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Cleaver-Brooks CRE Series Operation Manual

Economizer
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Economizers
CRE / CCE / C2X / C1X
Operation Manual
750-266
1/15

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Summary of Contents for Cleaver-Brooks CRE Series

  • Page 1 Economizers CRE / CCE / C2X / C1X Operation Manual 750-266 1/15...
  • Page 3 CLEAVER-BROOKS Economizers CRE - CCE - C2X - C1X Operation Manual  Cleaver-Brooks 2015 Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-266 Printed in U.S.A. 1/15...
  • Page 4 Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however, proper operating techniques and maintenance procedures must be followed at all times.

  • Page 5: Table Of Contents

    CONTENTS Section 1 - Model CRE and CCE Economizers......1-1 GENERAL ..........1-2 UNLOADING .
  • Page 6 NOTES...

  • Page 7: Section 1 - Model Cre And Cce Economizers

    Section 1 - Model CRE and CCE Economizers GENERAL ..........1-2 UNLOADING .

  • Page 8: General

    Standard Economizers 1.1-GENERAL The Cleaver-Brooks economizer is essentially a static reactive type heat exchanger. The performance of this type of exchanger is ultimately dependent upon the dynamic conditions of temperature, pressure and mass or flow available on both the liquid and gas side.
  • Page 9 Standard Economizers The exchanger is shipped ready to be mounted in the vertical or horizontal position as originally specified (consult the factory if a change in the gas flow direction is desired). For existing retrofit installations, ensure that the combustion source has been turned off and has cooled.
  • Page 10 Standard Economizers Figure 1.2 - Installation, horizontal flow unit w/floor support Figure 1.3 - Installation, horizontal flow unit w/ceiling support Two (2) supported I-beams or channels can be used where larger economizers are being installed. The exchanger can then be set on the beams and slid to the lower stack and/or stack adapter for final securing.
  • Page 11 Standard Economizers Apply expansion joints (supplied by others) as required by the installation to ensure that no outside forces from thermal expansion to either the exhaust gas connections or to the piping will be permitted. Exhaust connections are generally mated with optional mating flanges and/or stack transitions. The mating flanges can be butt or slip fit welded to the stack breaching once aligned.
  • Page 12 Standard Economizers Do not insulate the exchanger where factory insulation has already been applied or damage to the exchanger can occur. Insulate piping and exhaust ducting as required. Ensure that no liquid connections interfere with the opening of access door panels. For the CCE series exchangers it is recommended that the liquid flow connects into the top of the economizer and out the bottom for cross flow.

  • Page 13: Startup

    Standard Economizers 1.4-STARTUP During the initial startup and before combustion heat can be applied to the exchanger, ensure that liquid is flowing through the economizer. NOTE: C-B requires that liquid must be flowing through the economizer at all times to avoid damage to the exchanger from stack exhaust overheat.

  • Page 14: Monitoring Performance

    Standard Economizers Bypass damper CCE Manual Damper Adjustment Bypass damper CRE While the exchanger is in a clean, like-new condition, note and record the following: • Liquid inlet and outlet temperatures • Exhaust gas inlet and outlet temperatures • Pressure gauge reading (if applicable) This information will provide a point of reference in the event of a future fouling condition.
  • Page 15 Standard Economizers combustion source is off and is cool, and the economizer is cool before attempting to inspect or clean the fin coil(s). On natural gas fired applications, with clean exhaust conditions, physical inspection will be minimal if proper combustion at the heat source is maintained. Oil fired applications may require more frequent inspection of the heat transfer core area because of the greater potential for soot loading and particulate buildup on the finned tube surface.

