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INC IRVINE
LRASYSTEMS MAR 83 NCEL-CR-83-022
CONT OCAMAINTENANCE
249 S B01LER COMBUSTIO'N
7AD-A127 NC 6DN2474-81-C-9388
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CR83022
NAVAL CIVIL ENGINEERING LABORATORY
Pot Huename, California
Sponsored by
CHIEF OF NAVAL MATERIAL
NAVAL FACILITIES ENGINEERING COMMAND
March 1983
An Investigaton Conducted by
ULTRASYSTEMS, INC.
2400 Michelson Drive .... i ' "'
Irvine, Calitornia L -.
C. APR 25 1983J
LL-
---J N62474-61-C-9388
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Unclassified
SECURITY~ CLA5SIFICATIO. 0f' Y.15 PAGE fWh-. D.,. F.111,1)
READ INSTRUCTIONS
REPORT DOCUMENTATION PAGE BEFORE COMPLETING FORM
ft SO PUMS ftCS0"OEPY CATA#.OG PUM119A
CR 83.022 I'll i
Boiler Combustion Control Maintenance Oica1981ft-_SepIC 1982t
Manual 6 PeRfFORMfING On. EPORT N.UMBERt
N62474-81-C-9388
ULTRASYSTEMS, Inc.
2400 Michelson Drive Z0829-01-144B
I~~~~ 0L .... 1b%,0 REPORT DATE
1AEAD40(2
tol MONITOVIING AGENCY NAME 6 AO0RESS(It 4,il.,..., #-. C-1-I,..5 9nOff-). 15 SECUNPIP' CL.AS$ (.1 'his /rpO")
If SUPPLI[MENTAftY NOTES
It KEY WOftDS IConlpnu., ati p..,.. sof of 0010....., Sond fo.lsnif bv block -berk.)
TABLE OF CONTENTS
Page
1.0 INTRODUCTION ..................................................... 1-1
-V- :
, r . - ., llI
LIST OF FIGURES
(Pneumatic) ............................................ 6
(Electric) ............................................. 7
- vi-
-- l
1.0 INTRODUCTION
6.0, and 7.0 deal with the maintenance requirements for major
Section 8.0 discusses the Mobile Boiler Controls Unit concept and
(~ C3
"7.
2.0 INSTRUMENT MAINTENANCE
?.1 General
fuel storage tank, combustion air fan, furnace casing and breeching
addressed.
boiler control and protective system. This will reduce the forced
2-1
.. ..
. ..
. .. .. . . . ... * . . .. .. . . . . . . . . . l .. . . i i
2.2 Maintenance Facilities
Several options are available for maintenance facilities. They
are: on-site instrument shop, a centrally dispatched mobile unit,
an instrument service contractor or a manufacturers' shop. The
selection of approach for each boiler installation is dependant on
economies and the criticality of the boiler operation at its
particular facility.
The test equipment requirements for a local or mobile facility
would be similar and are listed as follows. In general all
instruments should be high accuracy test quality.
Pressure Gauges - Ranges; 0-20, 0-60, 0-100, 0-500, 0-100
PSIG, 0-30"HG
Manometers - Ranges; 0-6", 0-12", O-30"HO, 0-10", 0-30"HG.
Dead Weight Tester - 5-100 PSI
Pressure Regulators
Instrument Air Supply - 0-100 PSIG (bottled)
Thermometers
Temperature Bath
Potentiometer
Megger
Multimeter: ma, mv, V, Ohms, etc.
Recorders, multirange electric and pneumatic , miscellaneous fittings,
Tygon tubing, copper tubing, plastic tubing, etc.
In addition, instrument test stands, vises, benches and power
supply will be required. These facilities should be separated from
other work area for cleanliness and safety purposes.
2-2
2.3 Maintenance Records
the rhatir( (of problhem and th" cnrrc tions miiade, .hoild a] ;lo ho
included.
tCoMpIete
, 11,iItIhIJi e records not only pruvide readily
schedule; and (5) basis for estimating reliability and, in part, for
predicting shutdown schedules.
2-3
3.0 GUIDELINES FOR FIELD CHECKS
3.1 General
necessary to overhaul the boiler safety systems at the same time the
outlined here are also applicable to the safety systems. The boiler
3.2 Calibration
This work will he done with the boiler shut down ,ind isolated.
Each instrument or final drive shall be calibrated in accordance with
3-1
3. Calibrate temperature devices as follows:
thermometers.
chamber.
appIi :able.
value.
check.
c. Adjust deadbdnd if applicable.
3-2
6. Calibrate receiving devices, such as recorders, indicators, etc.,
as follows:
power if required.
measurement.
manufacturer's instruction.
pre-operational calibration.
