Cleaver Brooks FLX Premix 750-177 R5 Maintenance

Cleaver Brooks FLX Premix 750-177 R5 Maintenance

General

A well-planned maintenance program will help to avoid unnecessary downtime or costly repairs, promote safety, and aid boiler inspectors in performing required periodic inspections. An inspection schedule with a listing of procedures should be established.

WARNING: Shut off electrical power to the boiler when performing any service or maintenance work or work that requires removal of covers or component parts. Failure to heed this warning could result in electrical shock, serious personal injury or death.

Source: Cleaver Brooks

General

A well-planned maintenance program will help to avoid unnecessary downtime or costly repairs, promote safety, and aid boiler inspectors in performing required periodic inspections. An inspection schedule with a listing of procedures should be established.

WARNING: Shut off electrical power to the boiler when performing any service or maintenance work or work that requires removal of covers or component parts. Failure to heed this warning could result in electrical shock, serious personal injury or death.

Good housekeeping practices help maintain a professional appearing boiler room. 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 a

Even though the boiler has electrical and mechanical devices that make it automatic or semiautomatic in operation, the devices require systematic and periodic maintenance. Any “automatic” feature does not relieve the operator from responsibility. Automati

Alertness in recognizing an unusual noise, improper gauge reading, leaks, etc., can make the operator aware of a developing malfunction, permitting prompt corrective action that may prevent extensive repairs or unexpected downtime. Any leaks - fuel, water

Preventive maintenance measures such as regularly checking the tightness of connections, locknuts, setscrews, packing glands, etc., should be included in regular maintenance activities.

WARNING: Inspection and maintenance should be performed only by trained personnel who are familiar with the equipment. Failure to heed this warning could result in serious personal injury or death.

PERIODIC INSPECTION

Insurance regulations or local codes may require a periodic inspection of the pressure vessel by an authorized inspector. Inspections are usually scheduled for periods of normal boiler downtime such as during an off season. The major inspection can often

While the inspection pertains primarily to the waterside and fireside surfaces of the pressure vessel, it provides the operator with an excellent opportunity to perform a detailed check of all components of the boiler, including piping, valves, pumps, gas

Replacement spare parts, if not on hand, should be ordered well in advance of a shutdown.

Note: Cleaver-Brooks genuine parts should be used to ensure proper operation and to avoid damage to the equipment.

Cleaver-Brooks boilers are designed, engineered and built to give long life and excellent service. Good operating practices and consistent maintenance and care will promote efficiency and economy of operation and contribute to many years of reliable perfo

Cleaver-Brooks offers a Planned Maintenance Program that covers many of the items included on this chapter. For more information on the Planned Maintenance Program, contact your local Cleaver-Brooks authorized representative.

FIRESIDE CLEANING

Soot and other noncombustible deposits are effective insulators and, if allowed to accumulate on boiler heat exchanger surfaces, will reduce heat transfer to the water and increase fuel consumption. Soot and other deposits can absorb moisture and may attr

Inspection and cleanout should be performed at frequent intervals, depending upon the boiler's load, type and quality of fuel, internal boiler temperature, and combustion efficiency. Stack temperature can be used as a guide to determine cleanout intervals

Access to the furnace for tube and refractory cleaning is provided through a hinged burner door at the front of the boiler. When opening the burner door, first shut off the electrical and fuel supplies and then disconnect all fuel lines at the burner watc

WARNING: To avoid the hazard of electrical shock, which could cause serious personal injury or death, the use of a low voltage flashlight Is recommended when working Inside the boiler furnace area.

Tubes should be brushed with a wire brush to remove any soot or other accumulations. Refractory surfaces should be cleaned, if necessary, with a soft bristle brush. Loose material should be vacuumed from the bottom of the furnace.

UPPER PASS CLEANING

Upper pass access is gained through removal of the inner and outer side casing.

To remove the outer casing panels, first disconnect and remove any electrical conduit, boxes and brackets attached to the side outer casing.

Match mark the outer panels for repositioning.

Remove screw (if installed) from frame above each outer panel. Starting with center panel, slide panel up, swing bottom of panel away from boiler and then slide down from the upper frame and set panel aside. After the center panel(s) are removed, the end

It there are only two outer panels (Models 150 through 350), then slide one end panel further into the corner frame to allow the other panel to slide free from the corner frame. If obstructions are present, such as the gas train, there may not be enough r

Match mark all inner casing panels for repositioning later. Inner casing panels must be removed in sequence starting from either end.

Remove nuts, washers and clamp angles from the end and bottom of panels. Remove nuts, washers and bolt bars from vertical seams.

Loosen nuts on top clamp angles but don't remove until panel is ready to be removed. Inner casing panels can not be removed by pulling panel straight out from boiler because of a 1" gasket retaining strip that overlaps behind the panels.

Remove inner casing panels by sliding or angling panel away from remaining panels until the 1" retaining strip has cleared panel and then panel can be removed and set aside.

After removing the inner side casing, the pass cover plates (2nd pass only) must be removed. The cover plates are screwed together and are held in place by tabs inserted between the tubes.

