Cleaver-Brooks . $25.00 U.S CLEAVER-BROOKS IFGR Retro-Fit 250 - 800hp. Installation Instructions Induced Flue Gas Recirculation Manual Part No.
Cleaver-Brooks SAFETY PRECAUTIONS AND ABBREVIATIONS Abbreviations Following is an explanation of the abbreviations, acronyms, and symbols used in this manual. Safety Precautions 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.
Cleaver-Brooks CLEAVER-BROOKS IFGR Retro-Fit 250 - 800 hp Installation Instructions Induced Flue Gas Recirculation © Cleaver-Brooks 1997, 1998 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative. Manual Part No. 750-181 2/98 Printed in U.S.A.
Cleaver-Brooks ! WARNING DANGER DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF THE APPROPRIATE OPERATION AND MAINTENANCE MANUAL. DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY UNDERSTAND ALL APPLICABLE SECTIONS OF the appropriate Operation and Maintenance MANUAL. FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE PERONAL INJURY OR DEATH.
Cleaver-Brooks Table Of Contents 78” IFGR General Information ................................................................................................................................ 1-1 78" Model CB ........................................................................................................................................ 1-2 Boiler applications: ..................................................................................................................................
Cleaver-Brooks Table Of Contents 96” IFGR General Information .........................................2-1 Boiler Preparations: .........................................2-2 Site Preparations: .............................................2-3 Components Supplied ......................................2-4 Major Installation Field Tasks. ........................2-6 List of Figures Fan Motor Mounted on the Front Head........... 2-1 IFGR Linkage Requires Manual Change for Dual Fuel Units 3/4” Jackshaft.........
Installation Instructions IFGR RETROFIT General Information This manual identifies the installation of the Induced Flue Gas Recirculation (IFGR) systems for retrofit applications. These systems are used on 78" Model CB firetube dryback boilers (250 350hp). They are designed to provide a NOx performance of under 30 ppm (3% O2, dry basis) when firing natural gas. blanket insulation firmly held in place with wire mesh, retainers and rigidizer. Loose insulation could cause blockage of the burner air flow.
78” IFGR RETROFIT BOILER PREPARATIONS: Note: the boiler should be in good condition, with no ma jo r modifications to the original design. Components that are worn or in poor condition should be replaced or repaired. • This conversion is designed for burners firing natural gas, light oil (ASTM #1 or #2 oil) or a combination burner firing light oil or gas. Application of other gaseous fuels must be approved by Cleaver-Brooks. Figure 3: High Turndown Oil Gun.
78” IFGR RETROFIT SITE PREPARATION: • The stack draft (pressure) must be between -0.25” and +.25” (measured in inches of water column). The draft must also be consistent, providing the same amount of draft at any given firing rate, repeatable within 0.1" (measured at the stack temperature coupling). • Larger combustion air motors are required to provide the IFGR and maintain the rated boiler capacity.
78” IFGR RETROFIT Components Supplied. Figure 7: Aspirator Piping • New combustion air fan (impeller) and mounting hardware (see Figure 5). • New combustion air motor, and motor starter (see Figure 5). • IFGR piping for flue gas duct assembly (see Figure 6). • Aspirate line components (see Figure 7). • Modified air inlet assembly, to accept the IFGR duct (see Figure 8). • Front head insulation and mounting components (see Figure 9). A.Front door insulation, glue, wire mesh and retaining clips.
78” IFGR RETROFIT Figure 11: Optional Items; Burner Housing, High Turndown Burner and Diffuser and Fan Motor Options • Replacement gas burner housing. • High turndown burner. • The normal variations in motor options (high efficiency, TEFC, etc.) are available. Major Installation Field Tasks. ! WARNING DANGER Disconnect and lock out the main power to the boiler and the fuel supply to the burner before the front head is opened.
