Duoflex Kiln Burner

Duoflex kiln burner
DBC-244.5-750-11
Installation, operation and maintenance instructions

Plant name: XUAN THANH - VIETNAM
Created by: KANVE
Approved by: SASU
FLSmidth, 11-Dec-15 70031872-1.0
Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installation,
operation and maintenance of the equipment. An exhaustive enumeration of all
conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instructions, and which the operator is/or feels unable to handle, it is recommended that
FLSmidth is contacted without undue delay for advice on appropriate action.
All references to relevant safety standards are given at the EC declaration of conformity if
required.
Reference by seller to any international or national standard does not incur an obligation
on seller to provide any recipient, reader or user of the documentation with samples or
copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected – at his own cost –
to obtain necessary knowledge of the contents of any of the standards referred to.
Safety
Potential safety risks, and correct mode of conduct subject to such risks, are continuously
described in the text in relation to specific actions.
See instructions 32031 for general safety rules and the separate equipment-specific safety
instructions for a complete list of all unforeseen risks in connection with the installation,
operation and maintenance of the equipment.
Definitions and abbreviations
Authorized person A person who is qualified and who, by the responsible manager, is
entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is capable
of doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM Operation and Maintenance
Legend Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
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Warning text is concluded with a filled black triangle to symbolize end of warning text.

Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or parts of
the installation.
Attention text is concluded with a filled black square to symbolize end of attention text.
Table of contents
1.0 General information..............................................................................4
1.1 Content.............................................................................................4
1.2 Design..............................................................................................4
1.3 Documentation.................................................................................5
2.0 Construction and operating description ................................................6
2.1 Arrangement ....................................................................................6
2.2 Burner ..............................................................................................7
2.3 Burner tip .........................................................................................8
2.4 Burner rear end ................................................................................10
3.0 Safety instructions .................................................................................11
4.0 Erection .................................................................................................11
5.0 Operation ...............................................................................................12
5.1 Duoflex burner functionality ........................................................... 12
5.1.1 Flame shape adjustments ...............................................................12
5.1.2 Primary air calculations .................................................................13
5.2 Pre-operational check .......................................................................14
5.3 Lighting-up .......................................................................................14
5.4 Operation ..........................................................................................17
5.5 Stop of firing .....................................................................................18
5.6 Operational supervision ....................................................................18
6.0 Maintenance ........................................................................................... 19
6.1 Preventive maintenance .....................................................................20
6.1.1 Lubrication .....................................................................................20
6.1.2 Cleaning..........................................................................................20
6.1.3 Inspection and adjustment ..............................................................21
6.1.4 Status check ....................................................................................21
6.1.5 Replacement of spares ............................................................... …22
6.1.6 Replacement of burner pipe ........................................................ ...28
6.1.7 Burner nozzle concentricity check and adjustment ........................30
6.1.8 Duoflex burner disassembly and assembly.....................................33
6.1.9 Functional test ................................................................................36
6.2 Trouble shooting ...............................................................................37
6.2.1 Fault localization ............................................................................37
6.2.2 Reconditioning ...............................................................................38
The information transmitted by this document is the proprietary and confidential property of FLSmidth and
may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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8 1.0
General information
1.1 Content
This manual covers the instruction for operation and mechanical maintenance for the
Duoflex kiln burner installation.
The content in this instruction refers to the following instructions manuals

General safety regulations on erection site 32031
Duoflex kiln burner, Erection 70008635
Duoflex kiln burner, Safety 40271
Wear lining with Densit V3551
1.2 Design
Figure 1.1 – Duoflex Burner tip configuration Duoflex assembly
1 Primary air channel 03 Oil lance and Igniter lance channel

2 Coal channel 04 Fibre optic flame detector channel
The burner has been designed according to the following conditions
Thermal output, maximum 215 MW
Ambient air pressure 1012 mbar
Ambient temperature 45 °C
Primary air
Maximum pressure 250 mbar
Maximum capacity at ambient conditions 25118 m3/hr
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Main fuels
Coal
Net calorific value 4500 kcal/kg
Conveying air amount at ambient conditions 10380 m3/hr
Maximum capacity 41200 kg/h
1.3 Documentation
Burner type Duoflex DBC-244.5-75011

Parts list No. 50070804
Arrangement drawing No. 13105552
2.0 Construction and operating description
2.1 Arrangement
Figure 2.1 - Typical Arrangement of Duoflex Kiln Burner System (example)

01 Rotary kiln 13 Primary air fan
02 Closing plate assembly 14 Butterfly valve for emergency cooling

(example)
03 Clinker cooler 15 Emergency air fan (example)
04 Axial air valve 16 Travelling rails
05 Butterfly valve for cooling air 17 Primary air pipe
06 Cooling air hose 18 Coal meal hose
07 Swirl air valve 19 Burner trolley
08 Gas burner (example) 20 Air distribution pipe
09 Oil burner 21 Flexible Primary air inlet
10 Gas hose (example) 22 Expansion joint for primary air
11 Slide gate valve 23 Duoflex burner
12 Pipes for adjustment 24 Kiln hood door
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Duoflex burner which is suspended from a trolley and running on rails - is fed with
primary air from primary air fan. A special emergency air fan ensures the cooling of
burner in the event of power failure.
The primary air is divided into, respectively, axial and swirl air via distribution pipe and
axial & swirl air valves. A smaller part of the primary air is admitted to the central duct
via cooling valve and cooling hose ensuring the cooling of inner pipes.
The total primary air flow is measured by a flow transmitter at the inlet side of Primary
air fan. Primary air pressure is measured by a transmitter in the duct upstream of the
burner and by pressure gauges placed downstream of axial and radial valve. Since the
axial and swirl air flows are mixed after the swirler, the reading on these gauges will
normally be almost identical due to the limited pressure drop across the swirler.
Coal meal is introduced via the coal duct and coal hose. Upstream the coal hose, a slide
gate valve for maintenance safety is installed.
The position of the Duoflex burner tip in the kiln can be adjusted in horizontal as well as
in vertical direction by means of burner trolley. See separate instruction manual for
burner trolley.
The axial position of the burner can be changed by moving the trolley. Pipes for
adjustment are to be inserted or removed when the axial position is changed.
A two piece movable insulated closing plate assembly prevents the entry of false air
between Duoflex burner and kiln hood door to the combustion zone.
2.2 Burner
Figure 2.2 – Typical Duoflex Kiln Burner Assembly
1 Air nozzle 05 Spindle gear unit

