CleaverBrooks FLX 150, FLX 250, FLX 200, FLX 400, FLX 450 Operation, Service And Parts Manual

...

Table Of Contents

$30.00 U.S.

CLEAVER-BROOKS

MODEL FLX

PACKAGED BOILER

Operation, Service, and Parts Manual

1,500,000 to

12,000,000 Btu/hr

Hot Water and

Steam

Fuel: Light Oil, Gas

or Combination

Manual Part No. 750-177 r4

6/2001

SAFETY PRECAUTIONS AND

ABBREVIATIONS

Safety Precautions

Abbreviations

Following is an explanation of the abbreviations, acronyms, and symbols used in this manual.

It is essential to read and understand the following safety precautions before attempting to operate the equipment. Failure to follow these precautions may result in damage to equipment, serious personal injury, or death. A complete understanding of this manual is required before attempting to start-up, operate or maintain the equipment. The equipment should be operated only by personnel who have a working knowledge and understanding of the equipment.

The following symbols are used throughout this manual:

WARNING

DANGER

This symbol indicates a potentially hazardous situation which, if not avoided, could result in serious personal injury, or death.

CAUTION

DANGER

This symbol indicates a potentially hazardous situation which, if not avoided, could result in damage to the equipment.

Note: This symbol indicates information that is vital to the operation of this equipment.

AC Alternating Current

AR Automatic Reset

ASME American Society of Mechanical Engineers

ASTM American Society of Testing and Materials

BHP Boiler Horsepower

BTU British Thermal Unit

°C Degrees Celsius

CFH Cubic Feet per Hour

Cu Ft Cubic Feet

DC Direct Current

°F Degrees Fahrenheit

FM Factory Mutual

FS Flame Safeguard

ft Feet

GPM Gallons per Minute

Hd Head

HT Height

HTB High Turndown Burner

HZ He rt z

O Inches of Water

In H

IRI Industrial Risk Insurance

Lb Pound

LWCO Low-Water Cut-Off

M Million

MFD Micro-Farad

MR Manual Reset

NEC National Electric Code

No. Number

pH Measure of the degree of acid or base of a

solution

P/N Part Number

PPM Parts Per Million

PR Program Relay

psi Pounds Per Square Inch

SAE Society of Automotive Engineers

scfh Standard Cubic Feet per Hour

T Tempera ture

TC Temperature Control

TI Temperature Gauge

MODEL FLX

PACKAGED BOILER

Operation, Service, and Parts Manual

1,500,000 to 12,000,000 Btu/hr

Fuel: Light Oil, Gas or Combination

 Cleaver-Brooks 2001

Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative

Manual Part No. 750-177 R4

Revised 6/2001

Printed in U.S.A.

WARNING

DANGER

DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.

FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH.

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe personal injury or death.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who are servicing, repairing or operating the equipment, in all safety aspects.

Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and maintenance procedures must be followed at all times. Although these components afford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and hazards inherent in handling and firing of fuel.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before attempting to operate, maintain, service, or repair this equipment.

Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary considerably from one boiler to another. This manual contains information designed to show how a basic burner operates.

Operating controls will normally function for long periods of time and we have found that some operators become lax in their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and deficiencies in testing and maintenance.

It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly maintenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.

Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the need for the operator to periodically check his low water controls and to follow good maintenance and testing practices. Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected frequently to check for the presence of foreign substances that would impede float ball movement.

The waterside condition of the pressure vessel is of extreme importance. Waterside surfaces should be inspected frequently to check for the presence of any mud, sludge, scale or corrosion.

The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating practices are essential.

The operation of this equipment by the owner and his or her operating personnel must comply with all requirements or regulations of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before proceeding.

TABLE OF CONTENTS

Chapter 1

Basics of Flexible Watertube Operation

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

B. The Boiler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Chapter 2

ProFire™ Burner Operation and Control

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

B. Burner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

C. Recommended Fuels and Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

D. Controls and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Chapter 3

Pressure Vessel Care

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

B. Hot Water Boilers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

C. Water Requirements (Steam Boilers). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

D. Water Treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

F. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

H. Washing Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

I. Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

I. Preparation For Extended Lay-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Chapter 4

Sequence Of Operation

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

B. Circuit And Interlock Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

C. Sequence Of Operation - Oil Or Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

D. Flame Loss Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

TABLE OF CONTENTS(continued)

Chapter 5

Starting And Operating Instructions

A. General Preparation for Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

B. Startup Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

C. Burner Adjustments, Single Fuel Natural Gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

D. Burner Adjustments, Single Fuel Oil Fired . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

E. Burner Adjustments, Combination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

F. Startup, Operating and Shutdown - All Fuels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

G. Control, Operational Tests and Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Chapter 6

Adjustment Procedures

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

B. Linkage - Modulating Motor & Air Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

C. Modulating Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

D. Modulating Motor Switches Low Fire and High Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

E. Burner Operating Controls - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

F. Modulating Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

G. Operating Limit Pressure Control (Steam). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

H. High Limit Pressure Control (Steam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

I. Modulating Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

J. Operating Limit Temperature Control (Hot Water). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

K. High Limit Temperature Control (Hot Water) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

L. Low Water Cutoff Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

M. Combustion Air Proving Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

N.Gas Pilot Flame Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

O. Gas Pressure and Flow Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

P. Gas Fuel Combustion Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Q. Low Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

R. High Gas Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

S. Fuel Oil Pressure and Temperature - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

T. Fuel Oil Combustion Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

U. Low Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Chapter 7

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

iii

TABLE OF CONTENTS(continued)

Chapter 8

Inspection And Maintenance

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

B. Periodic Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

C. Fireside Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

D. Upper Pass Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

E. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

F. Oil Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

G. Gas Burner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

H. Refractory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

I. Casing Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7

Chapter 9

ProFire Burner Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1, 9-14

Casing Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-15, 9-32

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-33, 9-39

Notes

CHAPTER 1

GENERAL DESCRIPTION

A. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

B. The Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

C. Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

D. Steam Controls (All Fuels) . . . . . . . . . . . . . . . . . . . 1-2

E. Hot Water Controls (All Fuels) . . . . . . . . . . . . . . . . 1-4

A. General

The information in this manual applies directly to CleaverBrooks FLX Model boilers in sizes ranging from 1,500,000 to 12,000,000 Btu/hr input.

Fuel Series

700- Gas

100-No.2 0il

CAUTION

DANGER

The care taken in placing the boiler into initial service is vital to continuous, reliable operation. If the boiler is to be used for temporary heat (for example in new construction), properly treated water must be used. Failure to do so can be detrimental to the boiler.

200 - Combination Gas & No.2 Oil

Design Pressure

160 psig hot water

15 psig steam

150 psig steam

750-177 1-1

Figure 1-1: FLX Cut Away

Chapter 1 GENERAL DESCRIPTION

B. The Boiler

The Cleaver-Brooks Model FLX is a five-pass steel boiler with flexible watertubes formed and arranged so as to direct the flow of combustion gases through the boiler. The pressure vessel conforms to Section I or IV of the ASME code. The pressure vessel consists of the formed tubes, the external downcomer, and the top and bottom drums to which they connect. The heated area of the pressure vessel is contained within a gas tight insulated casing that is composed of removable formed steel panels.

