26 | Plant & Works Engineering>> www.pwemag.co.uk October/November 2026 Energy & Environmental Management Focus on: Boilers, Burners & Controls carrying out a dry run before introducing gas into the ignition sequence. This enables engineers to verify the safe operation of the burner controls and gas valve before combustion begins. The standard mode of operation for modern commercial burners is now fully modulating, making accurate commissioning across the entire operating range essential. Whether commissioning fully modulating or multi-stage burners, every operating point must be correctly configured to achieve the required combustion performance and emissions levels. If commissioning is rushed or key adjustments are overlooked, the consequences can extend well beyond poor efficiency. Incorrect heat input can reduce system performance, increase nuisance lockouts and, in some cases, place unnecessary stress on ancillary equipment or the appliance itself. Small errors can have significant consequences Many commissioning issues originate from relatively simple assumptions. For gas burners, one of the most common mistakes is incorrectly setting the appliance heat input due to an inaccurate gas rate. A frequent misconception is that range-rated gas valves are supplied pre-set from the factory. In reality, they require adjustment during commissioning, and failing to do so can result in burner outputs above or below the appliance’s design requirements. Oil-fired applications present similar challenges. Engineers may assume that a burner supplied with an installed nozzle is already correctly configured for the appliance. However, while Riello’s OEM residential burners are supplied with application-specific nozzles following match testing, commercial R40 G burners are supplied with a standard production-test nozzle. Because these burners are range-rated, engineers must calculate and install the correct nozzle size and type to achieve the required heat input. These may appear to be relatively small details, but incorrect heat input can affect efficiency, emissions performance and longterm reliability. Good diagnostics reduce downtime Effective fault diagnosis is another area where technical competence can make a significant difference. One of the most common burner faults encountered in the field is a failure to ignite during start-up. In many cases this can be traced to incorrectly positioned ignition electrodes, issues with the ionisation probe or incorrect gas valve settings. Rather than replacing components through trial and error, a structured diagnostic approach enables engineers to identify the true cause of a fault quickly and efficiently. This can have significant operational benefits. In commercial buildings, prolonged downtime may leave occupants without heating or hot water. In industrial environments, however, the financial implications can be far greater, with production delays, contractual penalties and lost revenue becoming significant considerations. Barker recalls one particular example involving a 24-hour medical waste incinerator where the primary burner failed unexpectedly. By asking a series of structured diagnostic questions over the telephone, it was quickly established that the UV flame sensor had failed. As the site held 1st line critical spares , the inhouse engineering team was able to replace the sensor immediately and restore operation with minimal interruption. The rapid diagnosis prevented a potentially costly build-up of unprocessed waste and avoided extended downtime for a critical process. The example demonstrates that technical knowledge is not simply about solving faults, it is about solving them quickly and correctly. Learning through practical experience Developing these skills requires more than classroom learning alone. Effective technical training combines theoretical understanding with practical experience, allowing engineers to apply commissioning procedures, burner adjustments and fault-finding techniques in realistic situations before encountering them on customer sites. Training covering burner selection, heat input calculations, combustion set-up, servicing and diagnostics helps engineers develop confidence while ensuring systems continue to operate safely and efficiently throughout their working life. Preparing for the future The pace of technological change within commercial and industrial heating shows no signs of slowing. Alternative fuels, increasingly sophisticated combustion controls, tighter emissions legislation and greater integration with building management systems are all changing the knowledge required of today’s engineers. Keeping pace with these developments will require continuous professional development throughout an engineer’s career. The technology will continue to evolve. Ongoing training ensures engineers remain up to date with new burner systems, changing regulations and the latest commissioning techniques, allowing them to deliver the safe, efficient and reliable performance that customers increasingly expect. As heating systems become more intelligent and more connected, specialist technical knowledge is becoming just as important as the equipment itself. For today’s engineers, investing in training is no longer simply about expanding knowledge, it is about ensuring the next generation of commercial and industrial heating systems performs as intended from the day it is commissioned. For further information please visit: https://www.rielloburners.co.uk/
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