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Summary of Contents for Limpsfield LC Series
- Page 1 O&M Manual LC burner series Limpsfield Combustion Engineering Limited. Unit 10 Airport industrial estate Wireless Way Biggin Hill Kent United Kingdom TN16 3BW Tel: 01144 1959 576633 Fax: 01144 1959 576644 E-mail: enquiries@limpsfield.co.uk Web: www.limpsfield.co.uk...
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Page 2: Table Of Contents
Limpsfield Combustion Operating and Maintenance Manual Contents Section Contents Section Legal statements and Disclaimers Burner Technical data Component Information Gas manifold Oil gun assembly Electrode settings Burner installation Typical UL Gas control Train Typical Oil Train General start up procedure for all fuels... -
Page 3: Legal Statements And Disclaimers
Section 1 Legal statements and Disclaimers Burner assembly area... - Page 4 Legal Notice Operation instruction for Limpsfield Combustion Equipment to guarantee safety, reliability and efficiency. The end user should carry out only operational adjustments & routine maintenance. Operational adjustments would include adjusting temperature or pressure settings on the burner management system. Maintenance by the end user should be limited to checking peripheral equipment such as fuel filters, fuel flow meters and fuel supply pressures.
- Page 5 Important Notice to the end user and operator. To ensure: 1. Safety 2. Efficiency 3. Reliability of the system. It is vital that all of the component parts in a combustion system installation are serviced and inspected for soundness/correct operation at 12 monthly intervals. The particular installation and the way in which it is used may require more frequent servicing and inspections.
- Page 6 Hints and General Advice to the End-User/Operator Please be aware that many components and systems in a modern installation are ‘service free’ or ‘lubricated and sealed for life’. This means that although no servicing is required it is still of the highest importance that these items of equipment are inspected regularly to ensure that they are sound and still meeting their originally specified performance.
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Page 7: Burner Technical Data
Section 2 Burner Technical Data Gas flame firing at 12,300,000 btu/hr... - Page 8 Burner Data Note: Volume of air and flue gases is calculated based around the following criteria. Exhaust gases at 230° C/446° F ambient air at 20° C/68° F, mix of flue gases and air at 62.9° C/145.22° F with O 18.5% dry volume in the wind box.
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Page 9: Component Information
Section 3 Component Information General assembled burner... - Page 10 Component Information 1. Sight Glass Assembly/Access Door 2. Oil Gun Assembly 3. Oil Flow to Lance Hose 4. Oil Return from Lance Hose 5. Gas Manifold 6. Combustion Air Servo Motor 7. Combustion Air Damper 8. Rear Burner Wind box 9.
- Page 11 Section 4 Gas Manifold assembly Split gas head assembly...
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Page 12: Gas Manifold
Figure 1: Burner Isometric Figure 2: Gas Manifold Removal A unique design feature of the Limpsfield burner is the accessibility to all internal parts without removing the burner from the boiler. This allows for ease in set-up, maintenance and servicing. - Page 13 Adjusting the Orifices Plate Gap Setting (Split Head Design) Figure 3: Gas Manifold 1. Primary Air Tube 2. Gas Manifold 3. 3 ea. Gap Adjusting Screw 4. 3 ea. Jam Screw / Washer 5. 3 ea. Diffuser Spacer 6. Diffuser P late 7.
- Page 14 Step 5: Once the desired gap has been obtained, tighten jam screws/washers as illustrated in Figure 6. The washer, once tight, should compress against the head of the gap adjusting screw (item 3). Ensure that this is the case. Replace washer as needed if compression does not take place. Step 6: After jam screws/washers have been installed, re-assemble diffuser and diffuser stand off pillars to their original position.
- Page 15 Adjusting the Orifices injector Setting (Spider Head Design) Spider heads are factory set for an inlet pressure of 5 psi to produce the required injection to enable correct fuel to air ratio. These settings can be adjusted to suit on site conditions. Below is the recommended procedure to adjust the gas injectors.
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Page 16: Oil Gun Assembly
Section 5 Oil Gun assembly Oil nozzle and lance assembly... - Page 17 Oil Gun Assembly KC2 Oil Gun (LC 9/15) The LC9 and 15 burner models operate on a bypass pressure atomization system. The KC2 series bypass nozzle requires approximately 300 psi (20 bar) of oil supply to the nozzle. Bypass pressures at high and low fire (for a 4:1 turndown) are approximately 220 psi (16 bar) and 60 psi (4 bar) respectively.