Always order genuine Cleaver-Brooks parts from your local Cleaver-Brooks authorized representative.

The boiler and related equipment installation are to be in compliance with the standards of the National Board of Fire Underwriters. Installation should also conform to state and local codes governing such equipment. Prior to installation, the proper authorities having jurisdiction are to be consulted, permits obtained, etc. All boilers in the above series comply, when equipped with optional equipment, to Industrial Risk Insurers (IRI), Factory Mutual (FM), or other insuring underwriters requirements.

The Model FLX boiler is a packaged watertube boiler of welded steel construction and consists of a pressure vessel, burner, burner controls, forced draft fan, damper, refractory, and appropriate boiler trim.

The type of service that your boiler is required to provide has an important bearing on the amount of waterside care it will require.

CAUTION

DANGER

Waterside care is of prime importance. For specific information or assistance with your water treatment requirements, contact your Cleaver-Brooks service and parts represen tative. Failure to follow these instructions could result in equipment damage

Feedwater equipment should be checked and ready for use. Be sure that all valves, piping, boiler feed pumps, and receivers are installed in accordance with prevailing codes and practices.

Water requirements for both steam and hot water boilers are essential to boiler life and length of service. Constant attention to water requirements will pay dividends in the form of longer life, less down-time, and prevention of costly repairs. Care taken in placing the pressure vessel into initial service is vital. The waterside of new boilers and new or remodeled steam or hot water systems may contain oil, grease or other foreign matter. A method of boiling out the vessel to remove accumulations is described in Chapter 3.

The operator should be familiar with Chapter 3 before attempting to place the unit into operation.

Hot water is commonly used in heating applications with the boiler supplying water to the system at 180 °F to 220 °F. The operating pressure for hot water heating systems usually is 30 psig to 125 psig.

Steam boilers are designed for low and high pressure applications. Low pressure boilers are limited to 15 psig design pressure, and are typically used for heating applications. High pressure boilers are limited to 150 psig design pressure, and are typically used for process steam applications.

Steam and hot water boilers are defined according to design pressure and operating pressure. Design pressure is the max imum pressure used in the design of the boiler for the purpose of calculating the minimum permissible thickness or physical characteristics of the pressure vessel parts of the boiler. Typically, the safety valves are set at or below design pressure. Operating pressure is the pressure of the boiler at which it normally operates. The operating pressure usually is maintained at a suitable level below the setting of the pres sure relieving valve(s) to prevent their frequent opening during normal operation.

C. Construction

Steam boilers designed for 15 psig and hot water boilers designed for 250°F at 160 psi or less are constructed in accordance with Section IV, Heating Boilers, of ASME Code. Steam boilers designed for 150 psig are constructed in accordance with Section I, Power Boilers, of the ASME Code.

D. Steam Controls (All Fuels)

1. Operating Limit Pressure Control (Figures 1-2 and 1-3): Breaks a circuit to stop burner operation on a rise of boiler pressure at a selected setting. It is adjusted to stop or start the burner at a preselected pressure setting.

2. High Limit Pressure Control (Figure 1-2 and 1-3): Breaks a circuit to stop burner operation on a rise of pressure above a selected setting. It is adjusted to stop the burner at a preselected pressure above the operating limit control setting. The high limit pressure control is equipped with a manual reset.

1-2 750-177

GENERAL DESCRIPTION Chapter 1

3. Modulating Limit Pressure Control (Figure 1-2 and 1-3): Senses changing boiler pressures and transmits the information to the modulating motor to change the burner firing rate when the manual-automatic switch is set on “automatic.”

4. Low Water Cutoff and Pump Control (Figure 1-2, 1-4 and 1-5): Float-operated control responds to the water level in the boiler. It performs two distinct functions:

•Stops firing of the burner if water level lowers below the safe operating point. Energizes the low-water light in the control panel; also causes low-water alarm bell (optional equipment) to ring. Code requirements of some models require a manual reset type of low-water cutoff.

•Starts and stops the feedwater pump (if used) to maintain water at the proper operating level.

CAUTION

DANGER

Determine that the main and auxiliary low water cutoffs and pump control are level af

ter installation and throughout the equipment’s operating life. Failure to follow these instructions could result in equipment dam

age.

5. Water Column Assembly (Figure 1-2): Houses the lowwater cutoff and pump control and includes the water gauge glass, gauge glass shutoff cocks.

6. Water Column Drain Valve (Figure 1-2): Provided so that the water column and its piping can be flushed regularly to assist in maintaining cross-connecting piping and in keeping the float bowl clean and free of sediment. A similar drain valve is furnished with auxiliary low-water cutoff for the same purpose.

7. Gauge Glass Drain Valve (Figure 1-2): Provided to flush the gauge glass.

8. Safety Valve(s) (Figure 1-6 and 1-8): Prevent buildup over the design pressure of the pressure vessel. The size, rating and number of valves on a boiler is determined by the ASME Boiler Code. The safety valves and the discharge piping are to be installed to conform to the ASME code requirements. The installation of a valve is of primary importance to its service life. A valve must be mounted in a vertical position so that discharge piping and code-required drains can be properly piped to prevent buildup of back pressure and accumulation of foreign material around the valve seat area. Apply only a moderate amount of pipe compound to male threads and

WATER COLUMN

LOW WATER CUTOFF

AND PUMP CONTROL

CONTROL PANEL

FLAME

DETECTOR

FORCED DRAFT

FAN MOT OR

GAUGE GLASS

DRAIN VALVE

WATER COLUMN

DRAIN VALVE

MODULATING

MOTOR

HIGH LIMIT PRESSURE

OIL SUPPLY

PRESSURE

GAUGE

OPERATING LIMIT PRESSURE CONTROL

MODULATING LIMIT PRESSURE CONTROLCONTROL

STEAM PRESSURE

GAUGE

750-177 1-3

OIL SOLENOID

VALV ES

OIL PUMP

Figure 1-2: Typical Steam Boiler - Light Oil Fired

Chapter 1 GENERAL DESCRIPTION

avoid overtightening, which can distort the seats. Use only flat-jawed wrenches on the flats provided. When installing a flange-connected valve, use a new gasket and

1. HIGH LIMIT PRESSURE CONTROL

2. OPERATING LIMIT PRESSURE CONTROL

3. MODULATING PRESSURE CONTROL

Figure 1-3: Steam Controls

draw the mounting bolts down evenly. Do not install or remove side outlet valves by using a pipe or wrench in the outlet.

WARNING

DANGER

Only properly certified personnel such as the safety valve manufacturer’s certified representative can adjust or repair the boiler safety valves. Failure to follow these instructions could result in serious personal injury or death

E. Hot Water Controls (All Fuels)

Figure 1-4: Low Water Cut Off (LWCO)

1. Water Temperature Gauge (Figure 1-7): Indicates the boiler internal water pressure.

2. Water Pressure Gauge (Figure 1-7): Indicates the internal pressure of the boiler.

3. Operating Limit Temperature Control (Figure 1-7): Breaks a circuit to stop burner operation on a rise of boiler temperature at a selected setting. It is adjusted to

Figure 1-5: Low Water Cut Off Pump Control

(Cutaway)

1-4 750-177

Figure 1-6: Safety Valve Cutaway

GENERAL DESCRIPTION Chapter 1

stop or start the burner at a preselected operating temperature.