  • Page 16: Options

    Standard Economizers 1.7-OPTIONS 1.7.1 - Sootblower Sootblowers are applied where combustion can foul to the degree where it is not cost effective to manually open inspection doors and physically clean the exchanger by other means. Typically diesel, No. 2 oil, and No. 6 oil having multiple coils with proper fin spacing can be used in conjunction with a sootblower assembly.
  • Page 17 Standard Economizers 1.7.2 - Stack Corrosion Control Stack Corrosion Control holds the stack temperature down in order to prevent condensation and corrosion. The damper will automatically modulate to maintain a predetermined temperature. ELECTRICAL COMPONENTS 1. INDICATING CONTROL PANEL (combining Automatic Sootblower and Stack Corrosion Control) including: •...
  • Page 18 Standard Economizers amount of nozzles depending on the economizer size. The ring nozzle assembly is attached to a manifold and powered up and down (vertical installation) or side to side (horizontal installation) by a Pneumatic Drive Cylinder. During the sootblowing operation, the internal damper automatically is adjusted to the full bypass position and steam or air is also automatically controlled to enter the economizer.
  • Page 19 Standard Economizers 7. The Delay Timer keeps the bypass and steam valve open until the cylinder returns to its original position. 8. The Damper control and Control Valve then return to the normal heat recovery operating position. 9. Upon completion of the sootblowing cycle, the Duration Timer resets for the next period. 1.7.3 - Circulating Recovery System The Circulating Recovery System/Tank assembly is a separate system used as an alternate to converting on/off boilers to modulating boiler feed water systems for preheating boiler feed water.
  • Page 20 Standard Economizers Figure 1.7 - Piping with circulating tank BOILER 1-14 Part No. 750-266...
  • Page 21 Section 2 - Model C2X and C1X Condensing Economizers GENERAL ..........2-2 UNLOADING .

  • Page 22: General

    Condensing Economizers 2.1-GENERAL The C-B condensing economizers are essentially static reactive type heat exchangers. The performance of this type of exchanger is ultimately dependent upon the dynamic conditions of temperature, pressure and mass or flow available on both the liquid and gas side. The units are virtually maintenance free, having no moving parts except the internal gas bypass assembly.

  • Page 23: Installation

    If there are any questions during the removal and installation of the exchanger please do not hesitate to contact your authorized Cleaver-Brooks representative for suggestions. All exchangers include steel pads for mounting to the final support (supplied by others) as required by the installation.
  • Page 24 Condensing Economizers Figure 2.2 - Header Connections LIQUID OUTLET LIQUID INLET For retrofit installations the economizer is installed in line with the existing exhaust stack or duct unless otherwise noted. Generally a section of the exhaust stack is cut and removed to accommodate the insertion of the economizer.
  • Page 25 Condensing Economizers Structural integrity of the building should be verified (by others) prior to installing an economizer by suspending from the ceiling. Apply expansion joints (supplied by others) as required by the installation to ensure that no outside forces from thermal expansion to either the exhaust gas connections or to the piping will be permitted. Exhaust connections are generally mated with optional mating flanges and/or stack transitions.
  • Page 26 Condensing Economizers Figure 2.4 - Installation, horizontal flow unit w/floor support Figure 2.5 - Installation, horizontal flow unit w/ceiling support Liquid connections are connected either with NPT threaded fittings or flange connections. Liquid piping should include shut-off, drain and bypass valve piping in the event the exchanger is required to be isolated.
  • Page 27 Condensing Economizers Deaerated water is recommended with any C-B economizer. Generally, schedule 80 steel pipe is used in the piping installation. In some applications other piping material may be needed. Consider the type of liquid, operating pressures and temperatures, and any corrosive elements in the liquid or in the atmosphere when determining the best piping material for your installation.
  • Page 28 Condensing Economizers Economizer relief valves shall not have set pressure ratings higher than the rated pressure of the economizer. Liquid storage tank relief valves shall not have discharge pressure ratings higher than the rated pressure of the storage tank. To avoid safety valve leakage, ensure that safety valve set pressure is sufficiently higher than dead head pressure of the feed pump.
  • Page 29 Condensing Economizers Figure 2.7 - Dimension diagram, C2X ‘BB’ Part No. 750-266...
  • Page 30 Condensing Economizers Table 2-1 Dimensions C1X (see Figure 2-8; all dimensions in inches) Economizer Model Dimension C1X-L286AL C1X-R2D6AL C1X-S2F6AL C1X-Z2N6AL 52.2 54.4 61.5 101.6 48.0 48.0 58.0 90.0 28.4 28.3 32.7 51.4 24.6 24.6 28.9 46.7 17.1 31.5 39.5 16.12 24.12 24.12 31.5...
  • Page 31 Condensing Economizers Figure 2.8 - Dimension diagram, C1X I.D. Part No. 750-266 2-11...

