COMBUSTION. Model HDR - RF. Manual Addendum. (To be used in conjunctin with HORS-RF Manual) For Gas, Oil and Combination burners

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Beverley Edwards
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Combination burners With and without Low NOx Flue Gas Recirculation (FGR)

1 W 8ST R COMBUSTION A Selas Heat Technology Company Model HDR - RF Manual Addendum (To be used in conjunctin with HORS-RF Manual) For Gas, Oil and Combination burners With and without Low NOx Flue Gas Recirculation (FGR) Manual Part No September, All Rights Resered

2 TABLE OF CONTENTS A. General Information... B. Component Description... C. Setup & Adjustment Ratings sheets. These represent the minimum size that can be safety used with this burner. Contact the factory if the furnace is smaller than the dimensions gien. In many cases, other sizes may work depending on the fuel being used. READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE. A. General Information This addendum coers the Model HDR-RF Combustion Head from Webster Engineering & Manufacturing Co. This combustion head is different from the combustion head used on the HDRS-RF burner and offers the capability to fi re into different furnace confi gurations. All other attributes of the burner package are as defi ned in the HDRS-RF burner manual (Part No ) and related documentation, including the Wiring Diagram, Fuel Trains and other manuals like the Flame Safeguard Manual. WARNING Read and understand all manual information before doing any work. This includes this manual, the HDRS-RF manual and the Flame Safeguard manual. Failure to properly understand how to adjust and set up this equipment could result in property damage, injury or death. The Model HDR-RF is offered in a wider size range than the HDRS-RF, and these differences are coered in this addendum. Other ariations are also addressed in this addendum. 1. Model Number Configuration Figure A-1 shows the model confi guration for the HDR-RF product, and the offering ariation. This is the model number that will appear on documents related to the burner, including the nameplate, although it may be truncated to fi t aailable space. The input rating is gien in millions of BTUs instead of Boiler HP as the HDRS-RF uses. This is a more common rating system for Watertube boilers. 2. Dimensions and ratings The Dimension and Ratings sheets for the Model HDR- RF are broken out by Watertube and Firetube application sheets attached. These proide the general sizing, dimensions and ratings for different applications. If there is a requirement for low NOx or altitude, the burner ratings will be reduced. The minimum furnace size is gien on the Dimensions and Page 2 Section A - General Information

3 MODEL HDR(X) BURNER MODEL CONFIGURATION FIGURE A-1 HDR-RFC SL 1500 MARK6 -M.25 VGD -MA -UL/CSD-1 BURNER SERIES HDR-RF HDRX-RF G O C FUELS Gas Oil Gas / Oil No FGR With FGR MMBTU Input mmbtu Use number equal to the required input of the burner equals 92,300,000 MBH mmbtu HEAD SIZE inches inches Head sizes aailable in 2 increments. 27 equals 27 head inches SL SR V I HOUSING ROTATION Slant left Slant right Vertical (std) Inerted MOTOR HORSEPOWER HP HP HP HP HP HP HP HP CODES AND LISTINGS CSD-1 FM IRI NFPA-85 PRESSURE, AIR or STEAM ATOMIZING MA MS Air atomizing Steam atomizing GAS TRAIN VENDOR MODEL VGD VGG M Blank M RM7800L M Mark 6 Mark 6 E110/EP170 Nexus LMV51 LMV52 Siemens Siemens Maxon All Others (ASCO) - (std) GAS TRAIN SIZE /2 inches.30 3 inches.40 4 inches.60 6 inches MODULATION Full modulation FLAME SAFEGUARD VENDOR DESIGNATION Honeywell AutoFlame - mini mark AutoFlame Fireye Fireye Siemens Siemens The aboe represents the common model designations. Contact the factory for other options and special applications. Page 3 Section A - Model Number

4 Figure A-2 DIMENSIONS and RATINGS for Webster Model HDR-RF - For Watertube Applications Page 1 of 2 Select the Head Size to obtain the required input. Select the fan size to oercome the furnace pressure. o Low NOx aailable to 50 ppm on natural gas. o Natural gas, propane, digester gas and No. 2 through No. 6 oil firing aailable o Plant air and steam atomization for oil firing aailable. o Linkage with fuel cams standard, parallel positioning controls aailable o Oil Firing aailable to 84 MMBTU/HR (#2 through #6 oil) Head Size I.D MMBTU / HR Net Gas manifold Press w.c #2 oil GPH (2) Natural Gas CFH x1000 (1) Oil pump motor HP Oil Firing Not Aailable in These sizes Air compressor motor HP House Air or Steam Atomization Minimum furnace height in inches Minimum furnace width in inches Minimum furnace length in inches Max heat release Kbtu/cf (3) Combustion air CFM Fan selections with maximum furnace pressure and motor HP Max furn wc 2 0 The 13.5 through 18.2 Fans operate at Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc 0 The 22.2 through 49 Fans operate at 1745 Motor HP 3 Max furn wc Motor HP 5 5 Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Notes: (1) Natural gas based on 1000 Btu/cf (2) #2 oil fl ow based on Btu/gal Bullitin , R1 11/3/04 (3) Heat release based on furnace width, height and length Page 4 Section A - Figure A-2 : Watertube