4. High Limit Temperature Control (Figure 1-7): Breaks a circuit to stop burner operation on a rise of temperature at a selected setting. It is adjusted to stop burner at a preselected temperature above the operating control setting. The high limit temperature control is equipped with a manual reset.

5. Modulating Temperature Control (Figure 1-7): Senses changing boiler water temperature and transmits the information to the modulating motor to change the burner firing rate when the manual-automatic switch is set on “automatic.”

6. Low Water Cutoff (Figure 1-7): Breaks the circuit to stop burner operation if the water level in the boiler drops below safe operating point, activating low-water light and optional alarm bell if burner is so equipped.

7. Auxiliary Low Water Cutoff (Not Shown) (Optional): Breaks the circuit to stop burner operation if the water

level in the boiler drops below the master low-water cutoff point.

WATER PRESSURE

GAUGE

WATER TEMPERATURE GAUGE

LOW WATER CUTOFF PROBE

1. High Limit Temperature Control

2. Operating Limit Temperature Control

3. Modulating Temperature Control

4. Low Water Cutoff Control

750-177 1-5

Figure 1-7: Hot Water Controls

Chapter 1 GENERAL DESCRIPTION

SUPPORT FROM BUILDING

DISCHARGE OPENING MUST BE EQUAL TO OR LARGER THAN INLET

SAFETY VALVE

NOTICE: BACK-PRESSURE OF STEAM EXHAUST SYSTEM MUST BE LESS THAN 6% OF SAFETY VALVE SETTING.

WATER LEVEL

CONSTRUCTION

CAUTION - VENT PIPE MUST NOT TOUCH DRIP PAN EXTENSION

DRIP ELL DRAIN

TO STEAM

VENT

VENT PIPE

DRIP PAN

EXTENSION

AND ELBOW

OPEN DRAIN

TO WASTE

BOILER SHELL

Figure 1-8: Recommended Piping For Steam

Relief Valve (Not furnished by Cleaver-Brooks)

DRIP PAN

1 1/2”

MIN.

DRIP PAN

DRAIN

remove side outlet valves by using a pipe or wrench in the outlet.

WARNING

DANGER

Only properly certified personnel such as the relief valve manufacturer’s certified representative can adjust or repair the boiler relief valves. Failure to follow these instructions could result in serious personal injury or death.

1-6 750-177

CHAPTER 2

ProFire Burner Operation and Control

A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

B. BURNER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

C. RECOMMENDED FUELS AND VENTILATION . 2

D. CONTROLS AND COMPONENTS . . . . . . . . . . . . 2

The burner and all boiler related equipment must be installed in accordance with applicable local, state or provincial installation requirements including the National Electrical Code (NEC) and associated insurance underwriters. Where applicable, the Canadian Gas Association (CGA) B149 and Canadian Standards Association (CSA) B140 codes shall prevail.

Note: If the boiler is not equipped with a ProFire burner, Please refer to the specific Operation and Maintenance manual for the burner supplied.

Note: The main power disconnect for this equipment must be conspicuously labeled and placed within system, and/or equipped with lockout provisions.

Note: This manual must be readily available to all operators, and maintained in legible condition.

sight of the operating

A. GENERAL

The information provided in this manual covers ProFire burners installed on Flextube boilers.

The information in this chapter provides guidance for startup, testing, and adjustment of the Cleaver-Brooks ProFire burner. Personnel working on or operating the burner or related equipment must become familiar with all the procedures and information contained in this manual prior to initial startup, operation and/or adjustment of the burner.

This chapter applies exclusively to the Cleaver-Brooks ProFire Burner, and focuses specifically on tasks related to adjustment of linkages and controls for efficient combustion and safe operation, pre-startup checkout and initial burner startup.

B. BURNER

The ProFire Burner is designed to operate with natural gas or light oil at input rates from 1.5 to 12.0 MMBtu/hr. The burner can be configured to burn natural gas only, oil only, or as a natural gas or oil burner.

The burner includes all components and controls required for automatic modulating burner operation, and is also capable of operation over the full range under manual control.

The model number completely identifies its configuration. This information is located on the unit parts list, shipped with the burner. The model number components are as follows:

GP - W - X - Y - Z

Where:

GP designates the burner orientation, blower housing down.

W designates the fuel; gas, oil, or combination (700, 100, or 200, respectively).

• 100-Light Oil

• 200- Light Oil and Natural Gas

• 700- Natural Gas

X designates the frame size of the burner (1, 2, 3 & 4).

Y designates burner capacity (MMBtu/hr).

Z designates the insurance underwriter.

For Example:

GP - 700 - 2 - 3.5 - IRI

750-177 2-1

2-1

Chapter 2 ProFire Burner Operation and Control

MODEL NO. 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1100 1200

Gas

15480 20640 25800 30960 36120 41280 46440 51600 56760 61920 72240 82560 92280 103200 113520 123840

(scfh)

Comb

Air

(Dry)

Oil (scfh)

NOTES:

1. Natural gas @ 1000 Btu/cu-ft.

2. No. 2 oil @ 140,000 Btu/gal.

1207 1609 2012 2414 2817 3219 3621 4024 4426 4828 5633 6438 7243 8048 8853 9658

(lb/hr)

17050 22733 28414 34098 39782 45463 51146 56831 62514 68196 79562 90928 102294 113662 125028 136394

1269 1692 2115 2538 2961 3384 3807 4231 4654 5077 5923 6769 7640 8462 9308 10154

(lb/hr)

Table 2-1: Combustion Air Flow Requirements

indicates a blower housing “down” unit that burns only natural gas; it is made of size-two components, and is rated

for 3.5 MMBtu/hr fuel input at high fire and is configured to meet IRI (Industrial Risk Insurers) standards.

ABC

EFG

C. RECOMMENDED FUELS AND

VENTILATION

ProFire burners are designed to burn either natural gas or light oil (#2), as defined by ASTM D396 - 1978 specification.

WARNING

DANGER

This burner is designed to burn only those fuels shown on the burner data plate. Burning fuels not specified on the data plate could cause damage to the equipment, or can result in serious personal injury or death.

Note: Structural enclosures for this equipment must be configured to allow ample flow of combustion and ventilation air. See Table 2-1 for combustion air volume requirements.

D. CONTROLS AND COMPONENTS

The burner can be equipped with special operating controls, various types of flame safeguard systems, and/or a system to minimize NOx emissions. The wiring and dimension diagrams and construction reference list (available with the burner) confirm the specific features and equipment included. Refer to Figures 2-1 and 2-2 for component locations. The

A. FLAME FAILURE LIGHT B. LOAD DEMAND LIGHT C. BURNER SWITCH D. MANUAL FLAME CONTROL E. MANUAL-AUTO SWITCH F. FUEL VALVE LIGHT G. LOW WATER LIGHT

Figure 2-1: Control Cabinet

following list describes components and basic functions of the burner.

