A well-planned maintenance program will help avoid unnecessary downtime or costly repairs, and will promote safety and aid boiler inspectors.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly, and yearly maintenance activities will help to obtain economical and lengthy service from the equipment.
Only trained and authorized personnel should be permitted to operate, adjust, or repair the boiler and related equipment.
The boiler room should be kept free of all material and equipment not necessary to the operation of the boiler or heating system.
Be alert to unusual noises, improper gauge readings, leaks, etc. Any leaks - fuel, water, steam, exhaust gas - should be repaired promptly and with attention to safety.
Preventive measures, such as regularly checking the tightness of connections, should be included in regular maintenance activities.
Insurance regulations and local laws normally require periodic inspection of the pressure vessel by an authorized inspector.
Inspections are usually, though not necessarily, scheduled for periods of normal boiler downtime, such as an off season. This period can be used to accomplish maintenance, replacement, or repairs that cannot easily be done at other times.
While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel, the inspection period provides operators with an opportunity for a detailed check of all boiler components including piping, valves, gaskets, refractory
Comprehensive cleaning, spot painting, and replacement of expendable items should be planned for and taken care of during this time.
Cleaver-Brooks recommends common replacement parts be on hand during inspection and maintenance. Please refer to the Recommended Spare Parts List In the Parts section of this manual.
NOTE: To insure proper operation, use only CleaverBrooks parts for replacement.
Figure 5-1 Bottom blowdown piping
Manual Blowdown Procedure
Blowdown is most effective when the boiler is under a light load, and when the water level is at the Normal Operating Water Level.
Be sure the blowdown piping is in proper operating condition. Waste should be piped to a point of safe discharge. To blow down the boiler:
It is generally recommended that bottom blowdown be performed at least once in every eight-hour period. Actual frequency may vary depending on water conditions and boiler operating conditions.
Consult the appropriate water treatment personnel regarding blowdown scheduling.
WATER COLUMN BLOWDOWN
Figure 5-2 Water Column and Gauge Glass Blowdown
FIRESIDE CLEANING PROCEDURE/ DISASSEMBLY
NOTE: Do not discard the air filter. It may be cleaned and re-used. Contact Cleaver-Brooks for cleaning kits.
Figure 5-3 Water column gauge glass
Figure 5-4 Casing top cover removed
The blower motor and assembly can now be swung open (CFV 50-60 HP) or removed (CFV 10-40 HP), providing access to the burner head and combustion chamber. The following inspections can now be performed:
If any adverse conditions are observed during operation or inspection, contact your authorized Cleaver-Brooks service representative.
When inspection and servicing are completed, reassemble the burner in reverse order.
Ensure that all connections are tight and secure before reconnecting power or fuel supply. After turning the gas supply on, reset the gas pressure switches.
NOTE: A gas valve leak test is recommended during fireside inspection. See Appendix A for leak test procedure.
Figure 5-5 Ignition electrodes & flame sensor
Figure 5-6 Removing blower
Figure 5-7 Burner Assembly
Figure 5-8 Ignition Electrodes
Figure 5-11 shows the UV scanner wiring connections to the CFV control panel.
Figure 5-12 Inspection port (handhole) locations
Figure 5-13 Manual bleed valve
Important: Clean probes are essential to proper boiler operation. Always ensure that probes remain free of debris and buildup.