5 Figure A-2 DIMENSIONS and RATINGS for Webster Model HDR-RF - for Watertube Applications Page 2 of 2 Firing Head Size (ID) and Fan size (diameter) HEAD FAN A B C D E F G H I J K L M N Firing Head Size (ID) and Fan size (diameter) HEAD FAN A B C D E F G H I J K L M N Application Notes Bulletin , R1 11/3/04 o The burner can be rotated from the position shown, to fi t the space aailable o The dimensions gien are approximate, and can ary with options and mounting ariations o Control panels, junction boxes, Fuel-Air-Ratio controls not included in dimensions o Fuel trains not shown o Air compressor and pump for oil firing are mounted separately o Fan can be mounted in remote location (optional) o Fan can be mounted in remote location (optional) Page 5 Section A - Figure A-2: Watertube

6 Figuure A-3 DIMENSIONS and RATINGS for Webster Model HDR-RF - for Firetube Applications Page 1 of 2 For Firetube Applications (see Specification cation Sheet for Watertube applications) Select the Head Size to obtain the required input. Select the fan size to oercome the furnace pressure. o Low NOx aailable to 50 ppm on natural gas. o Natural gas, propane, digester gas and No. 2-6 oil firing aailable o Plant air and steam atomization for oil firing aailable. o Linkage with fuel cams standard, parallel positioning controls aailable o Oil Firing aailable to 1000 BHP (#2 through #6 oil) Head Size I.D Boiler HP Maximum MBH Natural gas CFH Net Gas manifold Press w.c #2 oil GPH Oil pump motor HP Oil fi ring not aailable in these sizes Air compressor motor HP Minimum furnace dia Minimum furnace length Max heat release Kbtu/cf (3) Combustion air CFM Fan selections with maximum furnace pressure and motor HP Max furn wc 2 0 The 13.5 through 18.2 fans operate at 3450 Motor HP 5 5 Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc 0 The 22.2 through 49 fans operate at 1745 Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP Max furn wc Motor HP 150 Notes: (1) Natural gas based on 1000 Btu/cf (3) Heat release based on furnace diameter and length with turnaround Bulletin R1 11/3/04 (2) #2 oil flow based on Btu/gal Page 6 Section A - Figure A-3: Firetube

7 Figure A-3 DIMENSIONS and RATINGS for Webster Model HDR-RF - For Firetube Applications Page 2 of 2 Firing Head Size (ID) and Fan size (diameter) HEAD FAN A B C D E F G H I J K L M N Firing Head Size (ID) and Fan size (diameter) HEAD FAN A B C D E F G H I J K L M N Application Notes Bulletin R1 11/3/04 o The burner can be rotated from the position shown, to fi t the space aailable. o The dimensions gien are approximate, and can ary with options and mounting ariations o Control panels, junction boxes, Fuel-Air-Ratio controls not included in dimensions o Fuel trains not shown o Air compressor and pump for oil firing are mounted separately o Fan can be mounted remotely (optional) o BHP shown aboe is approximate, as burner can operate through a wide range of inputs Page 7 Section A - Figure A-3: Firetube

$Figure C-1 shows the detail of this fi ring head including the burner drawer, refractory and gas manifold. Figure B-1 shows a typical HDR-RF combustion head assembly.$ $Mounting Plate Gas Spuds (Primary) The outer ring of orifi ces are used to proide fl ame retention on the refractory, and their position is critical in relation to the refractory. 2.$