2 Movable burner part 06 Support beam
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8 upport
pipe
07 Stationary burner part
4 Suspension for movable burner part
The Duoflex burner consists of an outer stationary part and a movable part. The stationary
part is suspended from the supporting beam, which is welded to the supporting pipe. The
movable part which is supported at the burner tip and suspended at the rear end from the
supporting beam via the movable suspension can be displaced in axial direction by means
of the spindle gear unit and thereby adjusting the annular area of the air nozzle.
2.3 Burner tip
Figure 2.3 – Duoflex Burner nozzle tip (example)
01 Coal nozzle 12 Rod for detection of expansion

02 Air nozzle replaceable tip 13 Burner pipe
03 Central nozzle 14 Radial air pipe
04 Central nozzle front plate 15 Coal pipe
05 Sealing plate 16 Central duct
06 Air gap / Discharge area 17 Swirler unit
07 Refractory casting 18 Air nozzle
08 Axial air 19 Parallel key
09 Swirl air 20 Nozzle guide
10 Cooling air 21 Swirler vanes
11 Coal meal
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centreline of the Duoflex burner, there is a central duct. Depending upon the specific
application, this duct may have protective tubes for oil and/or gas burner set, ignition gas
burner, fibre optic flame scanner as well as separate tubes for injection of secondary
fuels, if any. See plant specific configuration sketch in section 1.2.
The space between the central nozzle and the inner tubes is closed by a central nozzle
plate with a number of small holes for cooling air. There is also a sealing plate provided
between central nozzle and inner tubes to ensure a relatively high air pressure is
maintained inside the central duct.
The coal pipe is kept in place around the central duct by means of guide fins. The coal
pipe is provided with a machined cylindrical nozzle at the outlet end. The axial position
of the coal pipe is adjustable and adjusting the position will change the discharge area for
the primary air.
Coal meal along with the conveying air is introduced through the annulus between coal
pipe and central duct.
The coal pipe is surrounded by radial air pipe and burner pipe forming two annular
channels for primary air.
Axial air is admitted through the annulus between burner pipe and radial air pipe. Swirl
air is introduced through the annulus between radial air pipe and coal pipe to the swirler
unit. The inclined vanes in the swirler unit induce a swirling action to the swirl air before
it is mixed with the axial air. The total primary airflow is then discharged through the tip.
The discharge area of the nozzle can be adjusted by displacing the coal pipe axially from
the burner tip. The discharge area will however change due to thermal expansion of the
burner pipe. This expansion is detected by a spring loaded rod.
To secure uniform air gap around the coal nozzle, the air nozzle replaceable tip is
adjustable in order to compensate for deviations in the air gap.
Attention
While making the refractory casting for the outer pipe, air nozzle tip must be casted
separately. For detailed description/dimensions of burner pipe casting, Please refer
refractory drawings. 
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Burner rear end
Figure 2.4 – Duoflex Burner rear end (example)

01 Suspension for movable burner part 07 Coal channel cooling air system
02 Swirl air valve 08 Oil burner
03 Axial/swirl air pressure gauges 09 Pipes for waste firing (Example)
04 Central air valves 10 Spindle gear unit
05 Axial air valve 11 Nozzle opening indicator
06 Central air hoses 12 Thermal expansion indicator
The Duoflex burner is shown with an oil/gas burner lance and additional pipes for
secondary fuels as an example. See section 1.2 for actual configuration for this contract.
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the
devices for manual burner adjustment are placed at the burner rear end:
• Primary air nozzle opening (discharge area) can be adjusted by a spindle gear unit.
Spindle gear position can be locked by a handle with lock nut placed at the centre of the
hand wheel. Actual nozzle opening, compensated for thermal expansion, can be read at
indicator. The thermal expansion can be read at indicator.
• Swirl can be induced by opening swirl air valve and further increased by partly
closing axial air valve.
• Central air for cooling the central duct nozzle and keeping the burner front clean
can be adjusted by central air valve.
• Coal channel cooling air system to be connected instead of coal hose when
operating with other fuels than coal/Petcoke.
• See separate instructions for adjustment possibilities on the liquid fuel lances, if
any.
3.0 Safety instructions
See separate instruction manual.
4.0 Erection
See separate instruction manual.
5.0 Operation
5.1 Duoflex burner functionality
The Duoflex burner is designed to be very flexible regarding types of fuels used and
regarding flame shape adjustment facilities.
With the adjustment possibilities available on the Duoflex, the burner can provide the
desired flame (short or long, sharp or soft, wide or narrow, and all intervening
combinations) required for coping with the different burning conditions and fuels used.
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Therefore a correctly adjusted Duoflex burner will solve most burning problems, except
for operational problems not related to flame shape or flame adjustment. These are
problems such as chemistry, homogeneity of raw meal, ovality of kiln shell, use of not
suitable lining bricks and various other factors.
5.1.1 Flame shape adjustments
Figure 5.1 – Flame shape Figure
• Primary air pressure is determined by the combination of primary air flow and
nozzle opening. Primary air pressure will normally be monitored by a pressure transmitter
placed on the primary air duct upstream of the burner.
Increasing primary air pressure will enhance entrainment of secondary air into the flame
and will therefore make the flame shorter and sharper. Reducing primary air pressure will
delay secondary air entrainment and will make the flame longer and lazier.
• Primary air flow is determined by the nozzle opening and by the adjustment of
the fan or blower used. Primary air flow is normally monitored by a flow meter placed at
the fan or blower inlet. If the primary air is supplied by a fan, air flow can be controlled
by either a damper, inlet vane control or by fan speed control (VFD drive). Adjusting the
nozzle area will also change the air flow.
If a rotary blower is used for primary air, it must be supplied with a VFD drive for flow
control. Adjusting the nozzle area will not change the air flow, only the air pressure.
Increasing primary air flow will increase the burner momentum and will enhance
secondary air entrainment. The flame will become shorter and sharper. Reducing primary
air flow will decrease the burner momentum and will delay secondary air entrainment.
The flame will become longer and lazier. There is a lower limit for how much the air flow
can be reduced due to the cooling requirements for the burner pipe.
However to obtain an acceptable flame shape the minimum air flow required will
normally be considerably higher than the flow required for cooling.
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8 rimar
y air
swirl will generate a recirculation zone which will yield a faster rate of ignition of the
fuel due to increased recirculation of hot gases in the flame core. A shorter and more
stable flame will be generated.
• Burner position adjustment may change the burning conditions in the kiln.
Before first light up, the burner should be positioned as close as possible to the kiln centre
axis. The burner tip should be placed in an axial position corresponding to approximately
0.5 m inside the kiln hot point. This position should then be clearly marked on the railings
for the trolley and on the burner trolley for the horizontal and vertical position.
If the settings are changed during operation, it will always be possible to bring the burner
back to the original position with the help of these markings, even during hot kiln
conditions.
5.1.2 Primary air calculations
As described in section 5.1.1 there is a close relation between primary air pressure and
flow. The combined effect of primary air pressure and flow can be expressed as primary
air amount which is then multiplied by nozzle velocity and divided by thermal burner
output (N/MW).
This relation is expressed as the primary air momentum G, which can also be expressed
as
G = Lp ×C[%m/ s]
Lp = Primary air, percentage of theoretical combustion air requirement [%] C = Primary