78” IFGR RETROFIT ! WARNING DANGER The insulation must be firmly attached to the door using high temperature glue, wire mesh, retainer studs and clips, to insure that the high air velocities will not allow the insulation to come loose and plug the burner air flow. Failure to properly attach the insulation can result in serious personal injury or death 4. Install the new fan and motor assembly. The fan and motor will be larger than the existing fan and motor to accommodate the IFGR flow.
78” IFGR RETROFIT BILL OF MATERIAL ITEM REQ'D PART NO. 1 1 530-C-472 2 1 507-C-7527 3 1 880-A-617 4 1 880-A-615 5 1 858-56 6 1 465-C-1680 (SEE NOTE 5) DESCRIPTION AIR INLET ASS'Y, MODIFIED FOR INDUCED FGR PIPING ASSEMBLIES, INDUCED FGR (3 SECTIONS) HARDWARE KIT-INDUCED FGR PIPING W/ ORIFICE PLATES PIPING KIT- ASPIRATION PIPING W/ GATE VALVE COUPLING, FULL, 2" FORGED STEEL INSULATION, FRONT HEAD INTERIOR, 78" DIA. EXISTING STACK 3-1/16" DIA. HOLE FOR ITEM #5 6-3/4" DIA. HOLE THRU EXISTING STACK.
78” IFGR RETROFIT 3-1/16" DIA. HOLE FOR ITEM #5 5 4" SEAL 1/8" 10-1/2" 4 8-1/2" 1 SEAL 1/4" 2 SEAL2 PLACES 1/8" TYP. 3 REF. ORIFICE SEAL 1/8" 1 6 SIDE VIEW Figure 13: Retrofit-Induced FGR-78” Dia.
78” IFGR RETROFIT 3/4"-4" 1/8" 5 Figure 14: Insulation, Front Head 78" LE SECTION VIEW OF FIGURE 15 750-181 1-9
78” IFGR RETROFIT 30 PPM 465-1680 ITEM REQ. 1 57 SQ FT 2 150 3 150 128 OZ 4 5 2 6 2 57 SQ FT 7 78" GENERAL BILL OF MATERIAL PART NO. 872-688 903-297 828-39 872-512 971-355 971-355 930-57 DESCRIPTION BULK INSULATION, INSULWOOL, 1/4" THK, PIN, WELDING, #10 GA. X 2-1/2" LG. ST. STL. CLIP, WELDING ST. STL ADHESIVE, SCOTCHGRIP #42NF STRIP, 14 GA. x 1-1/2" x 32-1/2" LG. STRIP, 14 GA. x 1-1/2" x 9-1/2" LG. SCREEN 1/2" 19 GA. GALV. "A" 5 TYP 45° TYP.
78” IFGR RETROFIT 14 13 12 11 6 7 1 2 4 8 3 9 10 5 18 19 BLOWER MOTOR SEE NOTE 1 1/32" 15 16 17 TABLE ITEMS 2 3 4 & 5 50-60 HZ. ITEM QTY PART NO. DESCRIPTION CB 300 CB 250 CB 350 1 1 IMPELLER GAS OIL/COMB.
78” IFGR RETROFIT 180 168 152 144 136 128 120 160 192 176 184 200 208 216 224 232 240 248 112 104 256 3 96 90 FIGURE 17: SPUD ARRANGEMENT FOR 300 AND 350 HP 4 264 2 272 280 270 88 80 72 288 64 296 56 48 40 304 312 320 32 24 336 16 16 328 NO HOLE ON BOTTOM 0 CENTERLINE NOTES! 1. SPUD PATTERN SHOWN IS AS VIEWED FROM FRONT OF BOILER, THROUGH THE HOUSING. 2. APPLY NEVER SEEZ COMPOUND, ITEM 1 , TO SPUDS AND PLUGS BEFORE INSTALLING.
