7. Take the belts off, and turn the fan shaft by hand. Check the bearings of the
fan shaft and the impeller inside of the fan, if the shaft does not turn easily
• Turn the motor shaft by hand. Check the bearings of the motor, if the shaft does
not turn easily. Change broken bearings
 Trouble Shooting
Motor trouble:
• Check and fasten the cable connections of the motor.
• Measure the current on each phase of the motor by a
tester
• Change the motor, if the current is more than the
rating shown on the label of the motor, even if the
other problems mentioned above are all cleared
 Trouble Shooting
• Burner faults (MISFIRE alarm will come out when
flame goes out in a way of burning.
oils supply will stop to put out both the burners
immediately)
• Check the driving belt, if found torned, renew the
same
• Take off he driving belt and turn the burner pulley
with hand , if not turning smoothly, check for the
further fault with the shaft, bearings etc.
• Check the primary air fan assembled in the burner and
remove any adhesive to the fan and any odds inside
 Trouble Shooting
• Flame Fault: This alarm will activate; when
the flame extinguishes during the firing. Once
the alarm is activated oil supply will stop to
put out both the burners immediately
• Flame eye may be faulty:
• Clean the flam eye
• If still gives flame failure(if the flame is stable),
change the flame sensor
 Trouble Shooting
• FUEL PRESSURE LOW : This alarm activates when the oil
pressure falls down to the set pressure or lower in 10
seconds after the ignition starts.
• Once the alarm is activated, Oil supply will stop and the
burners stop immediately
• Check the pipe lines and tank
• If the pump is running and the filters are clean; turn
the screw of the return—adjusting valve on the diesel
oil pump (electro—pump) to adjust the delivery
pressure. The set pressure is about 0.7 MPa (7 kg/cm2).
• Purge the gas from the oil pipe lines and pump
 Trouble Shooting
• Failure of firing of main burner (waste oil
burner) :
• Check the pipelines, the wires and the relays.
• Increase the oil rate or decrease the path area
of the primary air in order to avoid blowing
out
• Check the waste oil temperature
• Check the valves, line and tanks for the correct
line up
 Trouble Shooting
• Failure of ignition :
• Check the DO pressure
• If pressure is ok, Pull the ignition burner out and put on some
hazardless place check the spark and fuel flow separately.
• If the spark is weak , renew the ignition transformer after
checking the earthing etc(Ensure that the spark is tested after
disconnecting connection to diesel oil electro pump)
• While testing for the DO flow from the burner, ensure that
electrode connections to the burner is removed.
• If the DO pressure is not sufficient, please check the filters in
he line and the check the nozzle for clogging
• Also check the DO electro pump for the malfunction.
 Trouble Shooting
• High Exhaust temperature: Once the alarm is activated; The
damper will open immediately in case of automatic dilution
control. Oil supply to both the burners has already stopped. If
it is not on auto mode, open the damper and stop the burner
• Check the sensor and cable for malfunctioning
• Interchange the connection of the furnace temperature
gauge and exhaust temp. sensor, to check the correct
readings
• Check the gas passage for any obstructions
• If too much solids are burning, this can causer high exhaust
temperature
 Trouble Shooting
• High Furnace temperature: Once alarm is activated,
the fuel supply to burner is stopped automatically
• Exchange the exhaust gas temperature sensor and
furnace temperature sensor to check the furnace
temperature
• If the furnace temperature is very high, allow the
furnace to cool down, check the exhaust gas passage
and furnace for any accumulation of sludge, debris etc.
 Maintenance
• Daily or weekly maintenance :
• Remove ash with a shovel or the like after every running, and make it sure before
the next running. Blocking of the air path holes on the lower side wall obstruct
necessary air for the combustion chamber
• Remove any sticking carbon or ash onto the furnace wall, the burner and furnace
tile and so on, by a wire brush (or by a chisel against hard sticking) after every
running
• Sticking onto the burner and tiles in front of the main burner and the ignition
burner will make combustion abnormal. Sticking onto the tile in front of the flame
sensor will put the control out of order and obstruct sure safety.
• Clean the protect cover of the thermo—couple and the surroundings after a
running. Do cleaning gently with wire brush or the like, as the sensor is mounted at
first, then drawing it out because the cover is fragile
• Sticking onto the cover or the sensor hole will put the control out of order and
obstruct sure safety. If progressing of the sticking bridged between the cover and
the hole wall, the cover may break by some force
 Maintenance
• Daily or weekly maintenance :
• Clean the cover glass of the flame eye with rags after every
running.
• Disassemble and clean the atomizing CLIP of the main
burner with rags after every running
• Clean the air nozzle of the main burner with a wire brush
or the like while the atomizing cup disassembled after a
running
• Clean the atomizer of the ignition burner with kerosene
after a running
• Clean the electrodes of the ignition burner with a sheet of
sand paper or the like after a running
 Maintenance
• Daily or weekly maintenance :
• Clean the air nozzle of the main burner with a wire
brush or the like while the atomizing cup
disassembled after a running.
• Clean the atomizer of the ignition burner with
kerosene after a running
• Clean the electrodes of the ignition burner with a
sheet of sand paper or the like after a running
• Check the location of the atomizer and the electrodes
of the ignition burner before running, and adjust
them if necessary as per the maker
 Maintenance
• Daily or weekly maintenance :
• Clean the screen of the waste oil (sludge) strainer
with kerosene or the like before a running
• Clean the screens of the diesel oil strainer weekly
• Check the lubricant in the gear box of the burner,
and fill it up if necessary
• Clean the sampling pipes of the fan pressure by
purging air weekly
 Maintenance
• Monthly or 3 monthly maintenance :
• adjust tensions of driving belts
• Renew the lubricant in the gear box of the
main burner and the grease in the bearing
units of the exhaust fan in every 500 hours’
running
• Carry out the furnace inspection
 Maintenance
• 6 Monthly or Annual maintenance :
• Clean and oil the spindle of the air cylinder, if
equipped
• Clean contactors of electric parts by thinner oil
• Overhaul the burners, the pumps, the fans,
the valves and other moving parts
• Remove any deposits in the oil line and the
uptake
 Maintenance
Furnace
Sticking to furnace wall or others:
• Clean any sticking and deposit in an early occasion, because it will make
devices and instruments malfunction, damage them by heat accumulation
onto spoiled parts
• Sticking to the wall or the floor will shorten the lifetime of the material
• Sticking to the atomizing cup, the air nozzle, the atomizer or the electrodes
will cause a bad atomizing, oil dripping or oil scattering
• The atomizing cup may get some warp from heat or unbalance, and the
atomizer may get sonic warp from heat
• Spoiled cover glass of the flame eye will obstruct to detect actual flame for
safe operation
• Spoiled cover of the thermo—couple will obstruct to detect actual
temperature or at worst will break the sensor
• Spoiled cover of the thermo—couple will obstruct to detect actual
temperature or at worst will break the sensor
 Maintenance
Furnace
Sticking to furnace wall or others: Remedy
• clean sticking deposit on the wall, the burner and other
parts in he furnace after taking due precautions
• The followings are suggested as causes of sticking to
the wall and other parts
• The most frequent cause is exceeding burning of oil or
insufficient heating of the combustion chamber
• The viscosity of the oil is too high
• Some wastes may contain calcium or the like which has
very adhesive property