Workbook For Operators Of Small Boilers and Incinerators Self-instructional Text On The Proper Operation and Maintenance Of Small Oil Fired Boilers and Flue Fed Incinerators


                                              EPA-450/9-76-001
        WORKBOOK FOR OPERATORS OF
     SMALL BOILERS AND  INCINERATORS
A SELF-INSTRUCTIONAL TEXT ON THE PROPER OPERATION AND MAINTENANCE OF
       SMALL OIL FIRED BOILERSAND FLUE FED INCINERATORS
             BASED ON NEW YORK CITY CRITERIA
                      (say
                             p
                   EPA Contract 68-02-0321
                USEPA Project Officer: W.F. Todd
       UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
                Office of Air and Waste Management
              Control Programs Development Division
                 Air Pollution Training Institute
                Research Triangle Park, NC 27711
                     March, 1976

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US  EPA
This is not an official policy and standards document.
The opinions, findings, and conclusions are those of the authors
and not necessarily those of the Environmental Protection Agency.
Every attempt has been made to represent the present state of the art
as well as subject areas still under evaluation.
Any mention of products or organizations does not constitute endorsement
by the United States Environmental Protection Agency.
                                 I I
                           -"PROTECTION AGENCY

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To the user of this workbook	

          Unless otherwise infortoed,  the answers  you  write  in  this  book will
     not count toward certification.   However,  this book will  give  you
     information needed to pass the certification examination.

          For further information about certification or additional  directions
     about how to use this book, please read the  letter which  came  with the
     book.  If you are attending a training course, the instructor  or
     person-in-charge will be able to answer all  your questions.
                                Introduction
          This is a self--instructional workbook.   Self-instructional means
     you teaoh yourself.   You read the information given  about  boilers and
     incinerators.  This  information will  be followed  by  questions  about
     what you have read.   Always answer the questions.  Always  write your
     answers in the book.   (Always use a pencil.)   The  correct  answers to
     all questions are also given in the book.  Always  check your answers.

          The answer to a question may be an explanation  immediately following
     the question.  The answer may be at the bottom of  the  page.  However,
     most of the time the answer will be at the top of  the  next page.  For
     example, answer the  following questions.   If  the  answer is true, place
     a check in the blank in front of true.   If the answer  is false, check
     false.

               1)  The answer to some questions will come right after the
                   question in the book.  	True    	False.

               2)  The answer to some questions will be at  the  bottom of the
                   page.   	True     	False.

               3)  The answers to most of the  questions will be at  the top of
                   the jnext page.  	True    	False.

          Now turn the page and look at the top of the  page above the line.
                                       n

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Answers:  1)  True   2)   True   3)   True.

     This is how most questions  will  be  answered.
     Now, please continue reading  below.
             NEVER LOOK AT THE ANSWERS GIVEN IN THE  BOOK BEFORE  YOU ANSWER  THE
        QUESTION YOURSELF.  DO NOT JUST COPY THE CORRECT ANSWERS IN THE  BLANKS.
        IF YOU DO, YOU ARE NOT LEARNING.  If you cannot  answer a question or  if
        your answer was wrong, read the workbook again and  then  try to answer the
        question again.  Just remembering an answer  that is given in  the book
        will not help you as much as understanding why the  answer is  correct.

             If you do not understand the information in the workbook or if you
        do not understand a question, talk it over with  someone  - many times  this
        will help.  The city which provides this workbook will have someone in
        charge of answering questions.  If you received  the book by mail, the
        letter that came with it will tell you who you can  contact for help.   If
        you are in a training class, ask the instructor-in-charge.

             Take your time.  There is no certain time in which  you must complete
        the workbook.  The time needed will not be the same for  each  person.   If
        someone completes a workbook faster than you, do not worry about it.  The
        important thing is not how long it takes to  complete the book but how
        much you know when you are finished.

             There are many different kinds of boilers and  incinerators. The
        workbook shows the basic things which are found  on  most  kinds and types.
        The equipment in the drawings may not be exactly like your equipment.
        However, it will be close enough for you to  follow.

             Notice that some of the pages in this workbook have gray edges.  These
        pages are the HANDBOOK Sections and appear  in both  the boiler and the
        incinerator parts of the book.  You will complete the HANDBOOKS  as  you
        go along.  When you have finished the workbook,  you will have made  a
        HANDBOOK for your exact boiler or incinerator.   You can  then  quickly
        refer to your HANDBOOK pages whenever you have a problem.

         A final  note...
              As  you qo through the book, you may find words  that are unfamiliar.
         A listing of subject related words may be found on pages 59-64, Glossary.


                                                                        Good Luck
                                          I V

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                        Acknowledgment
     The content of this self-instructional  training  manual was  the
fulfillment of Environmental  Protection Agency Contract  68-02-0321.
The contractor was David Sage, Incorporated, 200 Park Avenue,  PanAm
Building, New York, New York  10017.   The developers of the materials
for David Sage, Incorporated, were David Sage, Project Manager,
Mariland Ruppart, Writer Analyst,  and C. George Segelar,  P. E.,  Staff
Engineer.  The EPA Project Officer was William C.  Todd,  Engineering
and Enforcement Section, Air  Pollution Training Institute.

     The material herein was  originally published  by  the  Air Pollution
Training Institute in August  1973  as  SI:466, Manual for  Boiler and
Incinerator Operators.  In the preparation  of this material for
publication by the Government Printing Office, the title  was changed
to more clearly indicate the  content  and identify  the user.  Minor
technical corrections were made,  based upon  review by James 0. Dealy,
Engineering and Enforcement Section,  APTI,  and changes in layout and
design were made, in the interest  of  cost,  by Jack Weaver, Instructional
Development Section, APTI.

