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CleaverBrooks CBLE User Manual
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Manual P
ar
t No. 750-91
12/09
P
rinted in U.S.A.
Cleaver-Brooks 2009
CLEA
VER-BROOKS
Model CBLE
250-350 HP
Light Oil, Heavy Oil,
Gas, or Combination
Operation and Maintenance Manual
2
4
Table of Contents
Default Chapter
5
Table of Contents
5
CHAPTER 1 Basics of Firetube Operation
15
Introduction
15
The Boiler
17
Construction
18
Steam Controls (All Fuels)
19
Operating Limit Pressure Control
19
High Limit Pressure Control
19
Modulating Pressure Control
20
Low Water Cutoff and Pump Control
20
Water Column Assembly
20
Water Column Drain Valve
21
Water Gauge Glass Drain Valve
21
Vent Valve
21
Stack Temperature Gauge
21
Auxiliary Low-Water Cutoff
21
Safety Valve(S)
21
Hot Water Controls (All Fuels)
23
Water Pressure and Temperature Gauge
23
Operating Limit Temperature Control
23
High Limit Temperature Control
23
Modulating Temperature Control
23
Low-Water Cutoff
23
Auxiliary Low-Water Cutoff (Optional)
24
Safety Valve(S)
24
IFGR Components
24
Flue Gas Transfer Port, IFGR Damper, & Flange Collar
24
IFGR Damper Linkage
24
Over-Travel Mechanism
25
Fuel Change-Over Linkage
25
Fan/Motor Cassette
26
Burner Drawer
26
Combustion Air Inlet
26
Front Door Insulation
26
Revised 2009)
27
CHAPTER 2 Burner Operation and Control
27
The Burner
27
Control and Component Function
28
Components Common to All Boilers
28
Controls for Gas Firing
30
Controls Common to Oil-Fired Boilers
34
Additional Controls for Heavy Oil
38
Controls for Combination Burners Only
40
Combustion Air
41
Automatic Ignition
41
Atomizing Air
42
Oil Fuel Flow: Light Oil
42
Oil Fuel Flow: Heavy Oil
44
Gas Fuel Flow
46
Modulating Firing
46
CHAPTER 3 Waterside Care and Requirements
49
Overview
49
Water Requirements: Hot Water Boiler
49
Air Removal
49
Minimum Water Temperature
50
Rapid Replacement of Boiler Water
50
Continuous Flow through the Boiler
50
Water Circulation
50
Multiple Boiler Installations
51
Pump Location
52
Pump Operation
52
Pressure
52
Water Requirements: Steam Boiler
53
Feed Pump Operation
53
Water Feeder (Optional) Operation
54
Water Treatment
54
Cleaning
55
Hot Water and Steam Piping
55
Pressure Vessel
55
Boil-Out of a New Unit
56
Washing out
58
Hot Water Boiler
58
Steam Boiler
58
Flushing of Pressure Vessel Interior
58
Blowdown: Steam Boiler
58
Intermittent Manual Blowdown
59
Continuous Blowdown
59
Frequency of Manual Blowdown
59
Manual Blowdown Procedure
60
Periodic Inspection
61
Preparation for Extended Lay-Up
62
Sequence of Operation
65
Overview
65
CHAPTER 4 Sequence of Operation
65
Circuit and Interlock Controls
66
Sequence of Operation: Oil or Gas
67
Pre-Purge Cycle
67
Ignition Cycle
68
Run Cycle
68
Revised 2009)
68
Flame Loss Sequence
69
Burner Shutdown: Post Purge
69
Loss of Flame
70
No Pilot Flame
70
Pilot but no Main Flame
70
CHAPTER 5 Starting and Operating Instructions
73
Preparation for Startup: All Fuels
73
Control Settings: Steam and Hot Water
74
Operating Limit Control
74
High Limit Control
74
Modulating Control
75
Low-Water Cutoff and Pump Control
75
Additional Considerations
75
Gas Pilot
75
Atomizing Air
76
Firing Preparations for No. 2 Oil (Series 100 - 200)
77
Oil Flow
77
Oil Pressure
78
Starting
79
Firing Preparation for No. 6 Oil (Series 400 - 600)
79
Oil Flow
79
Oil Pressure
80
Oil Temperature
80
Starting
81
Firing Preparations for Gas (Series 200-400-700)
81
IFGR Setup
83
Startup, Operating and Shutdown: All Fuels
85
Operating
86
Shutdown
87
Control Operational Test and Checks
87
Adjustment Procedures
89
Overview
89
High Turndown Burner
89
CHAPTER 6 Adjustment Procedures
89
Linkage: Modulating Motor and Air Damper
90
Modulating Motor
92
Modulating Motor Switches: Low-Fire and High-Fire
92
Burner Operating Controls: General
93
Modulating Pressure Control: Steam