air velocity at the nozzle tip, m/s.
Calculation of Primary air percentage and momentum can be done by the spread sheet
supplied with this instruction.
5.2 Pre-operational check
Attention
Check the following before the Duoflex burner is positioned in the kiln 
Primary air nozzle concentricity and spindle gear functionality according to section
6.1.4. 
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Attention
Check the following prior to lighting-up
• For the first light up, check protective interlocking, see separate electrical
documentation.
• The position of the Duoflex burner in the kiln.
• That all flexible connections are intact and properly connected.
• That manual valves upstream the connected flexible connections are open.
• That coal connection cooling air system is connected if constant operation on other
fuels than coal/Petcoke is planned.
• The kiln oxygen meter has been cut in and that full functionality is ensured.
• External interlocking fulfilled, for details, see electrical documentation.

5.3 Lighting-up
Figure 5.2 – Duoflex burner assembly (example)

01 Air nozzle 04 Central air valve
02 Axial air valve 05 Spindle gear unit
03 Swirl air valve
During lighting up of a cold kiln, the burner settings are different from the settings during
operation.
Local conditions will dictate the adjustments of the burner, and this can vary from
installation to installation. Normally however axial air should be reduced and radial air
should be maximized.
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Attention
To keep the burner pipe cooled however axial air valve should be at least partly opened as
soon as the flame is stable and before the kiln gets hot
It is recommended to adjust the air nozzle discharge area to its minimum by means of the
spindle gear unit. Especially, when using oil for lighting up, it is recommended to keep
the air nozzle discharge area at minimum for the first approximate 10 minutes until the oil
burner has been heated up. This will prevent oil dripping “into” the kiln burner, when
cold heavy fuel residues from the oil burner are trying to be atomized. If the flame is
stable at minimum air nozzle discharge area after the oil burner has been heated up, this
nozzle position could be kept. If not, open the air nozzle discharge area until the flame
becomes stable.
At the same time the primary air pressure in the axial and radial air channel should be
kept low in order to obtain the best and most stable flame.
When using oil for lighting up it is important to keep a relative high air pressure in the
central duct and oil burner protection pipe since this will enable a relative high air
velocity pass through the oil burner protection pipe and the cooling air holes at the front
plate. This will keep the burner front clean from oil dripping and droplets until the kiln is
hot.
In order to keep a low pressure in the axial and radial air channel, and a high pressure in
the central duct, it will be necessary to adjust the primary air fan to a relative high
pressure. This high pressure primary air shall then be throttled down in the axial and
radial air channels by using the axial and swirl air valves. It will then be possible to adjust
the air pressure in the oil burner protection pipe and central duct by using central air valve
for throttling.
It is normal to use a reasonably hard flame when starting the Duoflex burner in a cold
kiln. This means the primary air momentum is rather high when starting the burner,
giving a short and hard flame.
As the heating up of the kiln progresses the fuel amount is increased in order to follow the
heating up curve and primary air flow and pressure is increased as well to maintain a
good flame. Due to the higher fuel input however primary air momentum may be
reduced. The flame shape must always be adjusted according to visual inspection of the
flame.
Attention
Following procedure can be used for lighting up a cold-state kiln
• Restrict the air nozzle area to minimum according to the values given in the table
on kiln burner arrangement drawing. Keep this air nozzle position for approximate 10
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minutes until the oil burner is heated up. If needed for flame stabilization, adjust the air
nozzle area towards maximum, which will in-
crease the swirl effect.
• Open swirl air valve 30°, close axial air valve (partly or complete 0-15°) and open
central duct valve completely.
Attention
Axial air valve should be closed only if the kiln is completely cooled down, and must be
opened as soon as the flame is stable and before the kiln starts to warm up 
• Start the primary air fan and adjust the primary air pressure to approximately 20%
under rated maximum pressure for the primary air fan. Adjust the air nozzle pressure with
the swirl air valve to approximate 20 mbar if air nozzle area is at maximum, and
approximate 50 mbar if air nozzle area is at minimum.
• Shut-off the coal conveying air.
Attention
Coal conveying air shall only be shut-off, if the kiln is completely cooled down, and must
be turned on after app. 1 hour of heating up 
• Start the ignition gas burner – See separate Instruction manual - or use an
alternative approach to generate an open flame in front of the burner tip.
• Start the oil or gas burner. See separate instruction manual.
• Turn on the coal conveying air or coal channel cooling air after 1-2 hours of
heating up.
• If the flame extends upwards towards the ceiling, primary airflow must be
increased. However, an excessive increase of the primary airflow must be avoided since
this will disturb the stability of the flame.
• After the flame has stabilized, the ignition gas burner can be extinguished. At the
same time, the ignition gas burner should be slightly retracted to protect its nozzle from
dust and heat.
• As the temperature in the kiln increases, primary air flow can also be increased
gradually in combination with increased fuel flow. The air flow however must always be
high enough to prevent flame impingement against the lining. Axial air valve must now
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opened to at least 45°. The opening of swirl air valve can simultaneously be reduced if
necessary. The optimum setting must be determined on a trial-and-error basis.
• When the kiln lining is hot, coal firing can be started. Gradually as the coal flame
is stabilized, i.e. with a lining temperature around 800°C, the oil or gas burner can be
stopped.
• The above mentioned settings are to be regarded as suggestions only. They may be
changed according to actual experiences.
5.4 Operation
Adjust the flame shape when the kiln burning zone is hot enough to support the flame.
The flame should then be made longer to give a more uniform thermal load on the lining.
Use the following default settings at first start
Radial/Swirl air valve 30°-90° open