     The content was developed as  a training aid by the  Environmental
Protection Agency.  It is not intended to be an official  policy  or
standards document, nor does completion of these materials imply
Federal certification.  A certificate is not offered  by  the Air
Pollution Training Institute  for  the  completion of the text.   For
information regarding the use of  this manual, contact your city
officials.

     Purchase requests should be made directly to  the Government
Printing Office as indicated  on the inside  front cover.   In no case
should requests for manuals be directed to  the Air Pollution Training
Institute.

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Contents


Part 1   THE PROPER OPERATION AND MAINTENANCE
        OF SMALL  OIL FIRED BOILERS

           Section 1.
           THE BASICS  OF PREVENTING AIR POLLUTION EMISSIONS FROM BOILERS
             Topic
Page
              1.    Choking  	     3
              2.    Smoking  	     4
              3.    Smoke Laws  	     5
              4.    Smoke Reading   	     6
              5.    Review  	     8
              6.    Ash and Smoke   	     9
              7.    Other Pol1utants  	    10
              8.    Rev i ew  	    11
              9.    Air/Oil Ratio   	    12
              10.    Primary Air	    13
              11.    Secondary Air   	    15
              12.    Draft through the Furnace  	    16
              13.    Review  	    17
              14.    Getting Oil to  Burn  	    18
              15.    Boiler Parts 	    20
                    Summary  	    23

                   "BOILER  ROOM HANDBOOK .7777^727

                      Basic Information  	    29
                      Basic Parts   	    31
                      Circulating the Oil   	    32
                      Heating  the Oil   	    34
                      Steam Heater  	    35
                      Hot Water Heater  	    36
                      Electri c Heater  •	    37
                      Draft System  	    41
                      Control s  	    43
                      Phone Numbers  	    46
                      Basic Maintenance Supplies  	    47
                      Supplies/Reordering   ..-	    49
                      Operation - Maintenance Summary   	    51
                      Troubleshooting Summary - General  ....    54-56
                      Troubleshooting Your  System  	    55-57
                      Gl ossary  	    59
                                       VII

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Section 2.

THE BASICS OF BOILER OPERATION AND MAINTENANCE

  Topic                                               Page

    1.    Is Your Boiler Room in Good Shape	   65
    2.    Daily Checks	   67
    3.    Cl ean Your Smoke Al arm  		   70
    4.    Revi ew  		   71
    5.    Getting Ready to Start	   72
    6.    Check Out the Burner	   73
    7.    Fifteen Minutes Later	   74
    8.    Review  		   76
    9.    Cleaning the Cup   		   77
   10.    Clean Oil  Strainer	   82
   11.    Lubricate Weekly   	 	   85
   12.    Weekly Maintenance Summary  	...;   86
   13.    Cleaning Tubes	   87
   14.    Automatic Soot Blower	   88
   15.    Punching the Tubes		   89
   16.    Review  	   91
          Operation and Maintenance Summary  	   92
          Summary  	   94


Section 3.

TROUBLESHOOTING:  BOILERS -  CORRECTING OIL TEMPERATURE

  Topic                                               Page

    1.    Smoke; What To Do  When the Alarm Goes Off.   97
    2.    Electric Heater -  Cold Oil  	  100
    3.    Electric Heater -  Oil Too Hot  	  104
    4.    Cold Oil - From the Hot Water Oil Heater   .  106
    5.    Hot Water Oil Heater - Oil Too Hot   	  108
    6.    Cold Oil From the  Steam Heater   	  110
    7.    Steam Heater - Oil Too Hot  	  114
          Summary  	  118


Section 4.
TROUBLESHOOTING:  BOILERS -  FLAME READING

  Topic                                               Page

    1.    Fl ame Away From Burner  	  121
    2.    Smoky Flame  	  123
    3.    Fl ame Too Long  	  129
    4.    Another Bad Flame  (Too Wide)   	  132
    5.    Sparky Flame  	  137
    6.    Pulsating Flame   	  139
    7.    Review  	  148
                               VIII

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Part2   THE PROPER OPERATION AND  MAINTENANCE
        OF FLUE FED INCINERATORS
           Section  5.

           INCINERATOR:
BASIC PARTS AND  FUNDAMENTALS
             Topic                                            Page

               1.    Incinerator  	   153
               2.    Incinerator Parts  	   154
               3.    Burning  	   156
               4.    After the Burn  	   164
               5.    Review  	   165
               6.    Scrubbi ng the Gases  	   166
               7.    Ash Catchers  	   172
               8.    Review	   175
               9.    Multi-Chamber Incinerators  	   177
              10.    Roof Settling Chamber   	   178
              11.    Review  	   180
              12.    Double Flues  	   182
              13.    Review  	   186
                    Summary  	   188
           Section  6.

           INCINERATORS:  MAINTENANCE AND  TROUBLESHOOTING

             Topic
                                     Page
               1.    Daily Cleaning  	   191
               2.    Daily Scrubber Cleaning  	   193
               3.    Review  	   194
               4.    Daily Checks  	   195
               5.    Flue Gate   	   196
               6.    Last Two Daily Checks   	   198
               7.    Scrubber -  Daily Checks	   200
               8.    Review  	   202
               9.    Periodic Maintenance  	   204
              10.    Scrubber Maintenance  	   208
              11.    Scrubber Maintenance Tasks  	   211
              12.    Troubleshooting  	   213
                    Summary  	   217
                    Review  	   218

                    INCINERATOR HANDBOOK 	   221
                      Parts - Definitions   	   222
                      Schematic  	   223
                      Reference Information  	   225
                      Maintenance - Troubleshooting  	   226
                                         IX

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                 Parti
   THE PROPER OPERATION
      AND MAINTENANCE
OF SMALL OIL FIRED BOILERS

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Section 1
THE BASICS OF PREVENTING
AIR POLLUTION EMISSIONS  FROM BOILERS
  including your own BOILER ROOM HANDBOOK
 1.  Choking
    We've made a lot of progress toward cleaning up the air during the past few years, but we still have a

    long way to go.


