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  #1  
Old 09-18-2011, 10:10 AM
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Default 1000 HP Burner Installation

Its mid Sunday morning and I'm stating to pack the truck for the start of a 3 month job, installing a 1000 hp (42 million btu/hr) burner on the front of a 1961 Wickes watertube boiler in the not so great state of Vermont. The job will entail the burner installation, the complete natural gas, #2 oil and water piping, the complete electrical wiring and finally the actually burner start up (with complete environmental related paperwork).

Monday's job will be the hanging of the burner on the front of the boiler. This will involve the use of a Harbor Freight engine crane, a plasma cutter, welders, etc. I made the burner adapter ring, http://www.shopfloortalk.com/forums/...ghlight=burner the boiler makers who are putting the tubes in, welded the plate on the front of the boiler, now its the start of the assembly part of the job.

The fact the job is in Vermont is not adding any excitement to this job, the office is sending up help, a part time worker, a retired GE steam turbine technician/welder. He is a great guy, but wouldn't know a boiler if it bit him on the ass, but a guy who can do just about anything mechanical, if you lay it out for him, it will be perfect when he is done.

I'll start posting pictures tomorrow of the daily progress, so you people can suffer right along with me. I rank this job somewhere between a root canal and a gun shot wound to the head, the people who a running the job are very decent people, but are not proper boiler people. Oh Fun, Oh Joy!!!
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Old 09-18-2011, 11:02 AM
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Please post LOTS of pictures. This looks interesting and is a subject I know very little about.
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Old 09-18-2011, 11:04 AM
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What part of Vermont will you be in? With the roads in some areas still washed out you might not be able to get there from here. You'll have to go someplace else first. Check with John III, if you are around Burlington for the better places to frequent. If you remember, he is the fellow from the Steam Show that is the machinist, steam enthusiast, good cook etc. that runs his own CNC shop on the side. Try to avoid the OSHA folks, MX may have the bale fund, but we wouldn't want for her to have to use it.
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Old 09-19-2011, 04:30 PM
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Arrived in Vermont, at about 7:20 am, and stated to disassemble the burner, so it can be installed. All told the burner weighs about 1000#, too heavy to install in one shot. Had burner disassembled into 2 main pieces and a few minor sub-sections by about 10:45 am. Hung the burner housing and refractory ring, by about 12:30 pm, had the other main piece hung by 2:30 pm, then called it a day.



1 - the burner out of the crate
2 - crate with control cabinet and refractory ring
3 - air damper shroud removed
4 - air damper and FGRR inlet removed
5 - some of the parts removed



jack
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Old 09-19-2011, 04:35 PM
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6 - 300# refractory throat ring
7 - burner housing
8 - burner up, test fitting FGR inlet
9 - air damper assembly
10 - other side of burner


Job is already behind schedule as boiler makers and refractory people are not done yet.





jack
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Old 09-19-2011, 04:37 PM
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That ought to get ya' hot under the collar. Thanks for the pics.
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Old 09-19-2011, 04:38 PM
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Jack,
That room looks way too clean and orderly. How do you find anything?
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Old 09-19-2011, 04:40 PM
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Quote:
Originally Posted by nctox View Post
Jack,
That room looks way too clean and orderly. How do you find anything?
Thats because its the load dock staging area. Boiler room itself is not any where as clean.



jack
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Old 09-19-2011, 04:54 PM
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Quote:
Originally Posted by platypus20 View Post
Thats because its the load dock staging area. Boiler room itself is not any where as clean.



jack


LOL Jack I have been in a few boiler rooms and knowed that wasnt one . Show em pics of the boiler room they will go .



Rick
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Old 09-19-2011, 05:04 PM
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How much fuel/hr is used to make 42 million BTU/hr?
Thanks for the show.
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