1. Electrical Control Cabinet (Figure 2-1): The control cabinet houses many of the electrical control components and the flame safeguard. The operator control switches and indicator lights are located on the face of the control cabinet door. The following controls and indicators are provided:

• Flame Failure Light: Illuminates (red) 20 seconds after the flame is extinguished. When this happens, the system automatically shuts down; manual reset of the flame safeguard is required.

2-2 750-177

• Load Demand Light: Illuminates (white) when

ProFire Burner Operation and Control Chapter 2

the boiler operating controls indicate a demand for hot water or steam.

• Burner Switch: Activates or deactivates the operating cycle of the flame safeguard control.

• Manual Flame Control: When in Manual Mode, it provides manual adjustment of the burner fir

ing rate between low-fire and high-fire operation.

• Manual-Auto Switch: Allows the operator to override the automatic boiler controls for manual firing rate adjustment.

• Fuel Valve Light: Illuminates (green) when the selected fuel valve is energized.

A. FLAME SAFEGUARD B. FUEL SELECTION SWITCH

• Low Water Light: Illuminates (red) when the boiler low-water cutoff control is activated.

2. Flame Safeguard (Figure 2-2): The flame safeguard controls the operating sequences of the combustion system (prepurge, pilot, firing, and shutdown). The control also monitors the flame, using a scanner which is sensitive to specific flame frequencies. The flame safeguard also automatically shuts down the burner when the flame signal becomes too weak. Different types of flame safeguard devices can be installed in the combustion systems. Check the wiring diagram for your burner for information on the specific unit installed on your burner.

3. Fuel Selection Switch (Figure 2-2): Allows the operator to select either gas or oil as the active fuel on combination burners. (The switch is located inside the control cabinet.)

4. Pilot Gas Train (Figure 2-3). The standard pilot gas train consists of a manual stopcock, a gas pressure regulator, and a solenoid-operated gas shut-off valve. The gas pilot valve assembly controls a relatively small flow rate of natural gas to operate the gas-electric pilot.

5. Blast Tube (Figure 2-3). The blast tube functions as a duct for combustion air, and houses the fuel nozzle(s), gas pilot assembly, diffuser, and air baffle assemblies.

Figure 2-2: Control Cabinet (Open)

A. PILOT GAS TRAIN B. BLAST TUBE C. BLOWER HOUSING D. COMBUSTION AIR FAN MOTOR E. IGNITION TRANSFORMER F. COMBUSTION AIR PROVING SWITCH

Figure 2-3: ProFire Burner (Left Side)

6. Blower Housing (Figure 2-3). The blower housing encloses the impeller. The fan drive motor is mounted directly to the blower housing.

7. Combustion Air Fan Motor (Figure 2-3). The electric motor drives the combustion air fan and the oil pump (if so equipped).

8. Ignition Transformer (Figure 2-3). The ignition transformer produces the high voltage required for spark generation by the pilot electrode(s).

9. Combustion Air Proving Switch (Figure 2-3). The combustion air proving switch provides confirmation to the flame safeguard that the combustion air fan is

750-177 2-3

Figure 2-4: Impeller

Chapter 2 ProFire Burner Operation and Control

providing air flow. The fuel supply valves will not open if this switch does not sense adequate air pressure.

10. Impeller (Figure 2-4). The impeller is designed with backwards-inclined vanes. It is located inside the blower housing, and is driven by the combustion air fan motor. The impeller provides combustion air to the burner assembly. Removing the impeller requires the use of the impeller puller, part number 943-388 (Figure 2-8)

11. Gas Butterfly Valve (Figure 2-5). The gas butterfly valve regulates the flow rate of natural gas into the burner. The gas butterfly valve is connected, by linkage and a jack shaft, to the modulating motor, which provides the rotary motion to open and close the valve.

12. Valve Linkage (Figure 2-5). The valve linkage transfers the modulating motion from the main air shutter shaft to the fuel metering valve shafts. The linkage provides a means of adjustment to maintain the correct fuel-to-air ratio over the entire burner operating range, high fire to low fire.

13. Oil Metering Valve (Figure 2-5). The oil metering valve regulates the flow rate of oil into the burner. The oil metering valve is connected by linkage and a jack shaft to the modulating motor, which provides the rotary motion to open and close the valve.

14. Oil Pump (Figure 2-5). The oil pump provided for oil burning is coupled to an extension of the combustion air fan shaft.

15. Modulating Motor (Figure 2-5). The modulating motor is coupled to the jack shaft that operates the main air shutter and the fuel valve linkages. The modulating motor produces the torque and rotary positioning required for firing rate control.

20. Airbox (Figure 2-6). The airbox is attached to the inlet side of the fan housing. It serves as the inlet and flow regulating valve for combustion air, and houses the combustion air control shutters.

21. Main Air Shutter Shaft (Figure 2-6). The main air shutter modulates the combustion air between low fire and high fire conditions. The shaft connects the modulating motor to the main air shutter and to the fuel valve linkage assemblies.

A. GAS BUTTERFLY VALVE B. VALVE LINKAGE C. OIL METERING VALVE D. OIL PUMP E. MODULATING MOTOR F. OIL SOLENOID VALVES G. REAR CAP

Figure 2-5: Oil And Gas Piping To Burner

16. Oil Solenoid Valves (Figure 2-5). The oil solenoid valves are in series and downstream of the oil metering valve in the supply line to the oil burner assembly. Two valves are provided. These valves are simultaneously energized to open and release fuel oil to the burner. The valves close to stop combustion when oil is the fuel.

17. Rear Cap (Figure 2-5). The rear cap contains the locking setscrew for adjustment of the diffuser relative to the air

baffle, and also the flame scanner for the flame safeguard. The rear cap must be removed to enable removal of the oil gun assembly.

18. Low-Fire Shutter (Figure 2-6). The low-fire shutter provides a means to set the correct combustion air flow

rate for low-fire operation. The handle indicates relative shutter position.

19. High-Fire Shutter (Figure 2-6). The high-fire shutter provides a means to set the correct combustion air flow rate for high-fire operation. The handle indicates relative

A. LOW-FIRE SHUTTER B. HIGH-FIRE SHUTTER C. AIRBOX D. MAIN AIR SHUTTER SHAFT

shutter position.

Figure 2-6: Airbox and Shutters

2-4 750-177

ProFire Burner Operation and Control Chapter 2

ITEM

ACCOMPLISHED

REMARKS

Daily

Gauges, Monitors,

Operator Make visual inspection and record readings in log.

and Indicators

Instrument and

Operator Make visual check against recommended specifications.

Equipment Settings

Low-water Fuel Cut-

Operator Refer to instructions.

off And Alarm

Weekly

Low-water Fuel Cut-

Operator Refer to instructions.

off And Alarm

Firing Rate Control Operator Verify factory settings.

Igniter Operator Make visual inspection. Check flame signal strength if meter-fitted (see

“Combustion safety controls”).

Pilot and Main Fuel Valves

Operator Open limit switch. Make audible and visual check. Check valve position

indicators, and check fuel meters

Flame Failure Controls

Flame Signal Strength Controls

Operator Close manual fuel supply for (1) pilot, (2) main fuel cock and/or

valve(s). Check safety shutdown timing. Record in log.