Axial air valve 90° open, normally
Central duct valve 45-90° open
Air nozzle 30-100% open
These settings however are preliminary and should be reviewed after inspection of the
flame shape. The best settings are found by using the enclosed interface for calculating
the flame momentum, visual inspection in the kiln and monitoring the kiln shell
temperatures, which normally reflects the formation of coating, when the lining is in good
shape. The goal is to create an even distributed kiln shell temperature in the burning zone
area without getting ring formations or naked lining in the inlet and outlet of the burning
zone.
For regulation of the fuel input rates, see separate instruction manual for oil burner and/or
gas burner and coal dosage equipment.
Once the kiln is in normal operation, the flame should be monitored very closely.
Impingement of the flame against the lining must never occur since this may have a
disruptive effect on the coating, which in turn may entail a too high kiln shell temperature
and a reduced life span of the lining. If for example the flame is pointing too much
upwards and therefore will be too close to the kiln shell, the position of the Duoflex
burner should be adjusted to move the flame down towards the kiln charge. See separate
instruction for burner suspension.
Primary air momentum and swirl must be adjusted to make the flame hard and stable.
The optimum burner settings depend on the fuel. The table below can be used as a guide
line for initial adjustment.
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Fuel Swirl valve position Primary air momentum
Low volatile coal
45-90° 2500-3000 % m/s
(Petcoke, Anthracite)
Medium volatile coal 45-90° 1800-2200 % m/s
High volatile coal
0-30° 1800-2200 % m/s
(Lignite)
Fuel oil 0-30° 1500-1700 % m/s
Fuel gas 0-10° 1400-1800 % m/s
Secondary fuels 30-90° (based on fuel Up to 3000 % m/s
type)
If the secondary temperature is low (below 800-900 °C) extra swirl is needed to ensure
early ignition of the fuel.
The mentioned settings are provisional. A final setting can only be made subject to close
monitoring of the flame. Valve for axial air, should normally be kept fully open at all
time. To ensure cooling of the Duoflex burner, it should never be closed to less than 45°
during operation.
When the correct settings have been found, it is recommended to lock spindle gear unit.
This will prevent unintended movement of the spindle gear.
Attention
Even if the burner is fired with 100% oil or gas, airflow must always be drawn through
the coal duct when the kiln is hot.
For example, this can be done by deploying the conveying air rotary blower or by
establishing a bypass from the primary air fan.
If the coal duct is not cooled, this may cause the movable coal nozzle to get stuck.
Attention
If the coal duct is disconnected during operation, when firing with other fuels than coal,
then the coal slide gate valve installed upstream the coal hose must be closed.
5.5 Stop of firing
Stop the fuel supply as directed in instruction manuals for oil or gas burner and coal
dosage equipment, respectively.
The primary air fan must not be stopped until scavenging of the oil burner has been
carried out.
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Attention
If the kiln is in a hot state, the primary air fan must not be stopped until sufficient cooling
of the kiln and cooler has been ensured. If this is not possible, the emergency cooling air
must be started or the burner must be retracted from the kiln. 
5.6 Operational supervision
Calculation of primary air momentum etc. can be done with the “Operation calculation”
Microsoft excel sheet.
Get the excel sheet in http://www.myfls.com/
The spread sheet must be saved to a local desk as “operational calculations.xls” before it
can be used.
6.0 Maintenance
Placed on opposite
side
Figure 6.1 - Duoflex kiln burner maintenance (example)
01 Coal hose 12 Parallel key fastening

02 Gas/oil burner 13 Parallel key
03 Central duct 14 Lock brackets
04 Coal inlet 15 Coal pipe
05 Spindle gear 16 Radial air pipe
06 Burner assembly 17 Coal nozzle neck
07 Kiln hood closing plate 18 Air nozzle
08 Burner pipe 19 Coal nozzle
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09 Nozzle opening indicator 20 Central duct nozzle
10 Densit casting 21 Air nozzle tip
11 Centering guide
6.1 Preventive maintenance
and adjust-
Cleaning
Replacement
Status check
Lubrication
Inspection
Functional
Equipment
of spares
ments
Pos Job designation
description
test
Pipes, hoses (other than coal
Burner
00 hose), expansion joints, T D A
installation
closing plate, etc.
Burner pipe
01 Refractory and rhinos D M T
Duoflex, spindle gear,
Duoflex
03 valves, nozzle opening A A A
Burner
indicator etc.
06 Coal inlet Wear casting A T
Hose incl. couplings and
09 Coal hose T T
gaskets
07 Central duct Wear casting, vanes and
incl. nozzle deformations A T
14
Air nozzle
16
Air nozzle Refractory, steel parts A T
21
tip
18 Coal pipe
Wear, deformations A T
15 incl. nozzle
Explanation D: Every 8 hours of operation A: Annually

S: Weekly T: See explanation in text
below
M: Monthly Ts: See separate manual
A preceding number to a letter in the table indicates the frequency of the activity in
question. (Example: 2M means twice a month)
6.1.1 Lubrication
It will not be necessary with regular lubrication for the Duoflex burner itself. Other
equipment like for example the burner trolley and primary air fan must be lubricated
regularly, see separate instructions.
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Cleaning
Burner installation
General cleaning on and around the equipment. For extent and requirements, see separate
safety instructions for coal firing.
Burner pipe
Remove deposits from the burner pipe if/when required.
6.1.3 Inspection and adjustment
Burner
When the kiln is under shut down, check that the primary air gap is uniform. If air gap
isn’t uniform, check if the nozzles still are circular and/or check that the parallel key is
properly attached by tightening the fastening screws. If nozzles aren’t circular anymore
try to compensate for this by rotating the burner pipe in steps. Replace nozzles if needed.
Check that the Duoflex burner is correctly positioned in the kiln.
Attention
Make sure that all manual fuel isolation valves are closed and pad locked before any fuel
supply connections are taken apart 
6.1.4 Status check
Burner installation
Check that all hoses and expansion joints are intact and in good condition. Check the
tightness of the closing plate at the door.
Coal hose
Check for any leaks on a regular daily basis. Check for wear in connection with every
kiln shutdown. It is recommended to rotate the hose 180° around its centre axis at each
kiln stop, in order to distribute the wear over the entire internal surface and thereby
increase the life time of the hose.
Burner pipe
Make a visual check to determine if the ceramic coating has sustained damage.
Radial air pipe