INSTALLATION INSTRUCTIONS IFGR Retrofit GENERAL INFORMATION: This manual identifies the installation instructions for the Induced Flue Gas Recirculation (IFGR) systems used on retrofit applications. These systems are used on Model CB firetube dryback boilers (400-800 hp) produced after approximately 1970. They are designed to provide a NOx performance of under 30 ppm (3% O2, dry basis) when firing natural gas. The equipment is designed to be installed in the field on existing boilers.
96” IFGR Retrofit BOILER PREPARATIONS: Note: The boiler should be in good condition, with no major modifications to the original design. Components that are worn or in poor condition should be replaced or repaired. • The IFGR conversion is designed for burners firing natural gas, light oil (ASTM #1 or #2 oil) or a combination burner firing light oil or gas. Application of other gaseous fuels must be approved by Cleaver-Brooks. The IFGR conversion should not be made to a burner that will burn heavy oils.
96” IFGR Retrofit Figure 6: High Turndown Nozzle Parts. Figure 7: Larger Motors May Be Required SITE PREPARATIONS: • The stack draft at the boiler outlet must be between -0.25” and +0.25” water column. The draft must also be consistent, providing the same draft at any given firing rate, repeatable within 0.1" water column. • Larger combustion air motors are required to provide for both IFGR and combustion air delivery in order to maintain the rated boiler capacity.
96” IFGR Retrofit COMPONENTS SUPPLIED: • New combustion air fan (impeller) and mounting hardware. • New combustion air motor and mounting hardware (if required). • IFGR duct and related hardware. Front Head Insulation Combustion Air Fan IFGR Duct • Linkage to connect the jackshaft to the IFGR duct. Front Baffle • 3/4” jackshaft with extended length for the IFGR linkage connection. • Components to rework the front baffle. • Gas burner spuds (for fuel series 200 and 700) if not on the existing burner.
96” IFGR Retrofit 1.641" (APPROX) ADJUST TO ACQUIRE THE SPECIFIED IMPELLER TO IMPELLER HOUSING GAP, DIM "C" SPACER "A" 3-5/8" REF. NUT WASHER SPACER "B" +0.010 0.050 -0.005 MOTOR MOTOR SPACER FAN LAYOUT 96" "CB" USING NEW DESIGN THREADED SHAFT Figure 11: Impeller Assembly Table 1: Impeller Retainer Part Numbers and Size Requirements. MOTOR SHAFT IMPELLER IMPELLER HP SIZE SPACER "A" SPACER "B" NUT WASHER MOTOR SPACER 1-3/8" 77-478 (1/4") 77-478 (1/4") 869-177 952-225 NOT REQ.
96” IFGR Retrofit MAJOR FIELD INSTALLATION TASKS. The following outline covers the installation of major IFGR components. This work must be performed by qualified individuals who are trained in the installation and setup of low emission Cleaver-Brooks burners. In addition, other skills are required to perform welding, wiring and other tasks. It is the installers responsibility to insure that properly trained individuals are performing the work.
96” IFGR Retrofit NOTE: THIS MODIFICATION IS REQUIRED ONLY WHEN THE MOTOR FRAME SIZE INCREASES FROM 286TD OR SMALLER, TO 324TD OR LARGER. #7 (.201) DRILL TAP 1/4"-20UNC (2) HOLES 20" 1-1/4" 1-1/4" 21/32" DRILL, TAP 3/4"-10 UNC (4) HOLES, EQUALLY SPACED ON A 16" DIA. B.C. FOR STUDS. 45° "A" 14" (REF.) 5" 14-1/16" ±1/32" DIA. HOLE "A" 6" STUDS TO BE FLUSH WITH INSIDE FACE OF FRONT HD. SECTION "A-A" FRONT HEAD CL 1-1/8" DIA.
96” IFGR Retrofit 3. The next step is to insulate the front head. The insulation covers the lower portion of the head, as shown in Figures 14 and 15. ! WARNING DANGER The insulation must be completely and firmly attached to the door, so that the high air velocities will not allow it to come loose. Failure to properly attach the insulation can result in serious personal injury or death 3/4"-4" 1/8" 5 Figure 14: Insulation and Wire Mesh Installed Inside Front Head.