- Page 18 W2 Oil Gun (LC 21-310) Burner models from LC 21 upward operate on a high-pressure atomization system. The W2 series bypass nozzle requires approximately 368 psi (25 bar) of oil supply at the nozzle. Bypass pressures at high and low fire (for a 4:1 turndown) are approximately 310 psi (21 bar) and 160 psi (11 bar) respectively.
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Page 19: Electrode Settings
Section 6 Electrode settings Pilot injector and ignition setup... - Page 20 Figure 2: Staged Ignition Electrodes Lc9/15 Staged ignition Electrode Setting: Limpsfield LC9 and 15 burners utilize a “staged” pilot gas ignition system. The pilot gas is introduced into the main gas manifold, prior to the gas-metering valve. At the proper sequence, the ignition transformer energizes and a spark is generated at the electrode tips located directly above the orifice plate gap.
- Page 21 Pilot Ignition (LC 21-310) ST OCK ELECT RODE (manufactured by westwood) 10mm P-CLIP (RS 298 8003) PILOT INJECTOR ST ANDARD ELE CT RODE HOLDER 10mm BUNDY T UBE (1mm WALL) T O HAVE 10mm x 10mm COMPR ESSION E LBOW ON T HE E ND WITH A 10mm P IP E T O GO T O BUR NER OIL SIDE P LAT E.
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Page 22: Burner Installation
Section 7 Burner Installation Limpsfield LC9 dual fuel burners on Hurst boilers... - Page 23 Typical Burner Installation Installation Notes Any Installation of a Limpsfield burner to a boiler should be carried out to the satisfaction and compliance of all local codes and with reference to ASME CSD-1 (Controls and Safety Devices for Automatically fired Boilers).
- Page 24 Sample Typical fire tube installation...
- Page 25 Typical water tube installation...
- Page 26 ½” WC. To properly engineer and ensure job performance, Limpsfield combustion utilizes a vast array of fan types/sizes from several manufacturers. This allows for proper air delivery in both volume and pressure for installations of high altitude, elevated furnace pressures and varying ambient conditions which affect fan performance.
- Page 27 4 into the ¼” NPT nipple factory welded into the air transitional duct which is located between the blower and the burner, If the air inlet transition is supplied by those other than Limpsfield Combustion, a ¼” NPT full coupling should be fully welded through the transition wrapper 3” back from the burner connection flange and along the center line on the width of the duct so that 2 off ¼”...
- Page 28 Combustion Air Requirements Fresh air is required to support/maintain combustion as well as to provide adequate location ventilation, must be supplied to the burner/blower assembly as NFPA 31. All types of fuel require approximately 10 cubic feet of fresh air at sea level and 60° F per 1000 BTUs being fired for theoretical perfect combustion. When actually firing fuel into a boiler/application excess air is required to ensure complete combustion, the less excess air used will mean less fuel is required and therefore more efficient and higher fuel savings, but this can vary substantially with specific job conditions.
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Page 29: Typical Ul Gas Control Train
Section 8 Typical Gas control Train 2” gas control train assembled... - Page 30 NFPA 85 – Typical fuels supply system and safety control...
- Page 31 Typical Gas Train. Note: it is important that gas trains adhere to your local codes and requirements Schematic of a typical gas train (Lc9-15) Schematic of a typical gas train (Lc21-310)
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Page 32: Typical Oil Train
Section 9 Typical Oil Train Assembled oil pump with filter... - Page 33 Typical No2 Oil Train Note: It is important that oil trains adhere to local codes and requirements. Maximum return pressure of 2psi Figure 1: Typical Light Fuel Oil Hydraulic Schematic...
- Page 34 Typical No6 Oil Train – Pressure Atomising Note: It is important that oil trains adhere to local codes and requirements. Figure 2: Typical Heavy Fuel Oil Hydraulic Schematic...
- Page 35 Typical No6 Oil Train – Air Atomising Note: It is important that oil trains adhere to local codes and requirements. Figure 3: Typical Heavy Fuel Oil Hydraulic Schematic...
- Page 36 Section 10 General start up procedure...
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Page 37: General Start Up Procedure For All Fuels
Start up Procedure for all Fuels The start up of the Limpsfield burner on either or all fuels must be carried out by a fully trained and qualified burner technician at all times. Please contact Limpsfield Engineering Technical Help for clarification on any of the above. - Page 38 13. On completion of the start up/commission of the burner package, the Limpsfield Commissioning Report (found at the rear of the O & M manual in section 17) should be filled in completely, copy’s should be sent to the end user, held by the commissioning technician and sent to Limpsfield Engineering.