If the ceramic coating of the burner pipe has been severe damaged or after a longer power
cut without cooling, then the condition of the radial air pipe must be checked.
Coal pipe
Check for wear in the section closest to the coal inlet and close to vanes in the coal
channel. The only way to this check properly is to remove the entire central duct. The
internal protection pipes can be kept in the central duct when this is pulled out. It is
recommended to make this check at each longer kiln stop, or minimum once a year.
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8 inlet
and
central duct
Check the Densit lining for wear via the inspection hole on the coal inlet. The Densit
surface will be rough after a few months of operation, which is normal and therefore not a
sign of wear problems. If the Densit surface has big holes and cracks it will be necessary
to renew the Densit at first given opportunity. See separate instruction for Densit
installation. Condition of vanes in coal channel must also be checked and this requires
that the central duct is removed (see also coal pipe status check).
Air nozzle & Air nozzle tip

In connection with reconditioning of the burner pipe, check the condition of the casting
around the air nozzle and air nozzle tip. Also check whether the nozzle is affected by
deformations, corrosion and/or cracks. Check that the air nozzle and coal nozzle is
concentric. The gap must be measured at 4 opposite points, and the result when dividing
two cross measures are recommended to be kept within a ratio of 0.8 to 1.25. If this is not
the case, adjust the air gap as described in section 6.1.7.
Coal nozzle
Check whether the nozzle is affected by deformations or wear. Especially the vanes can
be worn.
Central duct nozzle

Check whether the nozzle is affected by deformations, wear, corrosion and/or cracks.
Nozzle opening indicator

Check the function of the nozzle opening indicator by pulling the pointer block
backwards with app. 25 kg force. When released the pointer block shall be able to slide
back to its origin.
Spindle gear
Check that spindle gear can be operated easily after releasing the brake, and that coal
nozzle can be adjusted to achieve minimum and maximum positions of the machined
conical surface on the inside of the air nozzle tip. In addition, the coal nozzle must be able
to reach a position of 40 mm beyond the face of the air nozzle tip in cold condition, to be
able to compensate for the burner pipe expansion during operation.
6.1.5 Replacement of spares
Burner installation
Replace the insulation cord for the closing plate in case of damages. Replace hoses and
expansion joints in case of damages and/or leakage.
Coal hose
Replace the coal hose in case of wear and/or leakage.
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Burner pipe
If the visual inspection reveals damage involving a partial exposure of the steel surface,
immediate replacement of the burner pipe is recommended. It is recommended to replace
the burner pipe in connection with the annual shut down for maintenance. A complete
spare burner pipe unit consisting of burner pipe with air nozzle assembly and air nozzle
tip, including refractory, must always be held available at the plant. For replacement of
burner pipe, see section 6.1.6.
Radial air pipe

If the visual inspection reveals deformations, then replace either a section of the radial air
pipe or the entire pipe if necessary.
Coal pipe
If the visual inspection reveals excessive wear, then replace either a section of the coal
pipe or the entire pipe if necessary.
Coal inlet and central duct

Densit lining to be replaced when deemed necessary. Vanes in coal channel to be
replaced if necessary.
Air nozzle
When reconditioning the burner pipe, the nozzle unit must be replaced if damaged. A
spare unit should always be held available. The spare unit is available in excess length in
order to avoid coinciding welds. Since the mounting of a new nozzle unit have direct
influence on the obtained air gap uniformity, it is important that this is carried out
according to following instruction
Attention
A digital spirit leveller with a minimum accuracy of 0.05° in vertical and horizontal
position must be used for assembly.
Figure 6.2 - Duoflex burner pipe (example)
01 Burner pipe 16 Air nozzle

01A Burner pipe flange 16A Air nozzle front tip
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8 trip
off
the refractory in a suitable length for nozzle replacement or if necessary due to refractory
condition remove it all. Place the burner pipe horizontal so that gasket surface of flange is
90° within +0.05°. Make sure that the burner pipe is even supported to avoid excessive
bending. Placing the digital spirit leveller in 0° and 90° normally improves instrument
accuracy.
• Note the position of the guide vanes inside the swirler casing with reference to the
burner pipe flange, since the new nozzle must be mounted in exactly the same position.
Cut off the old air nozzle with reference to the total burner pipe length. Burner pipe
length must be nominal length ±2 mm, see Duoflex assembly drawing. Note that the total
length will shrink approximate 2mm after finishing the circumferential weld.
• Ensure that the position of the new air nozzle is identical with the old air nozzle.
Tack weld air nozzle to burner pipe in top and bottom within circumferential tolerances
according to Figure 6.2. When the angle for both the machined gasket surface and the
machined nozzle front of the air nozzle is 90° within ±0.05°, then tack weld with full
penetration and approximate 10mm length. Rotate the burner pipe 90° around its centre
axis and tack weld with full penetration and approximate 30mm weld length, when both
flange and nozzle front is parallel within ±0.05°. Increase the first welds (top and bottom)
to 30 mm length and repeat process until a minimum of 8-12 tacks are placed depending
on burner pipe diameter. Always add tack weldings in a cross pattern, see Figure 6.3.
Figure 6.3 - Illustration for welding sequence
• After tack welding, check that gasket surface and air nozzle front tip is parallel
within +0.05° using the digital spirit leveller. Adjust if necessary.
• Finish the TIG root runs according to detail drawing in cross patterns between 1-6,
2-5, 3-8, 4-7 etc. according to Figure 6.3. Use the same procedure when finishing the
weld.
• After finishing the weld, check that gasket surface and air nozzle front is parallel
within +0.05° using a digital spirit leveller. Adjust if necessary by heat treatment. When
only
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8 side
of the
burner pipe is heating up, this side will expand when heated up and then shrink even more
when cooling down.
• Weld on anchor irons and cast new refractory according to separate instruction.
Air Nozzle tip
When reconditioning the burner pipe, the air nozzle tip must be replaced if damaged.
Figure 6.4 - Duoflex air nozzle replaceable tip
1 Hexagon lock nut 03 Air nozzle front tip