    PUT A CHECK BESIDE THE THINGS BELOW THAT HAVE HAPPENED TO YOU.


    	 Noticing that a thick gray cloud covers the city.


    	 Being amazed at how clear the air seems to be in the country.


    	 Finding that the metal work on the outside of your building is corroding due to pollution in
         the air.


    	 Taking a physical exam and wondering what pollution has done to your lungs.
    Too many people are having experiences like these. Smoky boilers are part of the problem.
                                                   — Please turn the page.

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   2.   Smoking

   We don't mind smoke, unless:
     a) there is too much smoke, or
     b) the smoke is too black

   When an inspector goes out to answer a complaint about smoke, he first finds out how black the
   smoke is. Look at the four chimneys below. PUT  "1" UNDER THE CHIMNEY THAT IS THE
   LIGHTEST. PUT "2" UNDER THE NEXT LIGHTEST, ETC.
 Check and correct
 your answers
A=l,  B=4, C2,D=3
    DO YOUR NUMBERS MATCH THE NUMBERS ABOVE ?
    If they don't,correct your answers on this page.

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3.   Smoke   Laws

Inspectors use the Ringelmann Chart to measure whether the smoke is dark enough to deserve a
summons. The darker the smoke, the more pollutants it contains. Study this chart.
         RINGELMANN SMOKE READINGS
  NEW YORK CITY LAW
                             LIGHTER
                             THAN*]
     ALWAYS O K
                                     1
O K if only 2 minutes an
hour
                                                       NEVER  O K
 Answer these questions:
 1. How long can you have $£ 1 smoke coming out
    of your stack without getting a summons?
 2. Are you allowed to have £~ 2 smoke coming
    out of your stack?
 3. An inspector tells  if smoke  is  illegal by how
    dark  it is and how long  it's been coming out of
    the stack.
    (True or False)
                                                                     —Check your answers
                                                                        on the next page.

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 Answers to Exercise 3: 1) 2 minutes per hour
                  3) True
2)  No
4.   Smoke  Reading
PUT THESE "READINGS" in the second column on the chart below.
STACK
A
B
C
RINGELMAIMN NUMBER
(fill in from above)



MINUTES
PER HOUR
1 Minute
3 Minutes
2 Minutes
VIOLATION
(yes or no)



  In the last column on the chart write "YES" if the stack is a violation of the law; write "NO" if it is
  OK. Look back to the previous page if you need to.
  After you finish the chart, answer this question:

  If you were an inspector, how many summonses would you hand out from the 3 above?
                                                                     — Check your answers
                                                                         on the next page.

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Answers to Exercise 4:
STACK
A
B
C
RING ELM ANN
NUMBER
#3
# 1
#2
MINUTES
PER HOUR
1 Minute
3 Minutes
2 Minutes
VIOLATION
Yes
Yes
Yes
       You would hand ouc three summonses.

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            5.   Review



            New York City is trying to clean up the air by:

               • not allowing dark smoke

               • allowing light gray smoke only a short time


            CHECK OFF (/) THREE THINGS in the list below that are being done to cut down on pollution.

               	  Low pollution oil is being delivered to your tank.

               	 You are taking a training and certification lesson.

               	 Your oil burning boiler will be taken out.

               	 Your boiler should be upgraded to meet certain standards.
                                                                                  — Check your answers
                                                                                      on the next page.
8

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 Answers to Exercise 5:   \   low pollution oil delivered
                           training and certification lesson
                           oil burning boiler taken out
                           boiler upgraded
 6.   Ash   and   Smoke
 Many things go up your stack. ASH and SMOKE are two of the main ones you can see.
POLLUTANT
ASH
SMOKE
WHAT IT'S ABOUT
Minerals in the oil that will not burn. Even the best oil
has a little.
Smoke — small, floating carbon bits
oil is not burned completely. Good
this.
are produced when
operation can cure
Answer these questions:

1. Which pollutant must we always get, no matter
   what we do?
2. Which pollutant is due to bad burning?
3.  Which pollutant can we prevent completely?
                                                                             — Check answers
                                                                                on the next page.

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              Answers to Exercise 6: 1) Ash  2) Smoke  3) Smoke
              7.  Other Pollutants

              Here are four more pollutants. Study the chart. Then ANSWER THE QUESTION  IN THE LAST
              COLUMN with  "Yes" or  "No".  Remember that you can  adjust  your boiler to burn the oil
              completely.
POLLUTANT
SOOT
SMUT
CARBON
MONOXIDE
NITROGEN
OXIDES
(large amounts)
WHAT IT'S ABOUT
Large pieces of carbon produced when oil is not fully
burned.
Soot and acid mixed together. If you stop soot, you stop
smut.
Formed when oil is not burned completely.
Formed when oil is burned at too high a temperature
with too much air.
COULD YOU STOP
ITV (yes or no)




             You should have "Yes" in all four boxes in the last column. You can reduce or get rid of a[[ of these
             pollutants if you operate your boiler correctly. ASH is the only pollutant you have to have.
             CHECK THE CORRECT ANSWER BELOW:
             The basic cause of the pollutants on this page is:
                                      bad fuel
                                      bad burning
                                                                                   — Check answer
                                                                                      on the next page
10

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Answer to Exercise 7:
bad burning
8.   Review
Check off the pollutants that you can prevent or reduce by good burning:
POLLUTANT
Ash
Smoke
Soot
Smut
Carbon Monoxide
Oxides of Nitrogen
(large amounts)
PREVENTABLE






          Check and correct
          your answers
You should have a checkmark next to every one except ash. All of these preventable pollutants are
due to bad burning.

