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Figure C-9 Ceramic
Blanket and Rope Gasket
2. Refractory Frontplate
The refractory front plate is used to adapt the burner to
the vessel. While the specific dimensions will vary with
different vessel and burner configurations, all will be
similar in shape to that shown on the drawings at the
beginning of this section. There is a difference in the
shape depending on the vessel type. Fig. C-1 shows a
scotch firetube and C-2 shows the shape for watertube,
firebox and cast iron. A mounting flange on the frontplate
is used to clamp the frontplate to the vessel. Bolts on the
frontplate are used to clamp the burner to the frontplate.
High temperature fiberglass rope gaskets are used to
seal each connection.
A rope gasket is applied to full surface of the frontplate
mounting flange (it must cover the full face of the flange)
to seal the refractory front plate to the vessel (a spray
adhesive can be used to hold the gasket in place tem-
porarily). The refractory frontplate is inserted into the
furnace and clamped to the end of the furnace. The
refractory must be centered in the furnace, so that the
gap between the refractory and furnace is uniform.
Clamp the frontplate to the furnace with uniform tension
on the bolts, starting with a low torque for all bolts and
then repeating with higher torque levels until tight.
Pack the gap between the refractory and furnace with
ceramic blanket insulation (or ceramic rope) for at least 4"
from the end of the refractory. This can be accomplished
by reaching in from the center hole and placing the
insulation between the refractory and furnace, then
pushing it in with a block.
3. Burner Mounting
A rope gasket is applied to the burner mounting flange,
completely covering the flange (the 3/8" fiberglass gasket
is provided with the burner). A ceramic insulation is
placed on the end of the burner, as shown in Figure C-9.
A spray adhesive can be used to hold these in place
prior to installation. The burner is then inserted into the
frontplate, centered evenly (the recess will center the
burner) and clamped into position. Clamp the burner to
the frontplate with uniform tension on the bolts, starting
with a low torque for all bolts and then repeating with
higher torque levels until tight. See Figures C-1 and C-2
for correct refractory shapes.
JBE(X) Manual
The burner should be checked for level and must be
perpendicular to the vessel. If the burner is not level or
perpendicular, loosen the mounting clamps, reposition
Ceramic Blanket
the burner and retighten. This will properly align the
burner flame with the furnace and allow the proper flow
Gas Spuds
of liquid. Oil combustion will not work properly if not level.
The burner is equipped with a mounting support to
Diffuser
secure it to the floor (Figure C-3). This is a pipe coupling
attached to the burner. To secure the burner to the floor,
pipe sections are installed to these couplings and a
flange mount is secured to the floor.
Rope Gasket
4. Gas Piping
NOTE TO INSTALLER: The manual shutoff valve on the
gas supply drop line to the burner must be conspicuously
labeled.
Figure C-10 shows a typical gas piping schematic. Some
components can vary based on size, insurance and other
requirements. Consult the job-specific gas train piping
schematic (provided with the burner if train is supplied
by Webster), along with a detailed list of components for
specific details. This must be followed to properly locate
the components in the gas train.
The gas piping must comply with all local and state codes
and must be in accordance with the local gas company
and insurance requirements.
If the gas train has not been factory assembled, the
components should be assembled as indicated on the
gas piping schematic furnished with the burner. The sec-
tion between the two manual shutoff valves is mounted
securely to the base rail on the side of the vessel. A drip
leg should be provided upstream of the first valve to
collect moisture or contaminates. Some general
considerations for this installation are:
Page 22
WARNING
DO NOT USE TEFLON TAPE OR COMPOUNDS
CONTAINING TEFLON. THIS COULD DAMAGE
THE VALVES CREATING AN UNSAFE OPERATION
a. Piping to the burner must be sized to provide gas
at the pressure and volume indicated on the order.
b. Gas piping should be installed according to local
regulations and applicable insurance requirements.
c. The gas pressure regulator requires a minimum
straight length of pipe leading into and from the valve
for proper operation. Some regulating valves require
a downstream pressure tap that must be located a
certain distance from the valve. These details are
found in the job details provided with the burner.
d. The piping between the train and burner must be
done in a way that will minimize the pressure drop.
The pipe size should be the larger of the two
connection points (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 pressure tested with inert gas at
two times normal operating pressure before use.
Section C - Installation
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