Modernize Aging Industrial Burner Systems
Industrial burner systems are built to operate for years. However, the controls and safety components around them can become outdated over time.
Replacement parts may be harder to find. Controls can become difficult to troubleshoot. Small failures can also lead to costly downtime.
Advanced Thermal Systems provides industrial burner retrofit and upgrade services for aging combustion systems. In many cases, key components can be upgraded without replacing the entire system.
The right retrofit can improve reliability. It can also simplify maintenance and help the equipment continue to meet production demands.
When Does an Industrial Burner Need an Upgrade?
Not every older burner needs to be replaced.In many cases, the burner still performs well while other parts of the system have become outdated.
An industrial burner retrofit may be worth considering if you notice:
- Frequent burner shutdowns
- Obsolete controls
- Hard-to-find replacement parts
- Aging flame safeguard equipment
- Igniition problems
- Unreliable gas valve train components
- Poor temperature controls
- Rising fuel use
- Uneven combustion
- Ongoing maintenance issues
Industrial combustion systems rely on many parts working together. ATS supports burners, control panels, valve trains, flame safeguards, regulators, sensors, switches, and ignition components.
That allows ATS to look at the system as a whole instead of treating each part as a separate problem.
What Is an Industrial Burner Retrofit?
An industrial burner retrofit updates part of an existing combustion system while keeping the equipment that still works well.
A retrofit may involve replacing old controls. It may also include updates to the valve train, ignition system, flame safeguard, or control panel.
The goal is simple. Keep the parts that still perform well and replace the parts that no longer do.
This can be a smart option for ovens, furnaces, dryers, kilns, and other process heating equipment that is still in good condition.
Industrial Burner Upgrades ATS Can Provide
Every combustion system is different. The right upgrade depends on the burner, fuel source, operating conditions, and production needs.
ATS can help with several types of upgrades.
Burner Control Panels
Older burner controls can become difficult to maintain. Replacement components may also become unavailable.
ATS provides industrial control panel solutions for both new systems and retrofit projects. These panels can include burner controls, flame safeguards, safety interlocks, ignition systems, sensors, pressure switches, and temperature controls.
Gas Valve Trains
The gas valve train plays an important role in burner safety and performance.
ATS can help with components such as shutoff valves, regulators, actuators, pressure switches, pilot valves, and fuel train controls. Upgrading an older valve train can improve reliability and make future maintenance easier.
Flame Safeguard and Ignition Systems
Reliable ignition and flame detection are essential for safe burner operation.
Older flame safeguard systems may become harder to service. Ignition components can also wear down over time. Replacing these parts can improve reliability and make troubleshooting easier.
Burners and Combustion Components
Some projects require more than a controls upgrade.
ATS can help evaluate burners, regulators, actuators, sensors, switches, and other combustion components. From there, the team can determine whether a small upgrade or a larger retrofit makes the most sense.
Improve Combustion Efficiency with Burner Upgrades
Burner upgrades can also help improve combustion performance.
A burner with the wrong air-to-fuel ratio may use more fuel than necessary. It may also struggle to maintain steady temperatures. Updated controls and properly selected components can help improve system performance.
ATS also performs combustion analysis and burner adjustments. These services can help identify excess oxygen, carbon monoxide, unstable combustion, and other efficiency problems. For facilities trying to reduce fuel costs, checking the combustion system can be a good place to start.
Burner Retrofit vs. Complete Burner Replacement
One common question is whether an older burner should be upgraded or replaced.
A burner retrofit often makes sense when the main equipment still works well, but some controls or safety components are outdated.
A full replacement may make more sense when the burner no longer meets production needs. It may also be the better choice if the system has ongoing reliability problems.
The right answer depends on the equipment. Fuel type, burner capacity, equipment condition, production goals, and available replacement parts should all be considered. ATS can help review the application and determine the best path forward.
Industrial Burner Retrofits for Ovens, Furnaces, Dryers, and More
Industrial combustion systems are used in many types of equipment.
ATS supports applications such as:
- Industrial ovens
- Dryers
- Furnaces
- Kilns
- Heat-treat systems
- Paint and powder-coat lines
- Make-up air systems
- Thermal oxidizers
- Food=processing equipment
- Tank-heating systems
- Foundry equipment
- Asphalt plants
- Process-air systems
- Radiant-tube applications
- Immersion-tube heating systems
ATS can also provide complete combustion assemblies for retrofit projects. These may include burner assemblies, valve trains, control panels, and flame safety packages.
Reduce Downtime Before Equipment Fails
One of the biggest benefits of a planned burner upgrade is avoiding an emergency shutdown.
Older controls may continue to work for years. The problem comes when a part finally fails and a replacement is no longer available. Planning an upgrade early gives facilities more control over the process.
It also makes it easier to avoid rushed repairs during production downtime.
Preventative maintenance can help identify worn or outdated parts before they fail.
Upgrade Your Industrial Combustion System with ATS
An industrial burner retrofit does not always require a full system replacement. In many cases, upgrading the right controls or components can extend the life of existing equipment.
It can also improve reliability and make the system easier to maintain. Advanced Thermal Systems helps industrial facilities identify practical upgrade options based on their equipment and process needs.
Whether you need to replace outdated controls, upgrade a valve train, or modernize an aging burner system, ATS can help.
Contact ATS to discuss your industrial burner retrofit or combustion system upgrade.