Sulphur Oxides are the last pouutants. They  are formed when  the sulphur contained  in oil is
burned. We take care of this problem by using fuel having a low sulphur content to start with.
                                                                            — Turn the page.
                                                                                              •11

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                9.   Air/Oil  Ratio
                Here is the right way to burn oil.
                1.  What are the two things it takes to make a flame?
                   	and	

                2.  Does this "good flame" touch the furnace wall or floor at any point?	

                      1. AIR,  OIL
                      2. no
           A correct mixture of air and oil will produce a good flame, which should fill the furnace without
           touching its walls or floor. Too much air causes the flame to become too large. UNDER EACH
           FLAME BELOW CIRCLE THE CORRECT ANSWER, "MUCH" or "LITTLE".
                      Flame Too Small
     Flame Too Large
                Too Much / Too Little Air
Too Much / Too Little Air,
           Thin flames like the one at the left result from too little air. Too much air produces a flame that is
           too big. Both kinds of flame produce smoke. Correct air/oil ratio is the name of the game when it
           comes to beating pollution.
             Answers  1. Too little
                      2. Too much
12

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       10.  Primary   Air
       Here's a good flame. It shows two kinds of air.
               Primary Air
                      Oil
               Primary Air
       Complete these sentences:
        1.	and	

        2	
              mix together to make a flame.
air is FIRST mixed with oil to start burning.
                 1.   Air, Oil
                 2.   Primary Air
Air  comes in through the PRIMARY AIR SHUTTER
and goes into the PRIMARY AIR FAN.
The fan pushes the air to form an AIR CONE which
forced out the AIR NOZZLE.
                         is
                                                            Primary Air Fan
                        Primary Air Shutter
                                                                            Primary Air Nozzle
                                                                          Primary Air Cone
                                                                                               13

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          Before  each part WRITE  THE  LETTER  from  the
          diagram that shows it.
                         Primary Air Shutter
                         Primary Air Fan
                         Primary Air Cone
                         Primary Air Nozzle
          Now answer these questions:
            1.  The Primary Air.
moves and pushes the primary air.
            2.  If there is the wrong amount of primary air, you get a good/bad flame, (cross out one)
14

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Answers to Exercise 10:
A Primary Air Shutter
B Primary Air Fan
C_ Primary Air Cone
D Primary Air Nozzle
1) Fan
2) Bad Flame
11. Secondary Air
A lot of Secondary Air is needed around the flame. More Secondary Air is needed than Primary Air.
Fresh air comes in from outside through a LOUVER in the wall.
Air goes through the WINDBOX into the firebox.
The FIREBOX is where the flame is.
BESIDE EACH PART below WRITE THE
LETTER FROM THE DIAGRAM WHICH
SHOWS IT:
OUTSIDE LOUVER
WINDBOX

FIREBOX
Answer these questions:
\xxxxxxxxxxxxxxxxxxxx
V\\V\\\x X\x\xx\xx x \x
L\\\\\\\\\\\\\\\\\\\\
1. Name the two kinds of air a good flame needs:
2. Do you need more Secondary or Primary Air?
3. When there isn't enough Secondary Air, what kind of flame will you get?
4. If the outside louver is covered up, enough
can't get in.
-Check your answers.
15

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            Answers to Exercise 11:
            C  Outside Louver
           A  Windbox
            B  Firebox
1) Primary, Secondary
2) Secondary
3) Bad Flame
4) air
            12.   Draft   Through   The  Furnace

            There must be draft to pull air into the firebox, to help air mix with the flame, and draw hot gases
            up the stack. Draft is very important for a good flame.

            A damper in the chimney uptake controls draft. In small plants, this damper is operated by hand. In
            plants burning 25 gallons per hour or more it is automatic.

            Label the parts of the primary air, secondary air and draft systems on the diagram with the correct
            letter from the list.
                                \\\\\\\\\\\\\\\\\\\\\\\NXS: >x
                 A. Primary Air Shutter
                 B. Primary Air Fan
                 C. Primary Air Nozzle
                 D. Outside Louver
      E. Windbox
      F. Firebox
      G. Draft Control Damper
                                                                       — Check answers on
                                                                              the next page.
16

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        13.   Review

        The right air/oil ratio is needed for good burning. Check your diagram on the opposite page with
        this one.
    ANSWERS TO PREVIOUS PAGE:
                                                        Draft Control Damper
                                                                       I
    Primary Air Fan
Primary Air Shutter
                            \\\\\\\\\\\\\\\\\\\\\\\N\\\
                      Windbox
Firebox
        When all of these parts are working right, the flame will get the air it needs.
                                                                         Turn the page.
                                                                                           17

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              14.  Getting   Oil   To   Burn
              CIRCLE THE PICTURE SHOWING WHAT OIL IS LIKE WHEN IT IS BURNED.
                         1.
                                                                -**>
                                                                 ,"=;,
                                                           Cup
                                                                            Fine Spray
                                                                      .   '   of # Soil
             2 is correct...
            -# 6 oil will burn only if it is sprayed into a fine mist. Most burners use a spinning cup to do this.
              THIS IS WHAT HAPPENS IN YOUR BURNER:
           Nozzle  feeds  oil  into
           cup.
Spinning cup picks up
oil stream.
When   cup   is
smooth - oil spins into a
fine mist.
Oil drops are sprayed
into  the  air coming
from   primary   air
around the cup - mixed
with air and burned.
              Only tiny oil drops will burn completely. When the cup is damaged, the oil drops become larger.
               What happens to an oversized oil blob in the firebox?
ift

-------
          If you said "big blobs don't burn completely" or something like that, you're right.
          CIRCLE COLD or HOT and THICK or THIN under each picture, which ever is right.
                    A
                 OIL TANK
          OIL OUTSIDE THE COIL IS
        .COLD/HOT and THICK/THIN
2.
        OIL CUP
           OIL IS
COLD/HOT and THICK/THIN
           Answers
             1. The oil starts out COLD and THICK and
             2. ends up HOT and THIN.
NUMBER THIS LIST IN THE RIGHT ORDER:
          _ Truck delivers oil to fuel tank.
          _ Oil is heated to proper temperature.
          _ Oil is pumped into the cup and spun for burning.
          _ Oil is pumped from tank to heaters.
    Check and correct
    your answers -
          Answers
              1     Truck delivers oil to fuel tank.
             _3	   Oil is heated to proper temperature.