2 Hexagon nut
Attention
A spare tip should always be held available. Since the mounting of a new tip have direct
according to following instruction 
• Dismantle the burner pipe by following the procedure in section 6.1.6 or fully open
the air nozzle by following the procedure in section 6.1.7 so the accessibility needed for
adjustment is assured.
• Grind off the weldings which are fixing the air nozzle tip in place.
• Loosen the nuts in the tip and dismantle it completely.
Attention
Do not use the torque spanner, delivered with the burner, for loosening the fasteners in
the tip 
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eep
ready the spare tip which should have been pre casted already according to FLS
recommendations.
• Apply heat resistant grease on the threaded pins of the replaceable tip.
• Insert the packing cord in the groove in the burner pipe tip flange.
• Reassemble the nozzle tip and apply nuts on the pins to secure the nozzle tip on
the burner pipe.
• Adjust and secure air nozzle position according to section 6.1.7.
Attention
Follow instructions in section 6.1.7 to ensure correct adjustment of the air nozzle tip 
Attention
The air nozzle gap can only be checked and adjusted with the burner fully assembled,
hence the adjustment according to section 6.1.7 should be carried out after mounting of
the burner pipe with the burner 
Coal Nozzle
Coal Nozzle must be replaced if damaged. A spare unit should always be held available.
Figure 6.5 - Coal pipe/coal nozzle (example)

15 Coal nozzle 18 Coal pipe
17 Coal nozzle neck 20 Lock brackets
Installation of new Coal nozzle
• Dismantle the burner pipe and move the coal pipe forward with the spindle gear on
the Duoflex until the lock brackets are accessible.
• If the brackets cannot be as described above, remove the Central duct and coal
inlet
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8 the
Duoflex assembly and finally pull out the coal pipe.
• Dismantle the old coal nozzle by cutting of the four lock brackets.
• Be careful not to damage the pins when cutting of the lock brackets.
• Slide the new coal nozzle on the coal nozzle neck. Note that the coal nozzle can
only be mounted in one position. Install new lock brackets in the groove on the coal
nozzle and weld according to the assembly drawing.
Coal pipe and Coal nozzle neck

Coal Nozzle neck shall normally not be replaced but must be replaced if damaged. A
spare unit should always be held available. The spare unit is available in excess length in
order to avoid coinciding welds. Since the mounting of a new nozzle unit have direct
according to following instruction:
• A digital spirit leveller with a minimum accuracy of ±0.05° in vertical and

horizontal position must be used for assembly.
• Dismantle the coal pipe and place it horizontal. Make sure that the coal pipe is
even supported to avoid excessive bending. Placing the digital spirit leveller in 0° and 90°
normally improves instrument accuracy.
Figure 6.6 - Coal pipe/coal nozzle neck (example)
17 Coal nozzle neck 18 Coal pipe
• Note the position of the parallel keys on the coal nozzle outside with reference to
the two fins on the outside of the coal pipe. Cut of the old coal nozzle neck with reference
to the spare nozzle length. Coal pipe length must be nominal length ±2mm.
• Ensure that the position of the new coal nozzle neck is identical with the old coal
nozzle neck. Tack weld coal nozzle neck to coal pipe in top and bottom, making sure that
the cylindrical surface of the coal nozzle and coal pipe is parallel within ±0.05°. Tack
weld with full penetration and approximate 10mm length. Rotate the coal pipe 90° around
its centre axis and tack weld with full penetration and approximate 30mm weld length
when nozzle and pipe surface is parallel within +0.05°. Increase the first welds (top and
bottom) to 30 mm length and repeat process until a minimum of 4-8 tacks are placed
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8
depending on coal pipe diameter. Always add tack weldings in a cross pattern, see Figure
6.3.
• After tack welding, check that nozzle and pipe surface is parallel within +0.05°.
Adjust if necessary.
• Finish the TIG root runs according to detail drawing in cross patterns between 1-6,
2-5, 3-8, 4-7 etc. according to Figure 6.3. Use the same procedure when finishing the
weld.
• Install coal nozzle (see replacement of coal nozzle).
Central duct nozzle

Central duct nozzle must be replaced if damaged. A spare unit should always be held
available.
6.1.6 Replacement of burner pipe
If the burner pipe needs to be replaced use following procedure:
Figure 6.7 - Replacement of burner pipe (example)

01 Burner pipe 08 Parallel key
02 Burner Carriage 09 Holes - Burner pipe flange
03 Support pipe 10 Pin - Support pipe flange
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04 Burner trolley 11 Nozzle opening indicator
05 Coal nozzle 12 Spindle gear
06 Radial air pipe 13 Fine thread bolt - burner pipe flange

07 Nozzle guide
Dismantling
• Retract the burner trolley to exact position where the burner tip is just clear of the
kiln doors
• Move a carriage to position under the burner pipe and then lower the burner pipe
to horizontal position by using the burner trolley adjustment facilities. If necessary insert
wooden blocks or similar means until the pipe is resting on the carriage
• Dismantle the flanged joint between support pipe and burner pipe
• Establish a gap between the flanges by tightening the fine threaded bolts
• Retain the burner pipe in its present position, while simultaneously the burner
trolley is moved backwards. As a result, the burner pipe will be released from the radial
air pipe. Check that a straight pull is being exerted. Stop the carriage when the tip of the
coal nozzle is clear of the burner pipe flange.
Attention
Insure a minimum of 45mm contact between trolley wheels and rail prior to dismantling
of burner pipe 
• Remove the old burner pipe
Mounting
• Fit the overhauled/lined burner pipe on a carriage and place it in front of the burner
and fix it in this position. Make sure that one of the two holes in the burner pipe flange is
positioned in line with the two pins provided on the support pipe flange. If the burner pipe
has got a permanent deflection it can be recommended to rotate the burner pipe 180° with
reference to its previous position, to compensate for the banana shape. By excessive
deflection it is recommended to renew the burner pipe.
• Before the burner pipe is mounted on the Duoflex burner, make sure that the
nozzle opening indicator is functioning by pulling the pointer block backwards with app.
25 kg force. When released the pointer block shall be able to slide back to its original
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position. If this isn’t possible check that the end of the steel rod hasn’t been bend or that
the protection pipe for the nozzle opening indicator rod has been damaged. When
function is accepted, add a small amount of grease on the end of the indicator rod. This
will prevent bending of the indicator rod during the final adjustments of the burner pipe.
Also check that the parallel keys mounted on the coal nozzle is properly attached. Both
the parallel key and the nozzle guide must be greased with heat resistant (high
temperature) grease prior to assembly.
• Move the burner trolley forward while making sure that the inner pipes slides into
the burner pipe without touching the nozzle opening indicator.
Attention
Remember to apply the burner pipe gasket to the flange on the supporting pipe 
• Check once again that one of the two holes on the burner pipe flange is in line with the
pin on the support pipe flange. Note that the pin prevents damaging of the nozzle opening
indicator and air nozzle centring arrangement. Continue forward and make sure that the
radial air nozzle slides into the swirler, see Figure 6.11. When flanges are joined fit the
nuts and bolts and tighten them in a cross pattern. Finally pull the pointer block for the
nozzle opening indicator backwards and release it again to make sure that no radial
tension is added to the end of the indicator rod.
Attention
Check that spindle gear can be operated easily after releasing of brake, and that coal
conical surface on the inside of the air nozzle tip. In addition, the coal nozzle must be able
to reach a position of 30-40 mm beyond the face of the air nozzle tip to compensate for
the burner pipe expansion during operation. 
6.1.7 Burner nozzle concentricity check and adjustment
Attention
Check that the air nozzle and coal nozzle is concentric. The gap must be measured at 4
diagonal points, see Figure 6.7, and the result when dividing two cross measures are
recommended to be kept between a ratio of 0,8 and 1,25. For example if the air gap in
position 9 o’clock is 4 mm and in position 3 o’clock is 5 mm, then the result will be
4/5=0.8 or 5/4=1.25 which is just within the ratio. It is acceptable to check the cross
measure in the normal operation position of the coal nozzle, since the offset of the coal
nozzle normally always is constant. 
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8
Figure 6.8 - Concentricity measurement
This means that if the example from before was measured at minimum nozzle area where
the coal nozzle front is flush with the air nozzle front, then the cross measure at the
normal operation position could be for example 6 mm at 9 o’clock and 7 mm at 3
o’clock. When checking the result of 6/7=0.86 or 7/6=1.17 it can be seen that the constant
offset gets less influence on the air gap uniformity.
Adjustment of the air nozzle gap
1 Hexagon lock nut 03 Air nozzle front tip