Operator If flame signal meter installed, read and log for both pilot and main

flames. Notify service if readings are very high, very low, or fluctuating. Refer to instructions.

Monthly

Low Fan Pressure,

Operator Manually adjust until switch opens.

Interlock

High & Low Gas

Operator Refer to instructions. Manually adjust until switch opens.

Pressure Interlocks

High & Low Oil

Operator Refer to instructions. Manually adjust until switch opens.

Pressure Interlocks

Semi- Annually

Low-water Fuel Cutoff And Alarm

Operator Perform a slow drain test in accordance with ASME Boiler and Pres-

sure Vessel Code Section VI.

Firing Rate Control Service Technician Verify factory settings.

Figure 2-7: Recommended Test Schedule

750-177 2-5

Chapter 2 ProFire Burner Operation and Control

ITEM

Inspect Burner

ACCOMPLISHED

Service Technician Refer to instructions.

REMARKS

Components

Annually

High Limit Safety

Service Technician Manually adjust until switch opens.

Control

Firing Rate Control Service Technician Check with combustion test.

Pilot and Main Gas

Service Technician Perform leakage tests. Refer to instructions or Main Oil Fuel Valves

Operating Control Service Technician Manually adjust until switch opens.

Fuel Valve Interlock

Service Technician Refer to instructions. Disconnect POC wire at valve. Switch (POC)

Burner Position

Service Technician Refer to instructions. Disconnect wire at valve. Interlock

Low Fire Start Inter-

Service Technician Refer to instructions. lock

Automatic Change Over Control (Dual Fuel)

Pilot Turndown Tests

Refractory Hold-In Controls

High & Low Oil Pressure Interlocks

Pilot Turndown Tests

Service Technician Under supervision of gas utility.

Service Technician Required after any adjustments to flame scanner mount or pilot burner.

Verify annually. Refer to instructions.

Service Technician See “Pilot turndown tests.”

As Required

Operator Refer to instructions. Manually adjust until switch opens.

Service Technician Required after any adjustments to flame scanner mount or pilot burner.

Verify annually. Refer to instructions.

Figure 2-7: Recommended Test Schedule (Continued)

2-6 750-177

ProFire Burner Operation and Control Chapter 2

Special Tools

The Impeller puller, part number 943-388 should be used to remove the impeller from the fan motor shaft.

To order special tools, contact your authorized Cleaver-Brooks representative.

Figure 2-8: Impeller Puller Part Number

943-388

750-177 2-7

Chapter 2 ProFire Burner Operation and Control

Notes:

2-8 750-177

CHAPTER 3

Pressure Vessel Care

A. General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

B. Water Requirements (Hot Water Boilers) . . . . . . . .3-1

C. Water Requirements (Steam Boilers . . . . . . . . . . . .3-3

D. Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

E. Blowdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

F. Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

G. Boilout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

H. Washing Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

I. Periodic Inspections . . . . . . . . . . . . . . . . . . . . . . . . .3-8

J. Preparation for Extended Layup . . . . . . . . . . . . . . . .3-9

A. GENERAL

This chapter is devoted primarily to the waterside care of the pressure vessel.

Proper water supply and treatment are essential to boiler life and length of service. Proper water treatment will pay dividends in the form of longer life, less downtime, and prevention of costly repairs.

Hot water boilers require proper circulation. The system must be operated as intended by its designer in order to avoid the possibility of thermal shock with severe stress to the pressure vessel.

Although it is of prime importance, the subject of water supply and treatment cannot adequately be covered in this manual. For specific information or assistance with your water treatment requirements, contact your local CleaverBrooks authorized representative.

B. WATER REQUIREMENTS

(HOT WATER BOILERS)

Air Removal

The hot water outlet (Figure 3-1) is located in the top drum of the boiler. This location reduces the possibility of released air (which is trapped at the top of the drum) from entering the system. Any air (or oxygen) that may be released in the boiler will collect at the top of the upper drum, where it will escape through the air vent tapping (Figure 3-1). The tapping must be properly piped to the expansion tank or a stand pipe and air bleeder to remove gases that collect at the top of the drum.

750-177 3-1

A. HOT WATER OUTLET B. AIR BLEED TAPPING C. PRESSURE/TEMPERATURE GAUGES

Figure 3-1: Upper Drum (Hot Water)

Continuous Flow

The system must be piped and the controls arranged so that there will be water circulation through the boiler under all operating conditions. Constant circulation through the boiler eliminates the possibility of stratification within the unit.

Refer to Fig. 3-1 to determine the maximum GPM circulation rate of boiler water in relation to full boiler output and system temperature drop.

Chapter 3 Pressure Vessel Care

DT = 20°F DT = 40°F DT = 60°F DT = 80°F DT = 100°F

MODEL

NO.

FLX-150 1.14 122.0 0.30 61.1 0.13 41.1 0.08 30.8 0.05 24.4

FLX-200 1.14 162.3 0.30 81.1 0.13 54.1 0.08 40.6 0.05 32.5

FLX-250 1.77 202.8 0.46 101.4 0.21 67.6 0.12 50.7 0.08 40.6

FLX-300 1.85 243.4 0.48 121.7 0.22 81.1 0.12 60.9 0.08 48.7

FLX-350 2.49 284.0 0.65 142.0 0.29 94.7 0.17 71.0 0.11 56.8

FLX-400 1.35 324.5 0.35 162.3 0.16 108.2 0.09 81.1 0.06 64.9

FLX-450 1.71 365.1 0.44 182.6 0.20 121.7 0.11 91.2 0.08 73.0

FLX-500 2.03 405.7 0.54 202.8 0.25 135.2 0.14 101.4 0.09 81.1

FLX-550 2.50 446.3 0.67 223.1 0.31 148.7 0.17 111.5 0.11 89.2

FLX-600 2.99 486.8 0.77 243.4 0.35 162.3 0.20 121.7 0.13 97.4

FLX-700 1.75 567.9 0.45 284.0 0.21 189.3 0.12 142.0 0.08 113.6

FLX-800 2.27 649.1 0.59 324.5 0.27 216.4 0.15 162.3 0.10 129.8

FLX-900 2.85 730.2 0.74 365.1 0.33 243.4 0.19 182.6 0.12 146.0

(PSIG)

GPM DP (PSIG) GPM DP (PSIG) GPM DP (PSIG) GPM DP (PSIG) GPM

FLX-1000 4.08 811.4 1.02 405.6 0.42 270.4 0.25 202.8 0.15 163.6

FLX-1100 4.42 892.6 1.15 446.2 0.48 297.4 0.28 223.0 0.18 178.4

FLX-1200 6.20 973.6 1.60 486.8 0.59 324.6 0.31 243.4 0.22 194.8

Table 3-1:Maximum Flow Rates for Hot Water Boilers

System Pressure

CAUTION

DANGER

In order to avoid damage to the equipment, a circulating pump should be interlocked with the burner so that the burner cannot operate unless the circulating pump is run ning.

It is recommended that the system circulating pumps be kept running, even though the heat users do not require hot water. The relief device or bypass valve will allow continuous circulation through the boiler and will help prevent rapid replacement of boiler water with “cold” zone water.

