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Gas Train

A gas train assembly is the equipment that is set up before a boiler/furnace, which feeds fuel in to a burner. The main function of a gas train is to Safely purify, reduce and regulate pressure of the incoming gas in accordance with the burner specifications. It also provide isolation or interruption of Gas Supply in case of any unexpected operating condition or parameter limit is reached. It is an essential part of Gas Burner Safety.

Gas Train Components:

Gas train assembly mainly consists of a series of components, each having their own unique purpose. The components and their purpose are governed by Safety Standards like NFPA-86 and EN 746-2.

Gas Train Design

  • Ball Valve
  • Pressure Gauge
  • Push To Test Valve
  • Gas Filter
  • Slam Shut Off Valve
  • Gas Pressure Regulator
  • Relief Valve
  • Pressure Switch
  • First Safety Solenoid Valve
  • Second Safety Solenoid Valve
  • Vent Valve
  • Base Frame
  • Junction Box

  • Ball Valve

The first of these components is the ball valve. These are 90 degree rotation type valves which are most usually used for the purpose of isolating or shutting off the Gas Supply. These are purely mechanical and manually operated devices.


  • Pressure Gauge

A pressure gauge is mounted right after the ball valve. Its sole purpose is to measure and display the incoming pressure of working fluid or gas in Gas Train.


  • Push To Test Valve

Push to test valve is attached to the pressure gauge. It is a 3-way type valve. When the push button is pressed, the working gas flows through the PTT valve, to the pressure gauge where the fuels pressure can be measured. On releasing the Button, the Gauge is isolated from the line pressure and the gas inside the Gauge is released into the atmosphere.


  • Gas Filter

Next comes the gas filter which removes solid sediments and impurities from a gas. The gas is made to pass through a filtering element that physically collects these particles leaving a cleaner gas. If gas contains liquid impurities too, a suitable separation system like Liquid Trap should be additionally incorporated in the Gas Train.


  • Slam Shut Off Valve

Immediately after the filter and before the Regulator, a slam shut off valve is installed as an safety measure in case of abnormal operation of Pressure Regulator or its failure. Thereby protects the pressure components and other equipment from being subjected to pressures that exceed their operating limits. It normally remains in an open condition. In case there occurs a sudden increase in the outlet pressure of the regulator (beyond the permissible limit, set in the Slam valve), the slam shut-off valve senses it through the impulse line & immediately shut off the flow to downstream.


  • Gas Pressure Regulator

Gas pressure regulators reduce high-pressure gas in a gas line to a lower, usable level as it passes to another piece of equipment. Gas pressure regulator is used to control delivery pressure only. A good Pressure Regulator should be able to deliver a fairly stable outlet pressure in spite changes in Inlet Pressure and Flow. This particular component is the heart of Gas Train assembly.


  • Relief Valve

A relief valve acts as an added safety measure in the gas train assembly. The relief valve is designed, placed and set to open at a predetermined set pressure, slightly higher than the Regulator set pressure. Sudden changes in flow and sudden operation of Solenoid Valves at the downstream of Regulator causes small pressure jumps in the Regulator outlet pressure. The Relief Valve releases this pressure buildup which is beyond. This also avoids the nuisance tripping of Slam Valve due to pressure jumps.


  • Pressure Switch

A pressure switch is a device placed right after the Gas Pressure Regulator. It is a SPDT switch with COM, NO & NC Contacts. When fluid pressure crosses above the set point the NO & NC contacts change positions. Due to SPDT Contacts these pressure switches can be used as both high and low pressure switches.


  • First Safety Solenoid Valve

An electronically operated solenoid valve is usually used for flow control applications where it is necessary to start or stop the flow in the circuit to control the fluids in the system. They are strategically positioned in remote locations and may be conveniently controlled by simple electrical switches or Programmable Logic Controllers. Their main function is to shut off and/or release gas in the system. Solenoids offer fast and safe switching, long service life, high reliability, low control power and compact design which are crucial in any gas-fired system.


  • Second Safety Solenoid Valve

Second safety solenoid valve is an added safety measure. The basic function is to shut off and/or release gas in the system. In case the First Solenoid Valve underperforms i.e. leaks internally, the second valve ensures that the Gas supply is shut off. It is usually a Slow Open Fast Close action valve. The Slow opening function is helps for smooth burner firing, in case of Single burner applications and in case of bigger size Gas Trains it avoids the actuation of Low Pressure Switch when valve is opened.


  • Vent Valve

Vent valve is strategically positioned in between the two safety solenoid valves. It is a normally open valve. Its sole purpose is to release gas to atmosphere in case both First and Second Valve are not performing, thereby avoiding accumulation of Gas in Combustion Chamber.


  • Base Frame

Structural Bases frames are specially designed and engineered to support gas train apparatus. They provide rigid platforms for attachment of vibration isolators, without allowing excessive differential movement between driving and driven members. The bases provide a means by which the equipment can be stabilized and motion reduced by lowering the equipment center of gravity.


  • Junction Box

A junction box is an enclosure that protects a connection (the junction) of two or more wires carrying electrical current. The use of junctions removes the need to run a wire from every outlet or switch back to the main service panel. This level of protection is needed to prevent fires and to maintain solid, reliable connections that stay tight over many years.

GAS TRAIN APPLICATION:

All manufacturing processes require energy, more precisely heat energy. Producing heat energy is of crucial importance in several sectors:

  • Steel and forging plants require heat to melt metals
  • A bakery/confectionery requires heat for baking/cooking
  • An automobile company requires heat for drying purpose
  • Boilers, kilns, furnaces for heat generation

Consequently, fuels are used for combustion purposes. Use of Fuel Gas is efficient but being highly explosive and inflammable, there is a lot of safety which needs to be exercised while using these gases as a fuel. This safety, regulation is exercised in the form of gas trains.

WE MAJORLY MANUFACTURE:

  • Boiler Gas Train

One of the crucial aspects of keeping a boiler safe and in the most effective operating condition is using a well-designed gas train. A boiler gas train ensures a secure and reliable function of the boiler. The Gas Trains manufactured by Innovative Automation, using MADAS Gas Safety and Regulation devices is an immensely popular combination among the OEM and end User customers.

  • Gas Train For Burner

Just like their construction, package burners demand for a more Compact Gas Train design to complete the system integration. Compact Mini Gas trains for Package Burners specially manufactured understanding this. Madas Mini Gas Train is designed exclusively for Package Burners (up to 500 kW) and made to be as easy as Plug & Play!

IAPL Manufactured Gas Trains

  • IAPL Standard Gas Train
    IAPL Standard Gas Train
  • IAPL Customised Gas Trains
    IAPL Customised Gas Train
  • Madas Gas Train
    IAPL Customised Gas Train

Enquiry to Order: A Journey

 
  • A thorough site and process study must be carried out to understand the requirement in a better way. Consequently, a well-suited, tailor-made system assembly must be proposed. Thoughtful selection engineering and designing gas train and piping diagrams in 3D environment proves very effective.
  • Gas Train Manufacturing Process
  • A well-constructed Quality Assurance Plan must be followed in order to manufacture an Industrial Standard gas train. Subsequently, the manufacturing and flow testing can be conducted, followed by installation and commissioning. Furthermore, operator training and after sales support are equally important for the smooth operation of the gas train assembly. Real time product simulation and continual development makes these Gas Trains a highly reliable solution and match dynamic demands of the industry.
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