96” IFGR Retrofit • Check the front door for unused openings. These must be closed to prevent recirculated flue gases from escaping into the boiler room. and glue it in place. • Cut away the insulation around the air proving switch, rear door sight glass cooling line, the IFGR linkage, and any other required opening. • Retainer strips are used to hold the edge of the insulation in place at the fan outlet, due to the high air velocities at the fan outlet.
96” IFGR Retrofit 4. Modify the inner door for the IFGR control valve fit-up and allow the baffle to go below the control valve opening. • Remove the insulation from the inner door as shown on Figure 17, to provide a 14 1/4” opening below the baffle. • Cut an 11” diameter hole in the steel portion of the door, as shown in Figures 16 and 17. • Remove the flat bar from the inner door baffle location as shown on Figure 17 to make room for the new baffle location. Remove a 6 3/8” section from the upper bar.
96” IFGR Retrofit 12-1/2" INSIDE 5. Modify the front baffle to provide a space for the IFGR control valve to pull gases from the end of the fourth pass. • Cut a 7 1/8” by 12 3/4” section out of the baffle, as shown on Figure 18. Also insure that the center bolts are no longer than 1 1/4” by cutting off any additional length. 1 6-1/4" 9/32" DIA. (11) HOLES 1" 8 2 9/16" • Weld the steel section to the baffle where the cutout has been made.
96” IFGR Retrofit 6. Windbox modification for the IFGR control valve and linkage • Remove and discard the cover of the back of the windbox. • Drill three holes in the bottom of the windbox for the linkage and bearing block mounting, as shown on Figure 20. Install the bearing block, item 2 on Table 4 and figure 25. • Install the IFGR control valve and cover plate, as shown on Figures 19 and 23. The valve shaft must pass through the bottom of the windbox (bearing block).
96” IFGR Retrofit Table 4: Parts List for IFGR Valve Installation. ITEM REQ. PART NO. 1 2 3 4 1 1 1 1 SEE TABLE 306-C-79 19-C-1328 872-278 5 6 1 1 797-2374 32A2556 7 8 9 2 2 2 868-405 869-21 952-294 10 11 2 952-92 869-36 8 8 8 12 13 14 15 1 1 16 17 18 1 1 4 19 20 4 21 BEARING PLATE ASSEMBLY COVER PLATE, AIR DUCT INSULATION, BLANKET 1" X 18" O.D. (SEE NOTE) ADHESIVE GASKET, DAMPER IFGR CAPSCREW, HEX. HD. 1/4"-20 X 7/8" LG. NUT, HEX. 1/4"-20 WASHER, FLAT 1/4" LOCKWASHER, 1/4" NUT, HEX.
96” IFGR Retrofit inner door, and insure that no insulation breaks free and plugs the valve or burner opening. Figure 24: Dual Position Linkage 7. There are two linkage styles used for IFGR systems, a single position drive used for single fuels (see Figure 27) and a dual position drive used for dual fuels (see Figure 28).The dual position drive allows for two different FGR flow rates, matching the combustion requirements for each fuel. (see Figure 24).
96” IFGR Retrofit IFGR DAMPER ASS'Y. (REF.) SEE NOTE #1 3 FRONT HEAD (REF.) 6 SEE NOTE #1 SEE NOTE #1 10 NOTE: 4 1 5 7 1.) REFER TO INITIAL IFGR SETTINGS Table 8, page 21 PLAN VIEW 2 FRONT HEAD (REF.) 9 1 8 1 IFGR DAMPER ASS'Y. (REF.) 3 SEE NOTE #1 2 6 SEE NOTE #1 5 3 2 7 10 6 10 4 SEE NOTE #1 SIDE VIEW 8" FRONT VIEW 9-3/8" 7 5 Figure 27: Linkage Assembly for IFGR Retrofit SINGLE FUEL Table 5: Linkage Assembly Part Numbers and Description SINGLE FUEL ITEM REQ.
