Man Hours 3
Special Instructions.
1. Review Manufacturers Instructions.
Items to Check & Initial Completion:
1. ___ Test and inspect burner (with or without firing) at rated pressure for
leaks.
2. ___ Timed trial for ignition for pilots and burners should be in accordance
with the instructions in the programmer timer.
3. ___ Check operation of automatic controls and combustion flame safeguards for
normal operation. There should be no presence of oil discharge, ignition
or flame.
4. ___ Check pre-ignition purging capability of burner, combustion chamber,
boiler passes, and breaching. Stack dampers should be fully open during
purge and light off period.
5. ___ Check delivery of fuel in relation to its response to the ignition system.
Examine electrodes for carbon buildup, discoloration, distortion, and
burning of parts, clean and adjust as necessary for proper operation.
6. ___ Check ignition transformer to supply dependable arc, adjust and regulate
as required for clearance and air gap.
7. ___ Clean and adjust draft regulator and air shutter on a natural draft burner
to ensure excess air quantities are minimum for complete combustion. Test
with flue gas analyzer.
8. ___ On mechanical draft burners clean and check power driven fan blower.
9. ___ Check out forced draft fan, clean fan and fan housing, check bearings,
pulleys and or couplings and adjust belt tension if required replace worn
belts and lubricate pivot points on linkages as necessary.
10.___ Check and clean filters, water separators, primary and secondary
strainers.
11.___ Clean, check operation, and adjust controls and safeties.
12.___ Burners designed to change firing rates automatically should be checked
for adequate proportioning changes in fuel and air rates.
13.___ Check oil level sight glass to see that burner maintains proper oil level
(within 1/3") at rated output.
14.___ Check to ensure that power cannot feed back and energize ignition devices
or feed valves after a control shuts off burner.
15.___ Clean or replace nozzles or cups, and check for tight shutoff of fuel.
16.___ Check stacks for smoke or haze and adjust burner accordingly.
17. Take flue gas readings to determine the boiler efficiency. Use the
manufacturer's instructions if available If they are not, use the attached table
as a guide for the performance criteria. If efficiency is low, check baffling
and passes for short circuiting, and boiler for air infiltration. Adjust dampers
and controls to optimize efficiency. Tests should be run at the following load
points.
a.___ 100%, 70%, and 40% of rated full load for boilers having metering
controls or modulation capacity at these load points.
b.___ At the high and low fire rates on boilers equipped with OFF/LOW
FIRE/HIGH FIRE control.
c.___ At the single firing load point on boilers equipped with OFF/ON
controls only.
Performance Criteria for Oil Burners
LIGHT OILS, Grade 2, Diesel Fuel, JP5, Navy Distillate
Percent Load
40.0%
70.0%
100.0%
Carbon Dioxide (CO2)
10.5%
11.0%
12.5%
Carbon Monoxide (CO)
0
0
0
Oxygen (O2)
6.0%
5.0%
4.0%
Excess Air (XA)
40.0%
30.0%
20.0%
Smoke Scale No.
2
2
2
MEDIUM OILS, Grade 4, NFSO
Percent Load
40.0%
70.0%
100.0%
Carbon Dioxide (CO2)
11.0%
12.0%
13.0%
Carbon Monoxide (CO)
0
0
0
Oxygen (O2)
6.0%
5.0%
4.0%
Excess Air (XA)
40.0%
30.0%
20.0%
Smoke Scale No.
3
3
3
HEAVY OIL, Grades 5 & 6
Percent Load
40.0%
70.0%
100.0%
Carbon Dioxide (CO2)
12.0%
12.6%
13.6%
Carbon Monoxide (CO)
0
0
0
Oxygen (O2)
6.0%
5.0%
4.0%
Excess Air (XA)
40.0%
30.0%
20.0%
Smoke Scale No.
0
0
0
Performance Criteria for Oil Burners
1. ___ Combustibles should be zero or negligible percent in flue gas.
2. ___ Output (steam flow or water flow) where meters are available should
correspond to combustion level not less than 100% of rated capacity at
rated load.
3. ___ Boiler section outlet flue gas temperature is not more than 30oF (17oC)
higher than rated. When expected gas temperature is not known, the
manufacturer should be contacted for typical conditions for the type
boiler being tested.
4. ___ Boiler section outlet flue gas temperature should not be more than 150oF
to 180oF (84oC to 100oC) higher than the corresponding saturated steam
temperature for water tube boilers and 100oF to 125oF (56oC to 70oC) for
firetube boilers.
5. ___ Excess air should be within 5 percent of manufacturer's expected
performance level.
6. ___ Feedwater temperature, burner atomizing pressure, fuel oil viscosity at
the burner, draft loss and combustion appearance should be in accordance
with manufacturer's data or be close to industry standards.
Tools & Materials.
1. Standard Tool kit.
Plus Pipe wrenches to 24"
Tubing cutters
Flaring tool
Small acetylene outfit
Packing tool kit and packing
3/4" socket set
Crescent wrenches to 14"
2. Flue gas analyzer.
3. Varsol and rags. Use varsol in well ventilated area! Dispose of as
hazardous waste!
4. Lubricants. Consult the Material Safety Data Sheets (MSDS) for hazardous
ingredients and proper personal protective equipment (PPE).
5. Clean wiping cloths.
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