96
Operating Limit Pressure Control: Steam
96
High Limit Pressure Control: Steam
96
Modulating Temperature Control: Hot Water
96
Operating Limit Temperature Control: Hot Water
97
High Limit Temperature Control: Hot Water
97
Low Water Cutoff Devices: Steam & Hot Water
98
Combustion Air Proving Switch
98
Atomizing Air Proving Switch
98
Gas Pilot Flame Adjustment
99
Measure and Adjust Pilot
99
Gas Pressure and Flow Information
100
Pressure
100
Gas Flow
103
Pressure Correction
103
Checking Gas Flow
104
Gas Fuel Combustion Adjustment
104
Standard Burner Low-Fire Adjustment
108
High Turndown Burner Low-Fire Adjustment
109
Revised 2009)
109
Low-Gas Pressure Switch
109
High-Gas Pressure Switch
109
Fuel Oil Pressure and Temperature: General
110
Fuel Oil Combustion Adjustment
111
Standard Burner Low-Fire Adjustment: Heavy Oil
113
High Turndown Burner Low-Fire Adjustment: Light Oil
113
Burner Drawer Adjustment
113
Oil Drawer Switch
114
Low Oil Temperature Switch
115
High Oil Temperature Switch (Optional)
115
Low Oil Pressure Switch (Optional)
115
Electric Oil Heater Thermostat (400 and 600 Series: Steam)
115
Steam Oil Heater Thermostat: No. 6 Oil (400 and 600 Series: Steam)
116
Hot Water Oil Heater Thermostat (400 and 600 Series)
116
Steam Heater Pressure Regulator (400 and 600 Series: Steam)
116
CHAPTER 7 Troubleshooting
117
Overview
117
CHAPTER 8 Inspection and Maintenance
121
Overview
121
Periodic Inspection
122
Fireside Cleaning
122
Water Level Controls
123
Steam Boiler
123
Hot Water Boiler
123
Water Gauge Glass
124
Electrical Controls
124
Flame Safety Control
126
Checking Pilot Flame Failure
126
Checking Failure to Light Main Flame
127
Checking Loss of Flame
127
Oil Burner Maintenance
127
Oil Strainers
127
Light Oil Strainers
127
Heavy Oil Strainers
128
Cleaning the Oil Nozzle
128
Cleaning Air Purge Nozzle (No. 6 Oil) and Back Pressure Orifice Nozzle (No. 2 Oil)
129
Ignition System
129
Gas Burner Maintenance
129
Motorized Gas Valve
130
Solenoid Valves
130
Air Control Damper, Linkage, and Cam Spring
131
Forced Draft Fan
132
Fan/Motor Cassette Removal
134
Inspection and Adjustment
135
Airbox Gasket Installation
136
Fan/Motor Cassette Installation
137
Safety Valves
138
Fuel Oil Metering Valve, Adjusting, and Relief Valves
138
Air Pump and Lubricating System
140
Air Compressor
140
Lubricating Oil
140
Lubricating Oil Strainer and Cooling Coil
141
Air Cleaner
141
Air-Oil Tank
141
Lube Oil Cooling Coil
142
Flexible Coupling Alignment
142
Air Compressor Replacement
144
Dismantling
144
Reassembly
144
Refractory
145
Furnace Liner
146
Throat Tile and Liner Installation
147
Installation
148
Head Inspection and Maintenance
149
Front Head
150
Rear Door
151
Closing and Sealing
153
Lubrication
153
Electric Motors
153
Control Linkage
154
Solenoid and Motorized Valves
154
IFGR Lubrication
155
Oil Heater: Electric, Steam, Hot Water
155
Combustion
156
Recommended Boiler Inspection Schedule
157
Parts
159
Ordering Parts
159
CHAPTER 9 Parts
159
Parts Lists and Drawings
160
Air Compressor and Piping
160
Side Mounted Air Compressor Piping
161
Air Line Piping
162
Burner Housing Support & Front Head Plt
163
Burner Housing Support & Front Head Plt
164
Control Panel
166
Entrance Box
167
Front Head (Electrical)
168
Front Davit
169
Front Head Insulation
170
Front Head Linkage
171
Gas Train
173
Light Oil/Air Piping
175
Heavy Oil/Air Piping
177
Heavy Oil Alstrom Heater
178
Cb-Le Ifgr
180
IFGR Impeller
182
Pressure Controls
183
Temperature Controls
184
W.C. - Main & Aux
185
Vessel Handholes & Manways
187
Rear Head Sealing - Davit
188
Throat Tile and Furnace Liner
190
Revised 2009)
190
4
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CleaverBrooks CBLE Specifications
General
Brand
CleaverBrooks
Model
CBLE
Category
Boiler
Language
English
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