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CleaverBrooks CBLE User Manual

CleaverBrooks CBLE
194 pages
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Table Of Contents
Model CBLE
Packaged Boiler
250 - 350 HP
Operation and Maintenance Manual
750-91
12/09
Light OIl, Heavy Oil, Gas, or Combination
Compliments of Power Mechanical, Inc.
Used Boilers
Rental Boilers

Table of Contents

Questions and Answers:

CleaverBrooks CBLE Specifications

General IconGeneral
BrandCleaverBrooks
ModelCBLE
CategoryBoiler
LanguageEnglish

Summary

Basics of Firetube Operation

Introduction

Overview of firetube boilers, their applications, and general information for Cleaver-Brooks Model CBLE boilers.

The Boiler

Description of the Model CBLE boiler's construction, horsepower rating, and firetube characteristics.

Construction

Details on boiler construction standards according to ASME Code for steam and hot water boilers.

Steam Controls (All Fuels)

Explanation of various controls for steam boilers including pressure controls, water column, and safety valves.

Hot Water Controls (All Fuels)

Details on controls for hot water boilers including temperature gauges, limit controls, and low-water cutoff.

IFGR Components

Description of Induced Flue Gas Recirculation (IFGR) system components like ports, dampers, and linkage.

Burner Operation and Control

The Burner

Description of oil and gas burners, their ignition, modulation, and safety interlock controls.

Control and Component Function

Explanation of the term 'control' and the function of various boiler controls and components.

Components Common to All Boilers

List and description of components common to all boilers, such as fan motors, ignition transformers, and detectors.

Controls for Gas Firing

Details on gas train components, including valves, pressure switches, and regulators.

Controls Common to Oil-Fired Boilers

Description of controls applicable to all oil-fired or gas and oil-fired boilers.

Additional Controls for Heavy Oil

Specific controls and components required for heavy oil firing, including oil heaters and thermostats.

Controls for Combination Burners Only

Information on equipment for burners that fire both oil and gas, including the Gas-Oil Selector Switch.

Combustion Air

Explanation of how combustion air is supplied and regulated by the forced draft fan and rotary air damper.

Automatic Ignition

Description of the automatic ignition process for oil or gas burners, including pilot ignition.

Atomizing Air

Details on the primary air supplied by the air pump for atomizing fuel oil.

Oil Fuel Flow: Light Oil

Explanation of fuel oil delivery and flow for light oil burners, including the fuel oil controller.

Oil Fuel Flow: Heavy Oil

Description of fuel oil delivery and flow for heavy oil burners, including preheating systems.

Gas Fuel Flow

Explanation of metered gas flow through the pressure regulator and gas train to the burner.

Modulating Firing

How the modulating motor controls air damper and fuel valves for constant air/fuel ratio.

Waterside Care and Requirements

Overview

Importance of water supply and treatment for boiler life and service. Feedwater equipment checks.

Water Requirements: Hot Water Boiler

Specific water requirements for hot water boilers, including air removal and minimum temperatures.

Water Requirements: Steam Boiler

Water requirements for steam boilers, including feed pump operation and water level controls.

Water Treatment

Objectives and methods of boiler water treatment to prevent scale, corrosion, and foaming.

Cleaning

Procedures for cleaning hot water and steam piping, and the pressure vessel waterside.

Boil-Out of a New Unit

Procedure for cleaning new boilers to remove manufacturing residues like oil and grease.

Washing Out

Methods for washing out hot water and steam boilers and flushing the pressure vessel interior.

Blowdown: Steam Boiler

Explanation of boiler water blowdown, including intermittent manual and continuous blowdown.

Periodic Inspection

Guidelines for periodic inspection of the pressure vessel and other boiler components.

Preparation for Extended Lay-Up

Procedures for preparing boilers for extended periods of non-use, including wet and dry storage methods.

Sequence of Operation

Overview

Outline of electrical sequencing for burner cycles: pre-purge, ignition, run, and shutdown.

Circuit and Interlock Controls

Description of burner control circuits and interlocks, including limit and proving circuits.

Sequence of Operation: Oil or Gas

Detailed sequence of operation for oil or gas firing, covering pre-purge, ignition, and run cycles.

Flame Loss Sequence

Explanation of the burner's response to flame loss, including safety shutdowns and lockout.

Starting and Operating Instructions

Preparation for Startup: All Fuels

Pre-startup checks for electrical, fuel, and water connections, and system readiness.