2 Hexagon nut
If the air gap is not within the range, the air nozzle tip can be adjusted to obtain uniform
air gap. Use following procedure for adjustment:
• Remove bolts as shown below in expansion joints between expansion joint and coal
inlet.
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Fastening joint for the expansion Fastening joint for the nozzle
01 02
joint movement indicator
Attention
These Bolts must be removed otherwise the expansion joint will get permanent
deformations 
• Remove nozzle movement indicator by unfasten the bolt as shown above.
Attention
If the indicator is not removed it will obtain damage when performing full adjustment 
• Retract air nozzle to fully open position to gain access to the fasteners and
weldings in the ait nozzle tip.
• Grind off the weldings which are fixing the air nozzle tip in place.
• Loosen the fasteners enough to move the air nozzle tip.
Attention
Do not use the torque spanner for loosening the fasteners 
• Adjust the air nozzle tip to correct position.
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8 ighten
the
fasteners with the torque spanner according to the table below.
Attention
Tighten the nuts in a cross pattern in 3 steps with the torques shown below 
Nut size [mm] Final torque [Nm] Steps [Nm]

16 100 35-70-100
• Recheck the position of air nozzle tip and adjust again if needed.
• Tack weld air nozzle tip as on Duoflex assembly drawing.
• Apply 2nd nuts on fasteners and tighten with the torque spanner according to the
table below.
Nut size [mm] Final torque [Nm]

16 60
6.1.8 Duoflex burner disassembly and assembly
Disassembly
Figure 6.10 - Duoflex burner explode view (example)
01 Air nozzle/burner tip 07 Coal pipe

02 Burner pipe 08 Duct suspension
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03 Support pipe 09 Spindle gear
04 Nozzle opening indicator 10 Coal inlet
05 Radial air pipe 11 Central duct

06 Steel expansion joint 12 Protection pipes
If the burner needs a big overhaul and inspection, which is recommended to do at least
once a year (during maintenance stop), it will be necessary to dismantle the burner.
Following procedure can be used, and can be carried out with the burner mounted in the
trolley or lowered to the floor.
Attention
Insure a minimum of 45mm contact between trolley wheels and rail prior to dismantling
of burner pipe.
If the burner is lowered to the floor, the burner must be completely supported at all phases
of the replacement to prevent the burner from overturning. 
• After dismantling the hoses for primary air, coal transport and cooling of central
duct, oil and/or gas burners, then pull the protection pipes out of the central duct
• Pull the central duct out of the coal inlet and coal pipe.
• Dismantle the spindle gear.
• Support the coal inlet and loosen the steel expansion joint and duct suspension.
Then lower the coal inlet down and remove the steel expansion joint. Handle the coal
inlet gently in order to avoid damaging of the wear casting.
• Pull out the coal pipe from the radial air pipe.
• Pull out the radial air pipe from the support pipe and burner pipe.
• Dismantle the burner pipe and lower it down on a carriage.
Assembly of Duoflex burner

Before assembling the burner it is important that all wear parts are checked carefully
according to chapter 6.1.4.
• Assemble burner pipe to support pipe assembly.
• Insert radial air pipe in correct position into above subassembly. During mounting
of the radial air pipe, care must be taken not to damage the nozzle opening indicator
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mounted to the radial air pipe. Add a small amount of grease on the end of the indicator
rod. This will prevent bending of the indicator rod during the final adjustments of the
radial air pipe. When mounted correct, the nozzle opening indicator will be pushed
backwards from the tip, by the brackets welded to the air nozzle. The spring mounted in
the device will force the rod to follow the thermal expansion of the burner pipe during
operation. Note that it will only be possible to rotate the radial air pipe ±15° just when the
radial air pipe has been inserted 10-15 mm into the swirler. When further inserted it will
only be possible to rotate the radial air pipe ±1° without any risk of damaging the nozzle
opening indicator. This means that flange bolt holes must be lined up quite accurate just
when the radial air pipe has been inserted 10-15 mm into the swirler.
• Mount steel expansion joint.
• Insert coal pipe into above assembly. Make sure that the parallel key fits into the
nozzle guide and that both parts have been greased with heat resistant grease.
• Mount duct suspension assembly.
• Install the coal inlet and attach duct suspension. Before tightening the connection
between the coal inlet and the steel expansion joint, make sure that the wear casting inner
diameter of coal inlet is flush with the coal pipe inner diameter. If not, adjust it by
pushing the coal pipe flange in-between the coal inlet flange and steel expansion joint
flange. Visually inspect the refractory work for the wear resistant casting in the coal inlet
for damages.
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Figure 6.11 - Burner tip assembly (example)
01 Air nozzle/burner tip 09 Spindle gear