CAUTION

DANGER

The operator should determine that a circulation of water exists through the boiler before initial firing or when firing after the unit has been drained and refilled. A reduced cir culation of water or no water circulation through the boiler when the burner is oper ating may result in damage to the equipment.

The design of the system and the usage requirements often will dictate the pressure exerted upon the boiler. Some systems are pressurized with nitrogen. Caution must be

240

230

220

210

200

190

180

170

SUPPLY WATER TEMPERATURE -

160

150

10 12 14

16 18 20 22 24

SYSTEM PRESSURE - PSI

Figure 3-2: Minimum System Operating Pressure

3-2 750-177

Pressure Vessel Care Chapter 3

exercised to make sure that the proper relationship of pressure to temperature exists within the boiler so that all of its internal surfaces are fully wetted at all times. It is for this reason that the internal boiler pressure, as indicated on the water pressure gauge, must be held to the level shown in Figure 3-3.

It is advisable to install a thermometer in the return line to indicate return water temperature. With the return water temperature and the supply water temperature to the system known, the temperature differential will be established. Knowing the flow rate, the operator easily can detect any excessive load condition and take appropriate corrective action.

Pressure Drop

There will be a pressure drop of less than 4 psi through all standardly equipped Cleaver-Brooks boilers operating in any system that has more than the 20°F temperature drop. This drop will vary with boiler size and circulation rate. For specific information, refer to table 3-1, Minimum Flow Rates for Hot Water Boilers.

Minimum Boiler Outlet Water Temperature

The minimum recommended operating boiler outlet water temperature is 150°F. When water temperatures lower than 150°F are used, the combustion gases are reduced in temperature to a point where the water vapor in the gases condenses. A result of condensation is that fireside corrosion occurs in the boiler and breeching. The condensation problem is more severe on a unit that operates intermittently or is oversized for the actual load. This is not a matter that can be controlled by boiler design, since an efficient boiler extracts all the possible heat from the combustion gases.

Multiple Boiler Installations

When multiple boilers of equal or unequal size are installed, care must be taken to ensure proportional flow through the boilers. Proportional flow can best be accomplished by use of balancing cocks and gauges in the supply line from each boiler. If balancing cocks or orifice plates are used, a significant pressure drop (for example, 3-5 psi) must be taken across the balancing device to accomplish proportional flow.

Variations in water temperature and firing rates will result if care is not taken to ensure proportional flow through the boilers. In extreme cases, differences in firing rates could result in a net header water temperature below the desired temperature.

C. WATER REQUIREMENTS

(STEAM BOILERS)

Deaeration

The most important factor in the life of a steam pressure vessel is the proper conditioning of the boiler feed water. Corrosive gasses, such as oxygen and carbon dioxide, must be removed from the feed water in order to prevent degradation of the pressure vessel. For this reason CleaverBrooks recommends the use of a deaeration system as an integral part of a complete boiler installation. If circumstances do not allow the implementation of a deaeration system, then serious consideration should be given to effective alternatives such as a feed water preheater combined with a chemical oxygen scavenger. Complete boiler water chemistry parameters are given in Table 3-3.

Note: In order to maintain a minimum outlet water temperature of 150°F the low limit of the Operating Temperature Control should be set at least 10° higher.

If the operating water temperature going to the system must be lower than 150°F, the operating boiler outlet water temperature should still be held to a minimum of 150°F. Mixing valves are used to reduce the supply temperature going to the system.

Note: The minimum return water temperature through the boiler is 120°F.

CAUTION

DANGER

Three-way valves and system controls should be installed or set so that the boiler cannot be bypassed. A reduced circulation of water or no water circulation through the boiler when the burner is operating may re sult in damage to the equipment.

750-177 3-3

Feed Water Supply

The internal dynamics of the Model FLX steam boilers require the capability to deliver large quantities of feed water to the boiler on demand. (Feed water inlet Figure 3-3.) Sudden changes in firing rate or operating pressure of the

FEED WATER SUPPLY PORT

Figure 3-3: Feed Water Inlet

Steam Boiler

Chapter 3 Pressure Vessel Care

BOILER MODEL 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 11 00 1200

Minimum Feed Rate (gpm) 4.9 6.6 8.2 9.9 11.6 13.2 14.9 16.5 18.2 19.8 23.1 26.4 29.7 33.0 36.3 39.6

Note: Feedwater to the boiler must be at least 60 °F, for minimum performance, 212 °F is preferred.

Table 3-2: Minimum Boiler Feed Water Flow Rates (Steam Boiler)

Because of the variables involved, no one “boiler compound”

Silica 150 ppm

Specific Conductance 3500 µmho/cm

Total Alkalinity 300 ppm as C

Total Hardness 0 ppm as CaCO

aCO3

Oxygen (O2)7 ppb

can be considered a “cure-all”; nor is it advisable to experiment with homemade treating methods. A sound treatment program should include a periodic analysis of the water in the system.

The internal or waterside surfaces of the pressure vessel should be inspected at sufficient intervals to detect the presence of any corrosion, pitting, contamination, or accumulations of foreign matter. If any of these conditions

pH 10

are detected, contact your local Cleaver-Brooks authorized Representative for advice on corrective action. It is

Total Iron 0.05 ppm

Oily Matter 1 ppm

Table 3-3: Boiler Water Quality Limits

(Steam Boilers)

recommended that a properly sized water meter be installed in the raw water makeup line to accurately determine the amount of raw water admitted to the boiler. It is a false assumption that a hot water boiler does not require water treatment. Even though a hot water unit generally operates on a closed system and blowdown seldom is practiced, the need

boiler will initiate a “call for water” from the make-up controller, which will require that the feed water be delivered to the boiler in sufficient quantities to prevent a low water

remains to be alert to system water losses. Knowing the amount of makeup water admitted to the system will aid in maintaining proper waterside conditions.

cutoff trip. Table 3-2 lists the minimum feed water flow requirements for the various boiler models. In addition, feed water must be warmed to a minimum of 60°F. in order to ensure reliable operation of the boiler. The feed water supply should be adjusted to deliver water to the boiler at or above these minimum rates.

A steam boiler requires periodic blowdown of the boiler and water column (Figure 3-4). Blowdown is the removal of some of the concentrated water from the boiler and the water level

E. BLOWDOWN

D. WATER TREATMENT

Properly treated boiler water will result in maximum effectiveness and long trouble-free life of the pressure vessel. Contact your local Cleaver-Brooks Representative or water management consultant for complete information on how to prevent damage resulting from inadequate water treatment.

The objectives of water treatment in general are to:

1. Prevent hard scale and soft sludge deposits that inhibit heat transfer and that could lead to overheated metal and costly downtime and repairs.

2. Eliminate corrosive gases in the supply or boiler water.

To accomplish these objectives, the boiler requires proper water treatment before and after introduction of water into the unit. The selection of pretreatment processes depends upon the water source, its chemical characteristics, the amount of makeup water needed, system operation practices, etc.