             _4	   Oil is pumped into the cup and spun for burning.
                    Oil is pumped from tank to heaters.
                                                                                              19

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15. Boiler Parts

A boiler system contains the parts shown below. Larger systems will have more parts; smaller
systems may have fewer parts. In this diagram all of the parts are stretched out to show them
clearly. Your equipment may be wrapped around the boiler.

Study this and answer the questions
Oil Storage-Tank
Heating Coil
Oil Pump
Boiler Tubes
Oil Steam or
Hot Water Heater
II "-••-• ^11 L—-J
\\ W Electri

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Answers to Exercise 15: 1) Heating Coil
2) Two
3) Oil Pump
4) Atomizer Cup
5) Air Damper in Windbox
6) Primary Air Fan
PUT A CHECK IN THE CORRECT COLUMN NEXT TO EACH BOILER PART. The first one is
done for you. Pipes are used in moving the oil.

BOILER
PARTS
1. Pipes
2, Electric Heater
3. Cup (Atomizing)
* Secondary Air
' (Windbox)
5. Primary Air Fan
6. Fuel Storage Tank
7 Steam or Hot
' Water Oil Heater
Automatic Damper
' Control
9. Stack Damper
10. Fuel Tank Heating Coil
HAS TO DO WITH
AIR

HEATING

STORAGE
& MOVING
/

BURNING

• Check your answers
on the next page.
21
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Answers to previous page

BOILER
PARTS
1. Pipes
2. Electric Heater
3. Cup (Atomizing)
4 Secondary Air
' (Windbox)
5. Primary Air Fan
6. Fuel Storage Tank
7 Steam or Hot
Water oil Heater
Automatic Damper
8- Control
9. Stack Damper
IQ Fuel Tank
' Heating Coil
HAS TO DO WITH
AIR

>/
y

y
v/

HEATING

y
STORAGE
& MOVING
s/

BURNING

22
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Summary

These questions review the important things in this section:

1. A Ringelmann Chart measures how the smoke is.

2 Ringelman 1 smoke is allowed if the length of is less than two minutes.

3. What happens if you have too much dark smoke?

4. Check the pollutants you can reduce or prevent:

Ash Smut
Smoke Carbon Monoxide
Soot Nitrogen Oxides
5. When air and oil are not properly mixed, the result is which results in smoke.

6. What term (including the ingredients of burning) is the key to good burning? ratio

7. Name the two "types of air" used in the burning of fuel:
8. What equipment delivers the two "types of air"?
9. What draws the air through the f urnance?
10. How does air first get into the boiler room?
11. What do you get if you have the wrong amount of air or if the oil is not atomized correctly?
23
-------
12. What form must oil be in, in order to burn?
13. What must be done to the oil before it can be atomized?
14. Circle the correct words:
a) All boilers are the same/different.
b) The atomizing cup is the center of the burner/heater.
c) Boilers ususally have electric and steam generators/heaters.
Answers to Summary

1. black or dark
2. time
3. summons
4. Ash _±/_ Smoke _V/ Soot ^ Smut _v/L Carbon Monoxide v/ Nitrogen Oxides
5. bad burning
6. air/oil
7. primary, secondary
8. primary air shutter or fan, windbox
9. draft or damper in the chimney
10. air louvers on outside wall
11. bad burning or poor flame
12. fine, even mist
13. heated
14. a)different
b) burner
c) heaters
24
-------
GRAY-EDGED pages are

Take this BOOK to your boiler room.

Get a pencil and a piece of chalk. As you follow the instructions given on each page, you will be
putting together a manual for running your boiler. It will contain lists of:

• correct instrument readings and control settings
• spare parts you should keep on hand
• names and model numbers of parts of your boiler system to use when ordering parts or calling
service
• fuel oil suppliers, service contractors and others whom you may need from time-to-time

These lists will be different for each boiler room. That's why only you can fill out your own
manual in your own boiler room. As you do it, make allowances for the fact that no two boiler
rooms are alike. Yours may be very different from the diagrams shown here. That's OK. The
important thing is to make sure you know where everything is and to get the information you
need to do your job right.

Remember...

Gray-Edged pages are

a Handbook for YOUR BOILER!
25
-------
BOILER ROOM HANDBOOK

OPERATING AND MAINTENANCE MANUAL
FOR THE BOILER AND BOILER ROOM
AT
Building
Street
Borough Zip

Prepared By
Boiler Operator
Date
27
-------
CONTENTS

Basic Information 29
Basic Parts _____^_ 31
Circulating the Oil 32
Heating the Oil 34
Steam Heater 35
Hot Water Heater 36
Electric Heater 37
Draft System 41
Controls 43
Phone Numbers 46
Basic Maintenance Supplies 47
Supplies/Reordering 49
Operation - Maintenance Summary 51
Troubleshooting Summary - General 54 - 56
Troubleshooting Your System 55 - 57
Glossary 59
28
-------
BASIC INFORMATION
The two things in the box are required by law to be posted in your boiler room.
1. Burner Manufacturers' Instruction Card
2. City Upgrading Certificate
Look around your boiler room and answer the questions below:

1. List the Manufacturers' Instruction Cards which
are posted in your boiler room:
2. Where is the City Certificate which
shows that your boiler has been upgraded?