02 Burner pipe 10 Coal inlet
03 Support pipe assembly 11 Central duct
04 Nozzle opening indicator 12 Protection pipes
05 Radial air pipe 13 Nozzle guide
06 Steel expansion joint 14 Parallel key
07 Coal pipe 15 Coal nozzle
08 Duct suspension
• Mount the central duct and protection pipe unit and wear inlet if any. Mount
spindle gear unit according to assembly drawing. Mount scales for nozzle opening
indicator etc. Pointer to be pointing at 0 mm on both scales, when coal nozzle is flush
with air nozzle.
• The burner should now adhere to assembly drawing, see Figure 6.11
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8 heck
that
all nozzles are flush up to +2mm, when steel expansion joint length is as indicated on
assembly drawing ±10 mm.
Attention
Check that spindle gear can be operated easily after releasing of brake, and that coal
conical surface on the inside of the air nozzle. In addition, the coal nozzle must be able to
reach a position of 30-40 mm beyond the face of the air nozzle to be able to compensate
for the burner pipe expansion during operation. 
Attention
Check that the air nozzle and coal nozzle is concentric according to section 6.1.7. 
6.1.9 Functional test
Figure 6.12 - Duoflex functionally test (example)

01 Axial air valve 04 Spindle gear
02 Cooling air valve 05 Trolley & oil/gas burner adjustment
03 Radial air valve
Burner installation
Move all adjustment devices to eliminate the risk of their movement being restricted at
any location. For oil/gas burner and trolley, see separate instructions.
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8 6.2
Trouble shooting
6.2.1 Fault localization
Remedy pos,
Observation Possible fault See section 0
for solution
Large, smooth flame extending
Momentum of primary air too
across the entire crosssectional 1
low
area of kiln
Hard, very bright flame 2
high
Very short flame plume, 2
high
resulting in overheated burner
Swirling of primary air too
tip 3
high
Defective oil nozzle 4
Unstable flame with long
plume 1
low
Defective oil nozzle 4
Defective gas nozzle 5
Skew flame Clogging of coal duct 6
Dust deposits on burner pipe 7
Unsymmetrical coal nozzle 8
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8 6.2.2
Reconditioning
Pos. Fault Possible cause Remedy

Incorrect adjustment Adjust, see section 5.1
Defective burner Install replacement unit
pipe
Incorrect connection Install replacement unit
1 Momentum too low
of primary air
Malfunction of fan See instruction manual
Blocked primary air Remove obstruction
fan inlet
2 Momentum too high Incorrect adjustment Adjust, see section 5.1
Adjust swirl air damper, see
3 Excessive swirl Incorrect adjustment
section 5.1
Retract burner and clean it.
Malfunction of oil
4 Oil nozzle defective See separate instruction
burner set
manual
Retract burner and clean it.
5 Gas nozzle defective Clogging of gas holes See separate instruction
manual
Clogging of coal Penetration of oil into Retract burner and clean it
6
duct coal duct.
Remove deposits on regular
basis.
Deposits on burner Excessive swirl or
7 If necessary, reduce swirl or
pipe momentum
momentum,
See sub section 5.1
Unsymmetrical coal Wear of coal nozzle or Replace if necessary, see sub
8
nozzle fins. section 6.1

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What are the main components of the Duoflex burner?

What are the main components of the Duoflex burner?

What safety precautions should be taken when operating the burner?

What safety precautions should be taken when operating the burner?

Duoflex kiln burner

Installation, operation and maintenance instructions

The content in this instruction refers to the following instructions manuals

Figure 1.1 – Duoflex Burner tip configuration Duoflex assembly

1 Primary air channel 03 Oil lance and Igniter lance channel

Burner type Duoflex DBC-244.5-75011

Figure 2.1 - Typical Arrangement of Duoflex Kiln Burner System (example)

02 Closing plate assembly 14 Butterfly valve for emergency cooling

Figure 2.2 – Typical Duoflex Kiln Burner Assembly

1 Air nozzle 05 Spindle gear unit

2.3 Burner tip

Figure 2.3 – Duoflex Burner nozzle tip (example)

01 Coal nozzle 12 Rod for detection of expansion

Figure 2.4 – Duoflex Burner rear end (example)

Figure 5.1 – Flame shape Figure

Lp = Primary air, percentage of theoretical combustion air requirement [%] C = Primary

5.2 Pre-operational check

• The position of the Duoflex burner in the kiln.

• That all flexible connections are intact and properly connected.

• External interlocking fulfilled, for details, see electrical documentation.

Figure 5.2 – Duoflex burner assembly (example)

• Shut-off the coal conveying air.

• Start the oil or gas burner. See separate instruction manual.

Radial/Swirl air valve 30°-90° open

Get the excel sheet in http://www.myfls.com/

Figure 6.1 - Duoflex kiln burner maintenance (example)

01 Coal hose 12 Parallel key fastening

6.1 Preventive maintenance

Explanation D: Every 8 hours of operation A: Annually

Check that the Duoflex burner is correctly positioned in the kiln.

Radial air pipe

Air nozzle & Air nozzle tip

Central duct nozzle

Nozzle opening indicator

Radial air pipe

Coal inlet and central duct

Figure 6.2 - Duoflex burner pipe (example)

01 Burner pipe 16 Air nozzle

Figure 6.3 - Illustration for welding sequence

Figure 6.4 - Duoflex air nozzle replaceable tip

1 Hexagon lock nut 03 Air nozzle front tip

• Loosen the nuts in the tip and dismantle it completely.

• Adjust and secure air nozzle position according to section 6.1.7.

Figure 6.5 - Coal pipe/coal nozzle (example)

Installation of new Coal nozzle

Coal pipe and Coal nozzle neck

• A digital spirit leveller with a minimum accuracy of ±0.05° in vertical and

Figure 6.6 - Coal pipe/coal nozzle neck (example)

17 Coal nozzle neck 18 Coal pipe

• Install coal nozzle (see replacement of coal nozzle).

Central duct nozzle

If the burner pipe needs to be replaced use following procedure:

Figure 6.7 - Replacement of burner pipe (example)

06 Radial air pipe 13 Fine thread bolt - burner pipe flange