  • Page 32: Operating Sequences / Example Installations

    Condensing Economizers 2.4-OPERATING SEQUENCES / EXAMPLE INSTALLATIONS This section describes four typical configurations utilizing the C2X 2-stage economizer. NOTE: the examples given are for illustrative purposes only; individual applications may vary. Contact CB to determine the specific requirements of your installation. 2.4.1 - Single boiler with deaerator (refer to Figure 2-9) 2-12 Part No.
  • Page 33 Condensing Economizers Figure 2.9 - Single boiler with deaerator Part No. 750-266 2-13...
  • Page 34 Condensing Economizers NOTES to Figure 2-9 CONTACT LOCAL CB REPRESENTATIVE IZING. 2-14 Part No. 750-266...
  • Page 35 Condensing Economizers 2.4.2 - Single boiler with deaerator and surge tank (refer to Figure 2-10) Part No. 750-266 2-15...
  • Page 36 Condensing Economizers Figure 2.10 - Single boiler with deaerator and surge tank 2-16 Part No. 750-266...
  • Page 37 Condensing Economizers NOTES to Figure 2-10 SURGE TANK CONTACT LOCAL CB REPRESENTATIVE IZING. Part No. 750-266 2-17...
  • Page 38 Condensing Economizers 2.4.3 - Two boilers with deaerator (refer to Figure 2-11) 2-18 Part No. 750-266...
  • Page 39 Condensing Economizers Figure 2.11 - Two boilers with deaerator Part No. 750-266 2-19...
  • Page 40 Condensing Economizers NOTES to Figure 2-11 CONTACT LOCAL CB REPRESENTATIVE IZING. 2-20 Part No. 750-266...
  • Page 41 Condensing Economizers 2.4.4 - Two boilers with deaerator and surge tank (refer to Figure 2-12) Part No. 750-266 2-21...
  • Page 42 Condensing Economizers Figure 2.12 - Two boilers with deaerator and surge tank 2-22 Part No. 750-266...
  • Page 43 Condensing Economizers NOTES to Figure 2-12 SURGE TANK CONTACT LOCAL CB REPRESENTATIVE IZING. Part No. 750-266 2-23...

  • Page 44: Economizer Controls

    Condensing Economizers 2.5-ECONOMIZER CONTROLS (C2X) Standalone C2X control offerings comprise the CEC-100 (standard) and optional CEC-200 with touch screen. For an integrated system including boiler and economizer control C-B offers the Hawk 4000. 2.5.1 - CEC 20x The system features: •...
  • Page 45 Condensing Economizers The graphical overview screen displays an overview of economizer performance. The setpoint entry screens allow the user to configure the system to match individual project requirements. These screens are password protected to discourage unauthorized access. Part No. 750-266 2-25...
  • Page 46 Condensing Economizers The alarm display screen informs the operator of any operating conditions that fall outside of the norm. The analog configuration screens allows the user to easily set the scaling values for the analog I/O. These screens are password protected to discourage unauthorized access. 2-26 Part No.
  • Page 47 Condensing Economizers The digital I/O screen allows the user to manually stroke valves and verify input status of the system for setup and troubleshooting purposes. This screen is password protected to discourage unauthorized access. 2.5.2 - CEC 10x System features: •...
  • Page 48 Condensing Economizers The alarm display screen informs the operator of any operating conditions that fall outside of the norm. The alarm setpoint entry screens allows the user to configure the system to match individual project requirements. This screen is password protected to discourage unauthorized access. The digital I/O screens allow the user to manually activate digital outputs and to verify the digital inputs of the system for setup and troubleshooting purposes.

  • Page 49: Monitoring Performance

    Condensing Economizers The analog configuration screen allows the user to easily set the scaling values for the temperature transmitters. This screen is password protected to discourage unauthorized access. 2.5.3 - Hawk 4000 The Hawk 4000 is a totally integrated control system combining precise boiler/burner control and advanced safety features with logic-based ancillary devices and functions.

  • Page 50: Maintenance

    Condensing Economizers exit temperature is lower than normal, then either the heat transfer surface is fouled or scaled on the inside of the tubing. This requires cleaning as soon as possible during a convenient shut down period. In a circulating system containing a pump and BTU storage tank, if the economizer pressure relief valve discharges, it is likely that there is no or little liquid circulating through the economizer.
  • Page 51 Condensing Economizers Part No. 750-266 2-31...
  • Page 52 e-mail: info@cleaverbrooks.com Web Address: http://www.cleaverbrooks.com...

This manual is also suitable for:

Cce seriesC2x seriesC1x seriesC2x-2m386alC2x-2m3a6alC2x-2r3a6al ... Show all

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