Webster JBE Series, Operation, Maintenance & Installation Manual

Page 1: ...y 619 Industrial Road Winfield KS 67156 Operation Maintenance Installation Manual Model JBE X Forced Draft Burners High Swirl Combustion Head Manual Part No 950107 www webster engineering com July 201...

Page 2: ...ORDANCE WITH OSHA STANDARDS ALL EQUIPMENT MACHINES AND PROCESSES SHALL BE LOCKED OUT PRIOR TO SERVICING IF THIS EQUIPMENT IS NOT INSTALLED OPERATED AND MAINTAINED IN ACCORDANCE WITH THE MAN UFACTURERS...

Page 3: ...Adjustments 1 Pre Start Check List 2 Linkage Adjustments 3 Fuel Cam Adjustments 4 FGR Adjustments 5 Burner Drawer Adjustments 6 Single Fuel Setups 7 Combination Gas and Pressure Atomized Oil 8 Combina...

Page 4: ...odel The serial number represents the unique number for that burner and is a critical number that will be needed for any communications with Webster Engineering The input rates define the maximum and...

Page 5: ...MS Pressure Atomizing MR Modulation By Pass Air or Steam Atomization MA Air Atomization MS Steam atomizing GAS TRAIN VENDOR VGD Siemens VGG Siemens M Maxon Blank All Others ASCO std GAS TRAIN SIZE 15...

Page 6: ...re are several other documents that should be considered as part of the complete manual for the burner All of these documents are needed to support the installation and startup of the unit These addit...

Page 7: ...9 750P 6 170 5 240 74 000 62 900 53 44 529 439 Figure A 4 Furnace Conditions Input BHP Input MBH Min Furn Length Min Furn Dia Max Heat Rel Min Furn Dia Max Heat Rel Min Furn Dia Max Heat Rel 200 8369...

Page 8: ...tor Wind Box Burner Mounting Flange Atomizing Air Pressure Switch Figure B 1 General Burner Arrangement Combination JBE X Burner Front Gas Control Valve Gas Spuds Oil Nozzle Access Cover Diffuser Diff...

Page 9: ...aches to the windbox This assembly is built and balanced as a sub assembly that can be removed for maintenance and repair The fan has a hub that is machined to match the motor shaft diameter and key S...

Page 10: ...tighten bolts to lock it in that position 2 On larger JBE X 7 and JBE X 9 burners with 16 L head and larger the diffuser is attached to the center tube of the drawer assembly Adjustment to this type o...

Page 11: ...valve and before the gas flow control valve It is set at a pressure that is greater than the highest gas pressure expected at this location If the gas pressure rises above this level it will trip the...

Page 12: ...Regulator An oil pressure regulator is used to maintain constant oil pressure to the burner It is adjusted to provide the oil pressure needed at the nozzle On small sizes this may be integral to the o...

Page 13: ...tical position with the word TOP located on top of the assembly This will allow for even oil distribution and prevent oil dripping out of the gun and lines after shutoff Nozzle Oil Pressure Gauge This...

Page 14: ...equipped with single point positioning linkage multiple setting modulating motor or parallel positioning system linkageless All of these systems provide the basic fuel air ratio control required for...

Page 15: ...l Panel The control panel Figure B 6 contains the flame safeguard control relays terminal strips for electrical connections and other components required for unit control Other components may be inclu...

Page 16: ...tion Control Transformer Optional The control circuit transformer is used to reduce the main power input to 115 VAC for the control circuit If this electrical supply could be provided as a separate in...

Page 17: ...the following can be used Webster recommends two air sources be provided one located high one low Each air source must be at least 1 ft2 If there are multiple burners the area must consider all burne...

Page 18: ...Section C Installation JBE X Manual Page 18 Figure C 1 Refractory Firetube Boilers...

Page 19: ...Section C Installation JBE X Manual Page 19 Figure C 2 Refractory Watertube Boilers...

Page 20: ...ure Regulator Fuel Oil Tank Note Location of check valve varies with system Check valve is usually located as close as possible to tank outlet Figure C 4 Typical 2 Oil Field Piping The gas piping from...

Page 21: ...600 1 1 1 2 2 700 1000 1 1 1 2 2 Heavy 6 Oil 2 C 7 Oil Pump Ratings To Tank Supply Return Gate Valve Strainer Vacuum Gauge Check Valve Gate Valve Oil Valve Pressure Regulator Boiler 1 Burner 1 Check...

Page 22: ...on the train or the burner and must use a minimum amount of elbows e The gas piping should be cleaned to remove filings and other debris common in the construction process f The piping should be press...

Page 23: ...copper tube to the pump inlet to feed the oil from a bucket The gauge must be removed and the tapping plugged The pump is run for a short time by manually engaging the motor starter If flow does not...

Page 24: ...uantities of flue gas and different FGR duct and valve sizes Proper sizing and installation of the FGR duct must be done to provide the required emission control and burner performance The FGR control...

Page 25: ...is higher than allowed Adjusting the pipe to 10 gives a new length of Length 3 x 22 22 88 ft New pressure drop 88 x 1 1 100 ft 0 97 This pressure drop is good Changing to a 90 degree T as shown in the...

Page 26: ...le 20 pipe can also be used j The duct components must be seal welded flanged or screwed together to provide an airtight duct Air leakage into the duct will prevent the system from working properly It...

Page 27: ...an be added to provide the total correction to the system draft Draft controls are also available to regulate the draft by controlling an outlet damper The speed of response is critical to allow these...

Page 28: ...to the basic principles defined here the component details and specific combination of components on your specific unit must be fully studied and understood The fuel diagrams wiring diagram component...