3. Does the electrical source to your boiler have fuses
or circuit breakers?
If fuses — write the number of fuses and size in
amps here.

4. Where is your remote control switch?
Go on to the next page.
29
-------
Stack
Damper
HEATERS

Steam Heater
Primary Air Fan
AIR
DRAFT
30
-------
SOME BASIC PARTS

Five major parts of a typical system are shown on this diagram. Using it for reference, take the
chalk and mark the following numbers on your boiler system (if you cannot find any part, skip it
and go on to the next one):
FIRST find the OIL PIPES:
Write a 1 anywhere on the oil supply pipe leading from the fuel tank to the heaters.
Write a 2 anywhere on the pipe leading from the electric heater to the burner.
NEXT find your OIL HEATERS:
Write a 3 on your Steam Heater or Hot Water Oil Heater
Write a 4 on your Electric Heater
NEXT you will mark the AIR delivering parts:
Write a 5 on your Primary Air Fan Casing.
Write a 6 on the Windbox (Secondary Air).
Write a 7 on the breeching as close to the stack damper as you can reach.
NEXT find your CONTROL BOARD:
Write an 8 on your Control Board.
LAST go to your BURNER ASSEMBLY:
Write a 9 on the front plate of the burner.
Go on to the next page.
31
-------
FUEL
OIL
TANK
PRESSURE
GAUGE

TEMPERATURE
GAUGE
A
MODULATING
METERING
VALVE
TEMPERATURE
GAUGE
PRESSURE
RELIEF
VALVE
J-
MAGNETIC
OIL
VALVE
CIRCULATING THE OIL

To complete this page, find parts on your boiler system that have to do with MOVING THE OIL.

Above is a general diagram.

Find each of the parts below on the diagram, then locate it in your boiler room. Put a check in
the box before each part when you find it. Then, answer the questions about it.
FUEL OIL TANK

1. How many gallons does your tank hold?

2. What is a five-day supply for you in winter?
D FUEL OIL PUMP

1. What is the make and model number of your pump?

2. What is the belt size for it?
32
-------
TEMPERATURE GAUGES ON OIL LINES
Complete this chart for
the number of tem-
perature gauges that you
have:
VACUUM GAUGE

PRESSURE
NO OF.
GAUGES
1
2
3
4
5
LOCATION

CAN
REPLACE?
(yes/no)

MAKE

Complete this chart for
these gauges:
VACUUM
GAUGE
PRESSURE
GAUGE
NORMAL
RANGE
REPLACEMENT
SPECS.
OIL STRAINERS
1. How many strainers do you have?
2. Are they single or double basket?
3. Do you know the make and model number?
PRESSURE RELIEF VALVE

MODULATING METERING VALVE

MAGNETIC OIL VALVE
Complete this chart for

these valves:

PRESSURE RELIEF
VALVE
MODULATING
METERING VALVE
MAGNETIC OIL
VALVE
LOCATED?
(yes/no)

DO YOU
ADJUST THIS?
(yes/no)

Go on to the next page.
33
-------
HEATING THE OIL

These pages will help you locate boiler parts which HEAT your oil.

FIRST - CHECK OFF THE OIL HEATERS BELOW WHICH YOU HAVE ON YOUR SYSTEM:

1. Steam Heater
2. Hot Water Oil Heater
3. Electric Heater
COMPLETE ONLY THE PAGES FOR THE HEATERS YOU HAVE.
Remember, you will
If you have a Steam Heater, complete page 35

If you have a Hot Water Oil Heater, complete page 36 ave to °
7 .1-1-3 yOUr own
If you have an Electric Heater, complete page 37
room.
CIRCLE THE PAGES BELOW WHICH YOU WILL COMPLETE.

35 36 37

COMPLETE THE PAGES YOU HAVE CIRCLED. When you have finished, go on to page 38

REMEMBER: Heater thermostat settings depend on what kind of oil you are burning.
34
-------
STEAM HEATER
Complete this page only if you have a Steam Heater. Use this general diagram to do the work
below.
STEAM REGULATOR
oil
PUT A CHECK IN THE BOX BEFORE EACH ITEM WHEN YOU FIND IT ON YOUR
SYSTEM. THEN, ANSWER THE QUESTIONS.

17 STEAM HEATER
1. What is the make and model number of your heater?
THERMOSTAT
1. At what temperature should your steam heater thermostat
be set?
STEAM REGULATOR
1. Is the set screw on your steam regulator tight?
STEAM TRAP
1. Is there any water (condensation) coming out of your
steam trap now?
If you have a Hot Water or Electric Oil Heater, go on to those pages.
35
-------
HOT WATER OIL HEATER
Complete this page only if you have a Hot Water Oil Heater. Use this general diagram for
reference.
THERMOSTAT
OIL
HOT WATER OIL HEATER
<—WATER
PUT A CHECK IN THE BOX BEFORE EACH ITEM AFTER YOU FIND IT ON YOUR
SYSTEM. THEN, ANSWER THE QUESTIONS.
Q HOT WATER OIL HEATER
1. What is the make and model number of your heater?
G THERMOSTAT
1. At what temperature should your Hot Water Oil Heater
Thermostat be set?
]_! PUMP SERVING THIS HEATER
1. Is there a separate pump for this heater?
2. If so, what is the make and model number?
3. If so, list the size of any belt on it.
4. What is the size of the motor (HP) for this pump?
CIRCLE any part or question above that you cannot find or answer. Ask your instructor about
these at the next class session.
If you have an Electric Heater, go on to the next page.
36
-------
ELECTRIC HEATER