3-4 750-177

Figure 3-4: Low Water Cutoff and Gauge Glass with

Blowdown Valve

Pressure Vessel Care Chapter 3

control system, in order to lower the concentration of solids in the water.

Solids are introduced to the boiler with the feedwater, even though this water may be treated prior to use. These solids become less soluble when the water is heated and evaporated, and tend to accumulate on heating surfaces.

Periodic blowdown and chemical treatment are necessary to prevent concentration of solids in the boiler water, and attachment of these solids to waterside heating surfaces (scaling).

Scale has a low heat transfer value and acts as an insulating barrier on heating surfaces. A buildup of scale will result in lower operating efficiency and, consequently, higher fuel consumption. More importantly, scale buildup can result in overheating of boiler metal. This can result in tube failures or other pressure vessel damage.

CAUTION

DANGER

Boiler and water level control blowdown must be performed on a regular basis to en sure that concentrated solids are removed from the boiler and in order to avoid damage to the equipment.

Water column and gauge glass blowdown valves are located on the water column assembly. The boiler blowdown tapping(s) can be found at the bottom of the lower drum.

Most blowdown lines are provided with two valves. These are generally a quick-opening valve nearest the boiler and a slow-opening globe-type valve downstream. Valves will vary depending upon pressure involved and the make or manufacturer.

When initially opening the blowdown valve, open the valve slowly to heat the discharge piping. Failure to follow this procedure could result in rapid expansion and damage to the piping.

The drop of the water level in the gauge glass can be used in determining the length of time that the blowdown valve is left open. This is to be used as a reference only, as proper water analysis on a regular basis will serve as an indicator of the effectiveness of the blowdown procedures used.

Do not pump the lever action valve open and closed when draining water during blowdown. The hydraulic forces resulting from this pumping action could break the valve bodies or pipe fittings in the blow down lines.

Blowdown valves should be closed in a specific order after draining water for blowdown. Close the downstream (slow opening) valve first, followed by the quick-opening valve next to the boiler. Open the downstream valve slightly to release the water trapped between the valves, then close the valve again.

The water column and gauge glass should be blown down by draining until the water in the gauge glass is clear. Open and close the water column and gauge glass blowdown valves slowly, allowing the water in the gauge glass to rise to a normal level before repeating the process.

CAUTION

DANGER

CAUTION

DANGER

Blowdown Procedure

Blowdown is most effective when the boiler water is hot and the burner is being fired at the lowest rate. This ensures that the water in the boiler is being circulated, and that the solids in the water are in suspension.

WARNING

DANGER

Be sure that the blowdown piping is in good condition, the discharge vents are clear of obstruction, and that the waste is piped to a safe point of discharge, in order to avoid serious personal injury or death.

If a quick-opening valve and globe-type or slow-opening valve are installed, the quick-opening valve is normally opened first and closed last. Control of the water released from the boiler is accomplished with the slow-opening valve.

750-177 3-5

Under no circumstances should a blowdown valve be left open and unattended during the blowdown operation.

Frequency of Blowdown

In practice, the boiler blowdown valve(s) should be opened periodically in accordance with a set operating schedule. Frequency and duration of the blowdown are to be determined by chemical analysis of boiler water and waterside boiler condition, as observed during regular inspections.

From an economy standpoint, frequent short blowdown is preferred to irregularly scheduled, lengthy blowdown. This is particularly true when the suspended solids content of the water is high.

Chapter 3 Pressure Vessel Care

F. CLEANING

Although it may be necessary to clean the system, information in this chapter deals primarily with cleaning the boiler under isolated conditions.

System piping connected to the boiler may contain oil, grease, or other foreign matter. These impurities must be removed to prevent damage to the heating surfaces of the pressure vessel. Chemical cleaning generally is necessary in this case and the entire system should be drained after cleaning. Consult your local Cleaver-Brooks authorized representative for recommended cleaning compounds and application procedures. For information on Boilout, see Section G, in this chapter.

Pressure Vessel

Cleaning of the waterside of the pressure vessel should be done during the course of initial installation. The waterside of the pressure vessel must be cleansed of grease, sludge, and foreign material. Such deposits will shorten the life of the pressure vessel and interfere with the efficient operation and function of control or safety devices. In addition, deposits might cause unnecessary and expensive rework, repairs, and downtime.

The pressure vessel and the hot water system represent in effect, a closed system. Although individual components of the system may already have been cleaned, it is possible that:

G. BOILOUT

Any oil, grease, or other contamination found to be present on waterside heating surfaces should be removed promptly by boiling out the unit with an alkaline detergent solution.

Note: Before boiling out, the burner must be ready for firing. Refer to the burner manual for details. The operator must be familiar with the boilout procedures outlined in this section.

Cleaver-Brooks recommends the use of CB3900,(P/N 797-

1797) an alkaline, detergent-based product suitable for cleaning all internal surfaces in heating and process boilers. Contact your local Cleaver-Brooks authorized representative for additional information or assistance.

If the system is to be cleaned with the boiler, consider the additional water content of the system in determining the

UPPER HAND HOLE

1. The cleaning was not adequate.

2. An old system was partially or totally involved.

DOWNCOMER

3. Conditions may have prevented an adequate cleaning of the piping.

Therefore, it is recommended that the entire system be cleaned, after installation of all components is completed.

SIGHT

PORT

The pressure vessel waterside should be inspected on a periodic basis. An inspection will reveal the true internal conditions and will serve as a check against conditions indicated by chemical analysis of the boiler water. An

SYSTEM

INLET

inspection should be performed 3 months after the initial start up, then at regular 6, 9, or 12 month intervals thereafter. The frequency of periodic inspections will depend upon the internal conditions found, the particular installation, and the operating conditions that the boiler is subjected to.

Figure 3-5: Rear Panel (Hot Water Boiler

If any deterioration or unusual conditions are observed, contact your local Cleaver-Brooks authorized Representative for recommendations.

150-

300-

400-

700-

Boiler Size

Water Capacity (US gal.) Hot Water

Water Capacity (US gal.) Steam - Flooded

3-6 750-177

Table 3-4: Water Capacity

250

350

91 106 174 228 269

194 215 293 464 562

600

900

1000-

1200

amount of chemical required. The water capacity of CleaverBrooks FLX Boilers is listed in Table 3-4.

Boilout Procedure

1. Prepare the boiler for firing by taking the standard precautions. Check for any situations that might present a hazard.

2. Remove upper and lower drum handhole covers and inspect all internal waterside surfaces. Remove debris

Pressure Vessel Care Chapter 3

and wash all internal surfaces, including tubes. It may be necessary to use a high pressure hose or a wash out lance to flush out inaccessible areas. Reinstall the lower drum handhole cover. (Use standard service gaskets during the boilout procedure.)

3. The relief valve(s) must be removed before adding the boilout solution so that neither the solution nor the contaminants that it may carry can come in contact with the valve(s). Use care in removing, handling, and reinstalling these valves.

Note: For relief valve installation information, refer to Chapter 8, Section E. “Controls.”

4. Replace the regular gauge glass with a temporary gauge glass that can be discarded after the cleaning (steam boilers).