Remove the insulation by starting at one end and carefully rolling it up. The insulation blocks can now be removed from the pass opening. Keep the insulation blocks in order once they have been removed so they can be re-installed in the same position. In

Now that the 2nd (left side) and 4th (right side) pass openings are exposed, cleaning can be done in the same way as the furnace area. Since the 3rd pass is only open on the ends, cleaning is done by pushing a wire brush mounted on a long handle, through

The fifth pass is cleaned from above the tubes. As in the furnace, loose material should be removed by vacuuming after brushing. The pressure vessel should be inspected for any signs of deterioration after cleaning.

The flue outlet and stack should also be inspected annually and cleaned as necessary. Commercial firms are available to perform this work. The stack should also be inspected for damage and repaired as required.

Once everything has been cleaned and inspected the boiler can be put back together. Install insulation blocks in the 2nd and 4th pass openings in their previous positions. Spray adhesive on tubes above and below pass opening and install blanket insulation

Prior to installing the inner casing, inspect studs on boiler and bolt bars for any thread damage. Any damaged threads should be cleaned and chased with a 3/8"-16 die. Apply a small amount of Cleaver-Brooks "Never-Seez" (p.n. 797- 1814 or 797-1816) on eac

Before the inner casing can be installed, the old gaskets must be removed from the panels and around the perimeter of the boiler and replaced with new ones.

After removing the gaskets, the surfaces should be cleaned to allow the new gasket to seal properly.

The gasket around the perimeter of the boiler should be one piece with the ends overlapping side by side somewhere along the upper (roof) surface. A small amount of silicone will be required to fill gaps and valleys where the gasket crosses.

This includes the roof to end wall seams and the base angle to end wall gaps. It is important that the entire gap between the end wall and the base angle be completely sealed.

The seal along the base of the end wall should also be checked and resealed if necessary. The gasket should be positioned to the inside of the studs with a 1/4" gap between the studs and the gasket.

Install gasket on side casing panels so it extends past the top and bottom by 1/4" or more and 1/16" to 1/8" out the back at the top and bottom of the panel. (See Figure 7-1).

Starting from one end, set panel edge 1/8" to 1/4" from the studs on the end wall. Install the first lower clamp angle over the respective studs, install washers and start nuts. Any nuts that are difficult to install should be replaced.

Place the upper clamp angle over the top studs and install washers and nuts but don't tighten.

The end clamp can now be installed and nuts on the end clamp can be snugged up but not completely tightened.

Before installing the next panel, apply a small amount of teflon paste to the area where the vertical gasket and the horizontal gaskets will overlap at the top and bottom.

This will help ensure an air tight seal. Install the next panel in line being careful to slide the 1" gasket retaining strip behind the panel but under the insulation.

Install the next panel in line being careful to slide the 1" gasket retaining strip behind the panel but under the insulation.

Install the bottom and top clamp angles to hold panel in place, but don't tighten.

Install the bolt strips, washers and nuts which clamp the panels together.

Pull panels together evenly and tighten nuts to 250 to 300 in-lbs.

Repeat until all panels are installed and securely bolted together. Now panels can be evenly pulled toward boiler with clamp angles. Tighten all nuts to 250 to 300 in-lbs.

The outer casing panels can now be installed starting with the end panels.

Slide each end panel under the upper frame and push the bottom section into the boiler and allowing it to slide down to catch the bottom clamp angle.

Then slide the end panels under the corner frames and install any remaining center panels.

The fireside should be thoroughly cleaned prior to any extended layup of the boiler.

Depending upon circumstances, a protective coating may be required. See Chapter 3, Section H "Preparation for Extended Layup".

Figure 7-1 Gasket application to inner casing

CONTROLS

Relief Valves

The relief valve is a very important safety device and deserves attention accordingly.

Proper removal, installation or handling of a relief valve is of primary importance.

Exercise care when removing, installing or handling a relief valve to ensure proper operation, long service life, and to ensure that the valve functions as designed.

! WARNING: Improper removal, handling or installation of a relief valve may adversely affect the valve's operation, resulting in serious personal injury or death.

Observe the following precautions when removing, handling or installing relief valves.

Use only flat jawed wrenches on the flats of the valve

Do not use a pipe threaded into the outlet to turn a valve

Apply only a moderate amount of pipe compound to male threads

Avoid over tightening, which can distort valve seating surfaces

Do not paint, oil or otherwise cover any interior or working parts of the valve. A relief valve does not require any lubrication or protective coating to work properly.

Discharge piping must be properly arranged and supported so that its weight does not bear on the relief valve.

Handle with care a valve that has been removed from the boiler. A dropped valve should be considered as damaged until it has been inspected and passed by the valve manufacturer's authorized representative.

WARNING: Only properly certified personnel such as the relief valve manufacturer's representative should adjust or repair the boiler relief valves. Failure to heed this warning could result in serious personal injury or death.

Relief valves should be operated only often enough to assure that they are in good working order.

Follow the recommendations of your boiler inspector regarding valve inspection and testing. The frequency and method of testing should be based on the recommendation of your boiler inspector and/or the valve manufacturer, and should be in accordance with

Low Water Controls (Hot Water)

Most instances of major boiler damage result from operating with low water. Since low water cutoff devices are set by the original manufacturer, no attempt should be made to adjust these controls in order to alter the point of low water cutoff.

If a low water cutoff should become erratic in operation, immediately replace it or contact your local Cleaver-Brooks authorized representative for assistance.