Page 29: ...ion D Fuel and Electrical Systems JBE X Manual Field Piped Pilot Manual Ball Valve Pilot Gas Pressure Regulator Pilot Solenoid Valve Gas Pilot Ignitor Gas Burner Manifold Fuel Flow Control Valve Main...

Page 30: ...of the first steps in setting up gas com Page 30 Section D Fuel and Electrical Systems JBE X Manual bustion is to adjust the regulator to get rated capacity This regulator is usually at the beginning...

Page 31: ...ed Items By Others Figure D 4 Air Atomizing Light Oil Schematic A standard oil pump provides oil at a pressure of about 300 psi to the nozzle At high fire the bypass is closed or nearly closed and all...

Page 32: ...alve is set manually and does not vary In other systems with higher turndowns the bleed valve is modulated with firing rate by connection to the jackshaft or by a direct drive actuator 5 Fuel Air Rati...

Page 33: ...d the temperature or pressure rises above the Burner Off point A on Figure D 6 The modulating control senses the temperature or pressure and signals the modulating motor to set the fuel and air input...

Page 34: ...TRAINED AND EXPERIENCED TECHNICIANS COULD RESULT IN EQUIPMENT DAMAGE PERSONNEL INJURY OR DEATH E PRELIMINARY ADJUSTMENTS Page 34 JBE X Manual Section E Preliminary Adjustments 1 Visual Inspection The...

Page 35: ...nsulation value The combustion air fan rotation is marked with an arrow on the windbox The rotation can be observed within the motor to verify correct rotation or if this is not accessible the burner...

Page 36: ...d on the wiring diagram so that the low and high points of each fuel are identified These would be adjusted independently to obtain the input rates The valves and linkage should operate smoothly witho...

Page 37: ...he roller must stay in the center of the adjusting screws within 1 8 If needed the two cam set screws can be loosened and the cam moved to center it on the roller c At high fire the roller should be b...

Page 38: ...rted through the burner drawer back plate and through a hole in the diffuser The scanner sight tube should extend about 1 8 past the diffuser This position ensures that the scanner only sees the actua...

Page 39: ...tment Page 39 JBE X Manual Section E Preliminary Adjustments 11 Operating and Modulating Controls The operating controls will not be used during the burner setup except that the high limit and operati...

Page 40: ...ll bolts secured ______The linkage is correct in low fire position and tight ______The stack is connected and routed to the outside Draft controls are installed and operational ______Gas vent lines ar...

Page 41: ...tention plate will help insure that the fuel valve position will not get far from its ideal position even with interference or sticky valve operation WARNING IF THE CAM ADJUSTING SCREWS DO NOT HAVE RE...

Page 42: ...r components during this sequence If these adjustments are required follow the sequence listed to perform the adjustments Before any adjustments are made the position of each component must be marked...

Page 43: ...fire rates as well as lightoff rates can be set independently for each fuel In this case the gas is adjusted first to set the air damper locations for gas firing as defined in Section 9 Once gas is se...

Page 44: ...required to obtain the final result as each can impact the other If the FGR valve does not travel at least 50 degrees the FGR inlet tube should be readjusted pushed into the FGR pipe t Modulate the bu...

Page 45: ...WHEN THE UNIT IS FULL OF VAPOR OR WHEN THE COMBUSTION CHAMBER IS HOT j After a few seconds the combustion analyzer should have an accurate reading of the O2 in the stack The O2 level should be betwee...

Page 46: ...ving the valve stem moving up with a motorized valve or hearing the clicking noise from a sole noid valve NOTE If the burner is not operating as indicated follow the troubleshooting steps to determine...

Page 47: ...ir proving switch on the burner Limits for gas operation could include the high and low gas pressure switches and for oil firing the high and low oil pressure switches high and low oil tem perature sw...

Page 48: ...f equipped the manual oil valve to the nozzle It is recommended that the burner be manually driven to low fire before turning the burner off as this reduces the dynam ic and thermal stress If the burn...

Page 49: ...ese items will wear and may not operate smoothly Corrective action must be taken There are several different types of controls and the cor rective action of each could be different The following gener...

Page 50: ...eds to be replaced it should be a Delevan Veriflow type i Check safety limits including pressure and temperature switches 6 FGR Systems The flue gas is corrosive and requires regular inspection of the...

Page 51: ...terlocks that may be used on the burner for smooth operation and correct action X X Firing Rate Control Check firing rate control and verify settings X X Combustion Tuning Conduct a combustion test ve...

Page 52: ...and CO2 which is typically obtained from a flue gas analyzer The values are based on a dry reading where the flue gas is extracted and cooled before the analysis if done 0 1 2 3 4 5 6 7 8 9 10 11 12 1...

Page 53: ...ontrol valve setting incorrect Readjust Fuel valve s not opening Check wiring to valves 5 No main oil flame Weak scanner signal Clean scanner lense and tube pilot OK Damper or fuel control valve setti...

Page 54: ...rods not consistent Linkage slip Check linkage and tighten all joints Fuel cam screws have moved Replace fuel cam Fuel line plugged Check and clean lines strainers filters Fuel supply pressure changi...

Page 55: ...w Increase oil pressure Flow valve set too low Adjust oil control valve 17 Cannot obtain NOx levels on Inlet tube in wrong position Adjust inlet tube to center of fan inlet gas Taper FGR valve to be f...

Page 56: ...Webster Combustion Technology LLC 619 Industrial Road Winfield KS 67156 Ph 620 221 7464 Fax 620 221 9447 e mail service webster engineering com www webster engineering com...