Control Settings: Steam and Hot Water

Instructions for setting operating limit, high limit, and modulating controls for steam and hot water.

Gas Pilot

Procedures for checking and adjusting the gas pilot flame for satisfactory performance.

Atomizing Air

Checks for atomizing air supply and pressure on oil-fired burners before starting.

Firing Preparations for No. 2 Oil (Series 100 - 200)

Steps for establishing oil flow, pressure, and atomizing air for No. 2 oil firing.

Firing Preparation for No. 6 Oil (Series 400 - 600)

Procedures for establishing oil flow, pressure, and temperature for No. 6 oil firing.

Firing Preparations for Gas (Series 200-400-700)

Steps for preparing gas burners, including linkage checks and gas availability verification.

IFGR Setup

Guidance on setting up and adjusting the Induced Flue Gas Recirculation (IFGR) system.

Startup, Operating and Shutdown: All Fuels

Instructions for boiler startup, operation, and shutdown procedures for all fuel types.

Control Operational Test and Checks

Procedures for verifying and testing the proper operation of boiler controls.

Adjustment Procedures

Overview

Explanation of why adjustments may be necessary after installation for optimal efficiency.

Linkage: Modulating Motor and Air Damper

Procedures for adjusting the linkage connecting the modulating motor, air damper, and cams.

Modulating Motor

Information on the modulating motor's stroke and proper installation of replacements.

Modulating Motor Switches: Low-Fire and High-Fire

Details on the modulating motor's internal switches and their adjustment based on application.

Burner Operating Controls: General

Explanation of high limit, operating limit, and modulating controls for burner operation.

Modulating Pressure Control: Steam

Procedure for setting the modulating pressure control for steam boilers.

Operating Limit Pressure Control: Steam

Instructions for setting the cut-out and differential for steam boiler operating limit controls.

High Limit Pressure Control: Steam

Procedure for setting the high limit pressure control for steam boilers.

Modulating Temperature Control: Hot Water

How to adjust the modulating temperature control for hot water boilers.

Operating Limit Temperature Control: Hot Water

Setting the cut-out and differential for hot water boiler operating limit temperature controls.

High Limit Temperature Control: Hot Water

Procedure for setting the high limit temperature control for hot water boilers.

Low Water Cutoff Devices: Steam & Hot Water

Information on low water cutoff devices, noting no adjustment is typically required.

Combustion Air Proving Switch

Procedure for adjusting the combustion air proving switch for proper operation.

Atomizing Air Proving Switch

Adjustment procedure for the atomizing air proving switch.

Gas Pilot Flame Adjustment

Instructions for adjusting the gas pilot flame size for proper ignition and flame detection.

Gas Pressure and Flow Information

Information on regulating gas pressure and flow for efficient combustion.

Gas Fuel Combustion Adjustment

Procedure for adjusting air/fuel ratios using a combustion analyzer for optimal efficiency.

Standard Burner Low-Fire Adjustment

Procedure for adjusting the low-fire fuel input for standard burners.

High Turndown Burner Low-Fire Adjustment

Low-fire adjustment for high turndown burners, including IFGR considerations.

Low-Gas Pressure Switch

Procedure for adjusting the low-gas pressure switch setting.

High-Gas Pressure Switch

Procedure for adjusting the high-gas pressure switch setting.

Fuel Oil Pressure and Temperature: General

General considerations for adjusting fuel oil pressure and temperature for optimal combustion.

Fuel Oil Combustion Adjustment

Adjusting air/fuel ratios for efficient combustion of fuel oil using a combustion analyzer.

Burner Drawer Adjustment

Checks and adjustments for burner drawer components, including diffuser and nozzle location.

Oil Drawer Switch

Ensuring the oil drawer switch is properly positioned for oil firing.

Low Oil Temperature Switch

Procedure for adjusting the low oil temperature switch.

High Oil Temperature Switch (Optional)

Adjustment procedure for the optional high oil temperature switch.

Low Oil Pressure Switch (Optional)

Procedure for adjusting the optional low oil pressure switch.

Electric Oil Heater Thermostat (400 and 600 Series: Steam)

Setting the electric oil heater thermostat for steam applications.

Steam Oil Heater Thermostat: No. 6 Oil (400 and 600 Series: Steam)

Setting the steam oil heater thermostat for No. 6 oil.

Hot Water Oil Heater Thermostat (400 and 600 Series)

Adjusting the thermostat for hot water oil heaters.