Complete this page only if you have an Electric Heater. Use this general diagram as reference.
WARP POINTS
(Inside Thermostat)
I
THERMOSTAT
-->,
ELECTRIC HEATER
COLD OIL INTERLOCK
PUT A CHECK IN THE BOX BEFORE EACH ITEM AFTER YOU HAVE FOUND IT ON
YOUR SYSTEM. THEN, ANSWER THE QUESTIONS.
ELECTRIC HEATER

Complete this chart for
your Electric Heater:

ELECTRIC
HEATER
MAKE

MODEL
NUMBER

WATTAGE

THERMOSTAT

1. At what temperature should your electric heater
thermostat be set? (atomizing temperature)

COLD OIL INTERLOCK

1. At what temperature should your cold oil inter-
lock be set? (15° below thermostat setting)

WARP POINTS (inside thermostat)

1. If you change these, what are the specs?
Go on to the next page.
37
-------
BURNER ASSEMBLY
FLAME SCANNER
V\\\\\\\\\\\\\\\\\\\\\\Vv\
MODULATING MOTOR
BURNER HINGE/LATCH
38
-------
BURNER ASSEMBLY
On this page you will locate the basic parts of your burner assembly. Refer to the diagrams on
the opposite page.
PUT A CHECK IN THE BOX BEFORE EACH PART WHEN YOU FIND IT ON YOUR
SYSTEM. THEN, ANSWER THE QUESTIONS.
D GAS PI LOT
1. What is your pilot electrode size?
G BURNER
1. Look on your burner main-plate to find the make
and model number.
2. What is your burner motor size (HP) ?
3. What are the belt sizes?
4. Do you have a lube oil indicator or must you look in
the reservoir?
G MODULATING MOTOR
1. What is the make and model number?
Q ATOMIZING CUP
1. What is the make and size? (If not given, measure
cup opening and side length.)
D SOLID LINKAGE
1. Are settings permanently marked on the burner plate
or do you mark them?
FLAME SCANNER
1. What type do you have: A. Lead Sulphide
B. Ultra-Violet Ray
C, Flame Rod
D. Photo-Ceil
2. What is the make and model number?
D BURNER HINGE/LATCH
1. How many twist plugs or "dogs" must be dis-
connected to open your boiler?
D COVER FOR BURNER OPENING
1. Where is this kept when your burner is operating?
Go on to the next page.

39
-------
DRAFT SYSTEM
MODULATING
METER
VALVE
PRIMARY
AIR FAN
INSIDE
AIR
LOUVER
UPTAKE STACK DAMPER
PRIMARY
AIR
LINKAGE
MOTQR
OPERATING
V\\\\\\\\\\\\\\\\\\\\\\\\\
PRIMARY
AIR
SHUTTER
SECONDARY AIR DAMPER
SECONDARY
AIR
LINKAGE
-------
DRAFT SYSTEM
Here you will locate parts of your system which provide air to the burner. Use the diagrams on
the opposite page.
PUT A CHECK IN THE BOX BEFORE EACH PART WHEN YOU LOCATE IT ON YOUR
SYSTEM. THEN, ANSWER THE QUESTIONS.

n FRESH AIR INTAKE INTO BOILER ROOM
1. How many windows or fixed louvers does your
boiler room have?
PRIMARY AIR SHUTTER, FAN, LINKAGE
1. Is the opening to the shutter clear?
2. What is the fan belt size?
3. Does the fan seem to be in good working order?
SECONDARY AIR DAMPER, LINKAGE
1. Does the damper move freely?
2. Does the linkage move freely?
3. Is the linkage in the right position?
UPTAKE DAMPER IN STACK, LINKAGE
1. Is your damper automatic or manually set?
2. Does this linkage move freely?
MOTOR OPERATING DRAFT DAMPER
1. What is the make and model number of this motor?
Go on to the next page.
41
-------
CONTROLS
MASTER
CONTROL
D
VACUUM TUBE
(Inside Master
Control)
B
MANUAL
RESET
BUTTON
42
-------
CONTROLS
This page and the next are concerned with basic boiler controls. This page (with the opposite
diagram) includes controls that usually appear on the Control Board.
PUT A CHECK IN THE BOX BEFORE EACH PART WHEN YOU LOCATE IT ON YOUR
SYSTEM. THEN, ANSWER THE QUESTIONS.
D CONTROL BOARD
Where is your Control Board?
D MASTER CONTROL SWITCH
Where is your Master Control Switch located?
D VACUUM TUBE (inside Master Control)
What type of Vacuum Tube does your system use?
D MANUAL RESET BUTTON
What color is your Manual Reset Button?
Go on to the next page.
43
-------
STEAM PRESSURE
GAUGE
LOW WATER
CUT-OFF
SMOKE ALARM
LIGHT SOURCE
SMOKE ALARM LEP
(Receiver)
^\\\\\\\\\\\\\\\\\\N\\\V

\AUTOMATIC
V DAMPER
CONTROL
SMOKE
ALARM
44
-------
CONTROLS (continued)

These controls will be located on and around your boiler.
PUT A CHECK IN THE BOX BEFORE EACH PART AS YOU FIND IT ON YOUR SYSTEM.
THEN, ANSWER THE QUESTIONS.
G LOW WATER CUT-OFF
How often do you clean your low water cut-off? .
G STEAM PRESSURE GAUGE ON BOILER
If you have one, what is the correct pressure reading on your
boiler?
G AUTOMATIC DAMPER CONTROL (on boilers
of 25 gallons per hour or more)
Do you have an automatic damper control?
G SMOKE ALARM
What kind of smoke alarm do you have (light, bell, etc.)?