12. Stroke control drive and adjust the 0-100 percent and travel
3-3
. . ,. m,-. - .. . . I "- I ] II l
3.3 Pre-Operational Testing
1. Confirm that process sensing lines, air lines are connected and
the correct level. Check the air to ensure that it is clean and
dry. Check the dewpoint of the instrument air to assure proper
dryness.
the fuel valve opening when it is less than set point and conversely
closing when it is greater than set point. This should be done for
75 percent and full load. Adjustments will be made to the fuel, air
3-4
and feedwater controls to ensure rapid response to changes in demand,
system malfunctions.
At the time boiler testing is being conducted, observers should
all times.
demand.
percent and full load. Data should be taken to ensure that the boiler
air, steam and feedwater flows, steam pressure, drun water level, all
control signals, drive and valve positions, and flue gas 02. These
.. ..
. ..
. .. .. . . . . . '. . .. . . ..
4.0 PERIPHERAL EQUIPMENT MAINTENANCF
4.1 General
Proper maintenance of combustion control systems requires that
support systems include oil and gas burner assemblies, fuel oil
discussed below.
since the required oil pressure is high (75 to 300 psig) and usually
provided by use of gear type rotary pump sets complete with heaters
every shift to ensure there is no oil blockage and that the burner
4-1
, , ,
worn rims, therefore, should be replaced. Cups can be protected from
carbon forming on the rim by removing the cup when the burner is shut
replaced.
Mechanical atomizing nozzles are more subject to wear than other
help loosen carbon accumulated at the tip and always use a wooden
The preheat temperature must be correct for fuel and burner type.
connection is closed tight and gas header vented when the burner is
4-2
A
4.5 Combustion Air Fan
boilers. They are usually motor driven through belt drives. Items
that require periodic maintenance include proper belt tension, bearing
lube system and lubrication requirements of the motor. The air damper
type of filter.
mortar diluted with water to the proper consistency for wash coating.
Note that a telltail sign for cracks is a soot mark along the crack.
4-3
5.1 General
A jackshaft control system is shown in Figure 5-1, and it is
discussed below.
5.2 Jackshaft
bearings.
proper functioning.
5-1
STEAM
PRESSURE
516MAL
I1PRESURE
ACOI4TROLLER
ADJUSTABLE CAM
JACKSHAFT
DRIVE
AllR FLOW
D AMPER
.- '--¢ . . .- .. -.
DAMPElt DRIVE
5HAFIr
ROLLER +
FOLLOWSR
AWUSTABLE
5ET SLCREWS
CAM-.,----'
JACKSHAFT
CAM MECHANISM-
F 5-3 A
STh. 14LADEK.M~
6.1 General
Maintenance requirements for pneumatic parallel positioning
follows:
6.2 Master Pressure Controller
the controller and the final control element, as shown in Figure 6-1.
The maintenance basically involves the inspection of the poppet valve
in the relay assembly for dirt or foreign matter in the inlet seat or
exhaust seat. The latter is indicated by a continuous leak at the
6-1
exhaust port. Cleaning and replacement of inlet or exhaust seat of
of light machine oil on the ball bearing fulcrum. The poppet valve
instructiens.
6-2
MAY UTiLZ.E PRESSURE
-MpWS.j-rr1ER 14ERE
'--"PROCE5S PIPING~
MA5TER -PKIEU1ATIC 516WAL
~ PRESSUIE -*-imSTRUMENT fAARF
COVNTROLLER CSU PPLY
~ AUTO
STPXT ION
AIR FUEL
fzATIO
CONTROLL
FUEL VALVE
5Y$TEM P'EMTL
6-3
C207-
ST1. PEAe
AIR /
FUEL RATIO COIHJTROUE95
MANU.k4. Au To
lGWOKE6 INP~UT OUTPUT SlINAL IS DI?-
SICiNAL I-KO.M MAN/ E-CTL-r rROF'OR-1iONAL
AUTO 5TATIOW~. TO INPUTY SkCNAL, RATIO0
OUTPUT SICNAL Or- OUTPUT TO INP'UT
1I- MANUALLY MAY 5E ARIU'STED
REqULATD. A'5 NECE.SSARY,
6-4
SHUTOF AALEMI OUTPUT PRESSURE
SYSTEM
HEADSMR
PRE SU
MASTER E ON RO LE
~PV~
6-53
7.0 ELECTRIC PARALLEL POSITIONING CONTROL MAINTENANCE
of the various control components are similar to, but less stringent,
than those for the respective components described in Section 6.0 for
7-1
T I l ll l I I . .%
PRE5SURE P(KOCEsS PlPIN6z
RAN$I1ITMRE 't'k ELECT1MICPL WII4
5R %NowL
RAk'
RTATI O
[FUIEL VALVE
OSIT5I70OMEI
000
COMBO -iom
approach will have merit for the Navy's small heating boiler controls
maintenance requirement since its mobility will allow extended
truck, trailer or van which would visit the Navy small heating boiler
installations on either a scheduled or "as-required" basis. The
mobile unit would be accompanies by at least the following personnel:
8-1
IF
the Navy's small heating boilers have combustion controls that should
be updated, which ones require maintenance, and which ones are working
9-1
0m