BURNER INSTALLATION PROCEDURE

UNITS 1, 2, & 3
Revision 1

Summary of changes

Change Comments
Rev. 1 Step 2 removed under Windbox Preparation Existing junction box to be
kept as per CFE requirements
Step added for connecting purge air to pilot As per e-mail Dec.13
Step 3 modified under Burner Hookup Only atomizing air is not
required for new pilot
Step 4 removed under Burner Hookup Existing valve for diesel oil to
pilot to be re-used
Additional instructions added under Burner Hookup For connecting instrument air
supply

Reference Drawings
Note: General arrangement drawings are specific to each unit. However, installation drawing
and procedure is the same for all units, except where noted.

Drawing
Description Revision Transmission
Number
Issued Nov.20,
CA-1000-INS Installation drawing Rev. 0
2006
Nov. 13, 2006
GA-1000 Burner General Arrangement (Units #1 & #2) Rev. 2
doc transmittal
Nov. 13, 2006
GA-3000 Burner General Arrangement (Unit #3) Rev. 1
doc transmittal
Nov. 13, 2006
BR-1000-XXXX Burner General Arrangement Detail Rev. 1
doc transmittal

144 Barr street, St-Laurent, Quebec, Canada H4T 1Y4

Tel: (514) 382-8866 Fax: (514) 382-8488
E-mail: bma@bma.ca Web Site: www.bma.ca
Windbox preparation
1. Disconnect all tie-ins
Ø fuel oil (from inlet of flexible)
Ø atomizing steam (from inlet of flexible)
Ø diesel oil to pilot ignitor (from inlet of flexible)
Ø cooling air for oil gun and ignitor (from inlet of flexible)
Ø ignition cable
Ø pneumatic tubing to cylinders
Ø cabling to existing solenoid valves
Ø flame scanner (scanner and flexible hose not provided)

2. Remove existing burner (bolted to inner windbox wall and outer windbox casing)

3. Remove existing burner throat refractory up to inner windbox wall

4. Cut new windbox inner wall opening (refer to drawing CA-1000-INS). Ensure that there
is a minimum clearance of 26.75" for the burner throat sleeve from the windbox inner
wall up to boiler front wall. Some existing refractory anchors may have to be cut.

5. Cut windbox exterior insulation (refer to drawing CA-1000-INS)

6. Cut new windbox outer wall opening (refer to drawing CA-1000-INS)

Brais Malouin and Associates Inc. BURNER INSTALLATION PROCEDURE – 15728

Combustion, Energy Engineering, CFD Rev. 1
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Burner installation
Note: To facilitate transportation, some components may be temporarily positioned and
fastened using braces that are painted orange. These braces must be removed during or after
installation.

1. Make sure that all the shipping supports (Painted orange) have been removed from the
burner throat. Tie-wrap retaining the air shutter must be removed.

2. Remove the burner from the burner rack, cut the tacks on bolts.

3. Place each burner and burner throat in the boiler front wall. Refer to the nameplate on
each burner and refer to the drawings GA-1000, GA-3000, and BR-1000-1CW, -1CCW,
-3CW, -3CCW to install burners in the right location on the windbox for each boiler.

4. Level the burner with the windbox, the burner must be centered in the burner throat.

5. Stitch weld* 3”-9” [76 mm – 229 mm] the burner throat flange to the windbox inner wall.
Refer to the drawing CA-1000-INS.

6. Install the refractory** around the outside of the burner sleeve. Refractory must be
flush with the end of the burner throat sleeve.

7. Seal weld* the burner adapter ring to the windbox. Refer to the drawing CA-1000-INS.

8. Install insulation (refer to drawing CA-1000-INS) to protect the adapter flange and the
flange of the burner front plate from heat.

9. Verify the following dimensions on drawing BR-1000:

Ø Distance between the end of burner throat (furnace side) and the Swirler is 4-1/4"
[108 mm].
Note: Contact BMA if any of the above dimensions are different before making any
adjustments to the burner.

10. After completion of electrical wiring, position switches must be adjusted and tighten in
place.

Brais Malouin and Associates Inc. BURNER INSTALLATION PROCEDURE – 15728

Combustion, Energy Engineering, CFD Rev. 1
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 * Welding:
Ø Burner throat (material A516-70) must be welded to windbox inner wall after
positioning using type E309L welding rod.
Ø Burner adapter flange to be seal welded to the windbox outer wall after having been
positioned.

** Refractory throat:
Ø The burner throat should be fabricated using a refractory material that can
accommodate high temperatures and that has very low shrinkage when cured.
Rammed Plastic or castable refractory with a minimum 70% alumina content is
recommended.
Ø The refractory must be installed to accommodate the burner throat as specified on
drawing BR-1000.
Ø All refractory work should be performed by qualified skilled tradesmen. Refractory
contractor should determine: procedure for installing the refractory; type of
refractory best suited for the application; location and type of anchors to be used;
need and location of expansion joints if necessary; curing schedule and procedure.

Brais Malouin and Associates Inc. BURNER INSTALLATION PROCEDURE – 15728

Combustion, Energy Engineering, CFD Rev. 1
Page 4 of 6
Burner hookup
1. Connect tie-ins
Ø fuel oil (connect new flexible hose from existing piping to new coupling block)
Ø atomizing steam (connect new flexible hose from existing piping to new coupling
block)
Ø diesel oil to pilot (connect new flexible hose from existing piping to pilot)
Ø purge air to pilot
Ø cooling air for gun and ignitor (connect new flexible hose from existing piping to
cooling air connection)

2. Install new pressure gauges on new coupling block

3. Cap atomizing air pipe for old ignitor (atomizing air not required for new ignitor since
mechanically atomized)

4. Install new junction box and ignition cable

5. Install piping for new pneumatic cylinders (oil gun retraction system, air shutter)

6. Install new cabling for switches:

a. 2 air shutter limit switches
b. 2 oil gun limit switches
c. 1 oil gun proof of insertion switch

Important note for instrument air supply to air shutter pneumatic cylinder solenoid valve

When connecting the instrument air to the air shutter pneumatic cylinder solenoid the first time,
make sure the air shutter is in open position with the solenoid valve de-energized. This will
avoid a sudden displacement of the air shutter when instrument air pressure is applied, which
could cause the system to jam or possible injury. You can also increase slowly the instrument
air pressure from zero to the specified operating pressure.

Important note for instrument air supply to oil gun pneumatic cylinder solenoid valve

When connecting the instrument air to the oil gun pneumatic cylinder solenoid the first time,
make sure the oil gun is in inserted position with the solenoid valve de-energized. This will
avoid a sudden displacement of the oil gun when instrument air pressure is applied, which
could cause the system to jam or possible injury. You can also increase slowly the instrument
air pressure from zero to the specified operating pressure.

Brais Malouin and Associates Inc. BURNER INSTALLATION PROCEDURE – 15728

Combustion, Energy Engineering, CFD Rev. 1
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Brais Malouin and Associates Inc. BURNER INSTALLATION PROCEDURE – 15728
Combustion, Energy Engineering, CFD Rev. 1
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