96” IFGR Retrofit NOTES: 1. REFER TO TABLE 8, PAGE 21 FOR INITIAL IFGR SETTINGS. 2. ATTACH CONDUIT ADAPTER, ITEM 19, TO PROXIMITY SWITCH, ITEM 18, AND RUN PROXIMITY SWITCH WIRES THROUGH NON-METALLIC CONDUIT, ITEM 30. IFGR DAMPER ASS'Y. (REF.) SEE NOTE #1 3 FRONT HEAD 6 (REF.
96” IFGR Retrofit Table 6: Linkage Assembly Part Numbers and Description DUAL FUEL ITEM REQ. PART NO. 1 2 3 4 5 6 7 8 9 1 1 1 1 2 1 4 2 2 427-C-251 67-A-798 476-C-223 974-42 2-A-332 287-A-50 860-39 868-136 952-92 10 11 12 13 14 15 16 17 18 19 2 1 1 1 2 1 1 1 1 860-101 883-70 869-22 952-93 NOT USED 952-106 2-A-333 2-A-334 836-1032 848-1158 20 21 2 1 848-1159 848-1160 DESCRIPTION DAMPER CONTROL, SHAFT ASSEMBLY LINKAGE ASSEMBLY, JACKSHAFT LINKAGE ASSEMBLY, DAMPER JACKSHAFT, 3/4" DIA. X 47-1/2"" LG.
96” IFGR Retrofit Table 7: Gas Spud Description and Part Numbers 400 HP. ASS'Y 090 1627 500 HP. 600 HP. ASS'Y 090 1623 ASS'Y 090 1624 700 & 800 HP. ASS'Y 090 1626 ITEM REQ. PART NO. REQ. PART NO. REQ. PART NO. REQ. PART NO.
96” IFGR Retrofit 180 152160 144 136 128 Figure 30: Spud Pattern CB 500 h.p. (#090 1623). 168 176184 192 120 200208 216 224 232 240 112 248 104 256 96 90 88 80 6 2 3 5 264 272 280 72 288 64 Note: Spud patterns shown as viewed from the front of the boiler 296 56 304 312 320 328 336 48 40 32 24 NO HOLE ON BOTTOM CENTERLINE 180 152 176 184 192 160 168 200 208 144 216 224 136 128 232 120 Figure 31: Spud Pattern CB 600 h.p. (# 090 1624).
96” IFGR Retrofit 180 152 160 168 176184192 200 144 136 128 Figure 32: Spud Pattern CB 700 & 800 h.p. (# 090 1626).
96” IFGR Retrofit Table 8: Initial Settings for Setup of the IFGR System of Standard CB Boilers 400-800 hp.
96” IFGR Retrofit "E" (LINKAGE CONNECTION POINT) 5 "F" 4 3 2 1 1 2 3 4 5 6 7 8 "G" "H" (LINKAGE CONNECTION POINT) FRONT VIEW Figure 35: Damper Control Shaft Settings. "C" 1 2 "B" "D" (LINKAGE CONNECTION POINT) COLLAR ASSEMBLY "A" PLAN VIEW Figure 36: Damper Settings. GAS ARM "J" OIL & SENSOR ARMS "K" SIDE VIEW Figure 37: Jackshaft Arm Settings.
96” IFGR Retrofit BURNER SETUP The burner setup and adjustments are defined in the CB-LE Firetube Operation and Maintenance manual (750-94). Burner setup and adjustments should only be performed by a combustion technician trained in low emission Firetube burner setup and adjustment • NOx levels on natural gas will be less than 30 ppm (corrected to 3% Oxygen, dry basis) throughout the operating range. There are no NOx emission guarantees for oil firing.
96” IFGR Retrofit Notes 2-24 750-181
NOTES
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