- Page 39 Gas start up specifics Gas Burners The Limpsfield gas burners are designed to have 25 inches WC supplied to the gas head at high fire (this can vary depending on application and boiler furnace pressure, the pressure detailed is based on firing into atmospheric pressure, therefore the boiler furnace pressure needs to be added to this detailed pressure example: boiler furnace pressure at high fire = 4 inches WC, therefore 25 + 4 = 29 inches WC).
- Page 40 LC9 and 15 burners The LC9 and LC15 Limpsfield oil burners are designed to have the oil pressurized to 300 psi supplied to the oil nozzle throughout the firing range including high and low fire. The firing rate is adjusted by a V slot spillback valve situated in the return oil line after the nozzle.
- Page 41 4. Check all mechanical components are securely fitted to the burner package. 5. Check all wiring is sound and meets compliance to local or national codes. Check all wiring connections terminations for correct and tight termination. 6. Remove oil lance and check for tightness and correct nozzle is fitted and tightened. 7.
- Page 42 switch should also be tested by isolating the power to the blower motor and trying to start the burner, when the blower fails to start the air pressure switch will cause a lockout on the Autoflame control system, reinstate the power to the blower motor and reset the Autoflame controller, fire the burner and check correct operation.
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Page 43: Service Recommendations
Section 11 Service Recommendations... - Page 44 Standard burner routine checks and maintenance Detailed below are general recommendations for routine checks and maintenance for the Limpsfield burner. These should be carried out in a safe and appropriate manner, and in accordance with any related heath and safety policies. Additional checks may be required by local codes and end user company policies.
- Page 45 manufacturer’s settings Check flame failure detection Semi annually Operator / Shut burner down via the main system Service Tech gas or oil valves to lockout burner. Check lockout timing and log data. Monitor UV signal via the MM display and log data Gauges and indicators Semi annually...
- Page 46 dependant) Oil filter / Oil atomiser Semi annually Service check Check clean and change as /as required / operator required. (site dependant) Pilot turndown test Annually (as Service Tech. Required after service or repair required) works – refer to manufacturer instructions Refractory hold in Annually (as...
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Page 47: General Burner Servicing Procedure
Section 12 General Burner Servicing Procedure... - Page 48 Burner Servicing Procedure The servicing of the Limpsfield burner on either gas or oil or both fuels must be carried out by a fully trained and qualified burner technician at all times. Please contact Limpsfield Engineering Technical Help for clarification if unsure.
- Page 49 If the flame shape has deteriorated or/and has become smoky this could be due to a worn nozzle or it could be that the oil supply or spillback pressure has been adjusted too low. Check nozzle condition, supply and spillback oil pressures and oil filter cleanliness during every service or if the flame is not burning cleanly. The nozzles are designed to be “non drip”...
- Page 50 Please follow the instructions below for burner strip down for servicing. Ensure all Fuel and Electrical supplies to the burner are isolated before commencing with the procedure listed below. Service work should be carried out by a fully trained service technician.
- Page 51 LCNO36 370 psi 6.5 psi All information shown in the table above is typical information, if in doubt please contact Limpsfield’s technical department. Gas Control Train Maintenance All electrical connections on the gas control train should be checked to ensure connections are tight. Any filters before the gas train should be checked and cleaned as needed to ensure correct operation.
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Page 52: Fault Finding
Section 13 Fault Finding... - Page 53 Fault Finding Gas, Oil and Gas/Oil combined burner Fault finding should only be undertaken by a fully trained qualified burner technician. The burner technician should ensure that he has the correct tools to carry out the required tasks. The burner technician should be trained and certified in the use of the Autoflame Micro Modulation and Flame Safeguard and associated products.
- Page 54 4. Check fuel supply to burner is ok. Gas supply can occasionally be low check with local gas supplier if required. 5. Check gas pressure regulator is set correctly. Gas pressure regulator must have the vent to atmosphere free from any obstruction. 6.
- Page 55 3. Oil flame is over aired, check for blocked oil filter, clean or replace as required. All information shown in the table above is typical information, if in doubt please contact Limpsfield Engineering’s technical department.
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Page 56: Commissioning Report
Section 14 Commissioning Report... - Page 57 Commissioning report Site Name Engineer Burner/ equipment Fuel type T exhaust Pwindbox Pfurnace Pstack Pfuel Pfuel return "WG "WG "WG supply (oil only) (Spillback) High FGR start Golden start Comments Engineer Customer...
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