8 B. Component Description See the component layout shown in the HDRS-RF manual. The combustion head is different in that it has parallel gas spuds and less swirl applied to the air stream. Figure C-1 shows the detail of this fi ring head including the burner drawer, refractory and gas manifold. Figure B-1 shows a typical HDR-RF combustion head assembly. Mounting Plate Gas Spuds (Primary) The outer ring of orifi ces are used to proide fl ame retention on the refractory, and their position is critical in relation to the refractory. 2. Dual Gas Housing Some applications require multiple gas fuels that are contained in separate housings with independent orifi ces. These burner heads will hae double the number of gas orifi ces to accommodate both fuels, with all orifi ces terminating in the same position to support a common fl ame front. Primary Gas Spuds Diffuser Diffuser Figure B-1 Combustion Head Assembly 1. Refractory Shape The refractory front plate for the HDR-RF burner has a unique shape as shown on Figure B-1. There is a notch in the surface close to the burner head that is combined with special gas spuds to form the fl ame front and retains the fl ame. This refractory must be in good mechanical condition for the burner to work properly. Burner Mounting Studs Steel Coer Anchors Notch Secondary Gas Spuds 3. Oil Gun Figure B-3 Nozzle Arrangement Tertiary Gas Spuds The oil gun (with oil nozzle) can be easily remoed from the burner by disconnecting the oil lines and pulling it apart. See Figure B-4. The position of the oil nozzle is adjusted by backing off the set screws that lock the pipes to the spacer, and sliding the pipes in and out. The spacer will proide the correct location when re-installed. If the burner will operate on gas for longer time interals, the oil gun should be remoed to preent the oil from solidifi cation in the nozzle. 4. Burner Drawer Mounting Plate Refractory The burner drawer holds the diffuser, pilot, scanner and oil gun tube. It can be remoed from the burner by disconnecting the mounting bolts on the back fl ange and pulling it out. CAUTION Use care in handling burner drawer, especially the ignition cable insulators, which can easily break. 5. FGR System Figure B-2 Refractory Front Plate Page 8 Figure B-6 shows the FGR sizing criteria for the full range of products offered by the HDR-RF line. For complete Section B - Component Description

9 details on selection and sizing the FGR system, refer to the HDRS-RF manual. Oil Nozzle Air Line Air Supply Spacer Heated Oil Line Spacer Return Oil Outlet Oil Supply Oil Gun (Heay Oil Shown With Heated Line Return Oil Supply (Heat Trace) Figure B-4 Oil Gun Assembly Diffuser Scanner Pilot Assy Pilot Support Tube Burner Drawer Less Oil Gun Figure B-5 Burner Drawer Assembly Less Oil Gun Sight Glass Support Tube (For Oil Gun) Page 9 Section B - Component Description

10 BHP Max inlet press Pressure Drop per 100 of Duct ppm NOx Leel ppm NOx Leel Figure B-6 FGR Sizing Criteria Page 10 Section C - Setup & Adjustment

11 BHP Max inlet press Pressure Drop per 100 of Duct ppm NOx Leel Figure B-6 FGR Sizing Criteria Page 11 Section C- Setup & Adjustment

12 C. Setup and adjustment 1. Burner Drawer Setup Figure C-1 shows he general arrangementof the burner, refractory and other critical burner components. A dual housing is shown. The O.D. plane of the diffuser should line up with the tapered end of the primary gas spuds (outer row). The position of the diffuser is adjustable by moing the guide tube. This can be done while fi ring from outside the burner. The oil nozzle position should be 3/8 behind the O.D. plane of the diffuser. The position of the oil nozzle is also adjustable from outside the burner while the burner is fi ring. These settings are starting points and the fi nal settings will be determined during start-up. Refractory Oil Nozzle Centerline of Spud Points to Centerline of Burner. Large Holes Inside, Small Holes Outside 3/8 Nozzle zle Tip to Diffuser Face Burner Head Must be Centered in Refractory Diffuser Gas #2 Inlet Tertiary Orifi ces Secondary Orifi ces Gas #1 Inlet Primary Orifi ces Figure C-1 Burner Housing Assembly (Dual Housing Shown) 2. Burner Adjustments The Primary adjustment for oil fi ring is the position of the oil nozzle relatie to the diffuser. This position should be maintained, especially if the diffuser positions adjusted for the gas fi re. The register setting and excess air leels also impact the oil combustion. For gas fi ring, the position of the diffuser relatie to the gas spuds would be a primary adjustment. The register setting and excess air leels also impact the gas combustion. In some cases the gas spud arrangement may need to be adjusted to get proper mix for the furnace conditions. Refer to the HDRS-RF manual for complete adjustment and setup details. WEBSTER COMBUSTION TECHNOLOGY 619 Industrial Road - Winfield, KS Phone: Fax: sales@webster-engineering.com serice@webster-engineering.com Page 12 Section C - Setup & Adjustment

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