5. An overflow pipe should be connected to one of the top boiler openings and routed to a safe point of discharge. A relief valve tapping is usually used for this purpose. The overflow connection to the boiler should incorporate a tee fitting for adding cleaning solution to the boiler.

6. Fill the unit with clean water to a point just below the access port in the upper drum. It is important that the water used for the filling process is at a temperature of 70°F or above.

12. Throughout the entire process, each blow-down point or valve should be blown at least once every two hours. The total amount of water blown from all points each time should be approximately one-half gauge glass, this amount being equally divided among the various manual blowdown points and continuous blowdown system. Blow the surface and/or continuous blow-down points first, followed by the other blowdown points lower on the boiler. After each blowdown cycle, the water level should be brought back to full. If the total alkalinity in the cleaning solution falls to a level below 3000 ppm, it may be necessary to add additional Cleaver-Brooks 3900, using a chemical pump.

13. Allow a small amount of fresh water to enter the boiler in order to create a slight overflow that will carry off surface impurities. Continue to boil and overflow until the water clears.

14. It is difficult to provide specific recommendations regarding the duration of the cleaning process. In general, a period of 18 to 36 hours will prove sufficient to internally clean the water-side of the boiler. The condition of the water blown from the boiler is the best indicator as to whether the cleaning process is complete.

15. Discontinue firing, and allow the water to cool. After letting the water cool to 120°F or less, drain the boiler.

7. Add the recommended amount of Cleaver-Brooks 3900, using a chemical pump. Never pump the cleaning chemical into the boiler before adding water.

WARNING

DANGER

The chemicals used in this procedure are corrosive to eyes and skin. Always refer to the Material Safety Data Sheet to ensure that the proper safety equipment and precautions are present. Failure to heed this warning could result in serious personal injury or death.

8. Reinstall the upper handhole cover.

9. Continue to fill the boiler until it is full (indicated by flow from the overflow connection).

10. Recheck the burner, gauge glass, pressure gauge, feedwater supply and the position of all valves. Make sure that all water feeding and level indicating apparatus are in proper working condition.

11. Fire the boiler intermittently at the burners lowest fire rate until the water reaches the boiling point. The water should be held at this temperature for at least five hours.

Note: Do not produce pressure in the boiler.

WARNING

DANGER

Be sure to drain the hot water to a safe point of discharge to avoid the possibility of scalding, serious personal injury or death.

16. Remove the drum handhole cover, and wash the waterside surfaces thoroughly, using a high pressure water stream. Direct the water stream into each individual tube. If possible, this washing should be done from the bottom up. A wash out lance is available from your local Cleaver-Brooks authorized representative.

17. Inspect the waterside surfaces. If they are not clean, repeat the boilout procedures.

18. Replace the handhole covers (using new gaskets) and reinstall the relief valve(s).

Note: Refer to Chapter 8, Section E, “Controls” for information regarding proper installation of relief valves.

19. If the boiler is to be put into service immediately, fill the boiler with clean, treated water and fire the burner until the water has been heated to at least 180°F to drive off any dissolved gases that might otherwise corrode the metal.

20. If the boiler is not to be put into immediate service, refer to the section on boiler layup procedures in this chapter.

750-177 3-7

Chapter 3 Pressure Vessel Care

H. WASHING OUT

Depending on system integrity, feedwater quality, or operating conditions, the water side of the boiler may need to be washed out on occasion.

In theory, a hot water system and boiler that have been initially cleaned, filled with clean, treated water, and with no makeup water added, will require no further cleaning or treatment. However, minor system leaks may allow the admission of additional water or air into the boiler.

Introduction of raw (untreated) makeup water or air to a hot water boiler may lead to pitting, corrosion, or formation of sludge, sediment, or scale on the pressure vessel waterside.

The waterside condition of steam boilers can be likewise affected by feedwater quality, load demands, operating conditions, or blowdown practices.

The waterside of a hot water or steam boiler should be cleaned and inspected no later than three months after the boiler is put into service. Subsequent cleaning of waterside surfaces should be performed as indicated through periodic inspection.

In order to thoroughly wash out the waterside of the pressure vessel, the handhole covers at the ends of the upper and lower drums must be removed. The interior surfaces of the drums should be washed with a high pressure hose. Tubes should be cleaned by directing a high pressure stream of water into the end of each tube, first from the bottom, and then from the top drum.

Note: A washout lance for this purpose is available from your local Cleaver- Brooks authorized representative.

available. Be prepared to perform any testing required by the inspector, including a hydrostatic test.

When shutting down a boiler, the load should be reduced gradually and the pressure vessel should be cooled at a rate that avoids a temperature differential that can cause harmful stresses. Normally, all pressure should be relieved before a vessel is drained in order to prevent uneven contraction and temperature differential that can cause tubes to leak. Draining the unit too quickly may cause the baking of deposits that may be present on the heating surfaces.

Note: Check to see that system valves, feedwater valves, all fuel valves, expansion tank, and electrical switches are shut off prior to opening the handholes or the burner access door. After proper cooling and draining of the vessel, flush out the waterside with a high pressure water stream. Remove any scale or deposits from the waterside surfaces and check for internal or external corrosion or leakage.

Fireside surfaces also should be cleaned so that metal surfaces, welds, joints, tube fittings, and any previous repairs can be readily checked.

WARNING

DANGER

To avoid the hazard of electrical shock, which could cause serious personal injury or death, the use of a low voltage flashlight is recommended during an internal inspection.

Control and water column connections on steam boilers should be checked for accumulated deposits, and cleaned as required.

After waterside cleaning has been completed, replace the handhole covers, using new gaskets.

Note: Handhole cover gaskets are installed dry; that is, without application of a sealing compound.

I. PERIODIC INSPECTION

Insurance regulations or local codes and good maintenance will require that the pressure vessel be inspected periodically by an authorized inspector. Sufficient notice is generally required to allow removal of the boiler from service and preparation for inspection. An internal inspection may be required before cleaning or flushing.

Have the following information available for the inspector: boiler design, dimensions, generating capacity, operating pressure and temperature, time in service, defects found previously, and any repairs or modifications made to the unit. Reference records of previous inspections also should be

3-8 750-177

Fireside Inspection

Access for inspection of the firing chamber, or furnace, is gained through the hinged burner door. Inspection of the upper pass requires removal of the side casing panels and second and fourth pass cover plates. Refer to Chapter 8, Section C, “Fireside Cleaning,” for information regarding outer and inner casing removal.

Fireside tube surfaces should be checked for corrosion or accumulation of soot. Use a vacuum cleaner and wire brush to remove light corrosion or soot.

Localized, heavy corrosion on fireside tube surfaces may indicate a leaking tube or ferrule connection. If a tube or tube ferrule leak is indicated, the source of the leakage must be found and repaired before putting the boiler back in service. A leak from a tube-to-drum connection may require removal and reseating of the tube. A heavily corroded or leaking tube must be replaced in order to assure continued reliable operation of the boiler. Information regarding tube replacement can be obtained from your local Cleaver-Brooks authorized representative.

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CleaverBrooks FLX 150, FLX 250, FLX 200, FLX 400, FLX 450 Operation, Service And Parts Manual

Specifications and Main Features

Frequently Asked Questions

User Manual