Steam Heater Pressure Regulator (400 and 600 Series: Steam)

Procedure for adjusting the steam heater pressure regulator for steam applications.

Troubleshooting

Overview

General guidelines for troubleshooting boiler issues, emphasizing safety and familiarization.

Inspection and Maintenance

Overview

Importance of planned maintenance for safety, efficiency, and reliability.

Periodic Inspection

Requirements and guidelines for periodic inspections of the boiler and its components.

Fireside Cleaning

Procedures for cleaning fireside surfaces to maintain heat transfer and prevent corrosion.

Water Level Controls

Importance of checking water level controls and the need for periodic maintenance.

Water Gauge Glass

Instructions for replacing and maintaining the water gauge glass.

Electrical Controls

Inspection and maintenance of electrical controls, including connections and switches.

Flame Safety Control

Maintenance and testing procedures for the flame safety control system.

Oil Burner Maintenance

Inspection and maintenance tasks for oil burner components like diffusers and nozzles.

Gas Burner Maintenance

Inspection of gas burner components for damage due to improper combustion.

Motorized Gas Valve

Checking the proper operation of the motorized gas valve.

Solenoid Valves

Maintenance considerations for solenoid valves, focusing on potential leakage and noise.

Air Control Damper, Linkage, and Cam Spring

Checking air control damper, linkage, and cam spring for free movement and wear.

Forced Draft Fan

Importance of fan housing position and clearance for output capacity. Installation and adjustment.

Fan/Motor Cassette Removal

Procedures for safely removing the fan/motor cassette for access to internal components.

Inspection and Adjustment

Checking NOx levels, linkages, and damper for proper operation and compliance.

Airbox Gasket Installation

Instructions for installing the airbox gasket after servicing the fan/motor cassette.

Fan/Motor Cassette Installation

Procedure for reinstalling the fan/motor cassette, ensuring proper alignment and sealing.

Safety Valves

Attention to safety valves for proper operation, testing, and avoiding excessive use.

Fuel Oil Metering Valve, Adjusting, and Relief Valves

Maintenance for fuel oil metering valve packing, adjusting, and relief valves.

Air Pump and Lubricating System

Maintenance of the air pump and lubricating system, including oil levels and filters.

Combustion

Importance of air-fuel ratio adjustments for efficiency and using a combustion analyzer.

Recommended Boiler Inspection Schedule

A schedule outlining daily, monthly, semi-annually, and annually inspection tasks.

Parts

Ordering Parts

Information required when ordering parts, emphasizing complete nameplate data.

Parts Lists and Drawings

Detailed parts lists and diagrams for various boiler components and systems.

Air Compressor and Piping

Parts list and drawing for the air compressor and associated piping.

Side Mounted Air Compressor Piping

Bill of material and drawing for side-mounted air compressor piping.

Air Line Piping

Parts list and diagram for the air line piping system.

Burner Housing Support & Front Head Plt

Parts list and drawing for the burner housing support and front head plate assembly.

Control Panel

Parts list and diagram for the boiler control panel.

Entrance Box

Parts list and drawing for the boiler entrance box.

Front Head (Electrical)

Parts list and diagram for the front head, focusing on electrical components.

Front Davit

Parts list and drawing for the front davit assembly.

Front Head Insulation

Parts list and diagram for the front head insulation.

Front Head Linkage

Parts list and diagram for the front head linkage assembly.

Gas Train

Parts list and diagram for the gas train components.

Light Oil/Air Piping

Parts list and diagram for the light oil and air piping system.

Heavy Oil/Air Piping

Parts list and diagram for the heavy oil and air piping system.

Heavy Oil Alstrom Heater

Parts list and diagram for the heavy oil Alstrom heater.

CB-LE IFGR

Parts list and diagram for the CB-LE Induced Flue Gas Recirculation (IFGR) system.

IFGR Impeller

Parts list and diagram for the IFGR impeller.

Pressure Controls

Parts list and diagram for various pressure controls.

Temperature Controls

Parts list and diagram for various temperature controls.

W.C. - Main & Aux.

Parts list and diagrams for Water Column (W.C.) main and auxiliary components.

Vessel Handholes & Manways

Parts list and diagrams for vessel handholes and manways.

Rear Head Sealing - Davit

Parts list and diagram for rear head sealing and davit assembly.

Throat Tile and Furnace Liner

Parts list and diagrams for throat tile and furnace liner components.

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