G SMOKE ALARM SENSOR (light source)
Where is your smoke alarm light source located?
G SMOKE ALARM SENSOR (receiver, lens)
Can your smoke alarm lens be reached for cleaning?
Go on to the next page.
45
-------
IMPORTANT TELEPHONE NUMBERS
Complete this list of "who to call" for future reference:
NAME AND ADDRESS
(Where Appropriate)
TELEPHONE
SUPERVISOR
BOILER SERVICE
- BREAKDOWN
(Boiler Mechanic)
BOILER SERVICE
-CLEANING
FUEL OIL
DELIVERY
LOCAL
HARDWARE
STORE
FIRE
DEPARTMENT
ELECTRIC COMPANY
DEPT. OF WATER
SUPPLY, GAS
& ELECTRICITY
46
-------
BASIC MAINTENANCE SUPPLIES
Here is a basic list of general supplies:
1. Broom
2. Dust Pan
3. Wooden Stick
4. Clean Cleaning Rags
5. Metal Scraper
6. Wrenches
7. Allen Wrenches
8. Pliers
9. Screwdrivers
10. Flashlight
11. Dipstick or Sounding Tape
12. Solvent (kerosene)
13. Heavy Cloth or Canvas
14. Heavy Duty Extension Cord
15. Disposal Can for Oily Rags
16. Equipment Manuals:
If you manually clean boiler tubes:
17. Vacuum Lance
18. Fibre Boiler Tube Brushes
List here the supplies from the top of this page which you do not have on hand and need to get:
47
-------
REFERENCE SPECIFICATIONS
On the next two pages are charts which will give you easy access to information
when you need it. If you have completed all of the pages before this one, you
already have what you need.

FILL OUT THE CHARTS ON THE NEXT TWO PAGES where they apply to
your system.

Get the information from pages 29 - 47.
48
-------
SUPPLIES/REORDERING
ITEM
ATOMIZING CUP
SPECIFICATIONS
(Model No., Type,
(Size, Wattage, etc)

SPARES
TO HAVE
ON HAND
1
BELTS FOR:
Burner Motor
Fuel Oil Pump
Modulating Motor
Primary Air Fan
Other
BULBS, LIGHTING
FUEL OIL -#6

Burning Temperature:
1
1
1
1

1 For every
5 bulbs in
use
5 days
supply
FUSES FOR:
Boiler Plant
Electric Circuits
Other

2 of each

GAUGES:
Pressure Gauge
Temperature Gauge
Vacuum Gauge
GAS PILOT - ELECTRODE
LUBE OIL
OIL STRAINERS
VACUUM TUBE
(Master Control)
WARP POINTS

Size:
Grade:

1
1
1
1

1
1
1 set
COMPANY (Supplier)
TELEPHONE NUMBER

49
-------
APPROPRIATE RANGE OR READINGS FOR THIS SYSTEM
Reading/Range
Vacuum Gauge
Pressure Gauge
Steam Pressure Gauge
(on boiler)
Thermostat — Steam or Hot
Water Oil Heater
Thermostat — Electric Heater
Atomizing Temperature
EQUIPMENT SPECIFICATIONS
Atomizing Cup
Burner
Flame Scanner
Heaters:
Electric Heater
Steam/Hot Water Oil
Motors:
Burner Motor
Draft Damper Motor
Modulating Motor
Other
Oil Strainers
Pumps:
Fuel Oil Pump
Other
Make
Model Number
50
-------
OPERATION AND MAINTENANCE SUMMARY

BOILER ROOM CLEAN-UP

Doors must lock
Oil slicks gone
Gauges easy to read

Tools put away
Air intakes clean
Garbage cleaned up

DAILY CHECKS

1. FUEL in the tank
2. WATER in the boiler
3. OIL TEMPERATURE - heater settings OK

FREQUENT CLEANING

1. SMOKE ALARM LENS
2. ATOMIZING CUP
Getting
Ready
Cleaning
The Cup
Other
Checks
1. Disconnect twist plugs and linkage
2. Open latch
3. Swing burner out
s 4. Cover burner opening

1. Clean cup with rag and solvent
2. Remove deposits with wooden stick
3. Spin cup to check for wobble.
4. Check cup surface and edge for nicks
1. Clean fuel nozzle
2. Clean air cone around cup.
51
-------
STARTING A COLD BOILER
Getting
Ready
Check Burner
1. Check oil pressure gauge
2. Turn on fuel oil pump
3. Turn on electric heater

1. Inspect cup, clean if necessary
2. Swing burner into place
, 3. Reset linkage, lock in burner
After
Start
Checks
1. Flame
2. Oil Temperature
3. Oil Pressure
WEEKLY MAINTENANCE

1. CLEAN OIL STRAINERS

Single Basket
1. Turn off oil valve
2. Shut down boiler
3. Remove basket & clean
4. Replace basket
5. Open oil valve
6. Start boiler
2. LUBRICATE WHERE NEEDED

MONTHLY MAINTENANCE

1. CLEAN BOILER TUBES
Double Basket
1. Switch oil to empty basket
2. Remove dirty basket & clean
3. Replace basket
52
-------
Please Stop

Pages 54-57 will be filled out
as you complete Sections 3 and
4. Please turn to page 65 and
begin Section 2.
TROUBLESHOOTING REFERENCE
In this section are TROUBLESHOOTING TABLES which

tell you exactly WHAT TO DO WHEN YOU GET SMOKE.

These pages will be completed with Troubleshooting, Boilers;

Sections 3 and 4.

Then, use them as reference if your smoke alarm goes off.
53
-------
TROUBLESHOOTING SUMMARY-GENERAL
CORRECTING OIL TEMPERATURE:
TROUBLESHOOTING
CHECKS FOR:
COLD OIL

OIL TOO HOT
ELECTRIC HEATER
1. Heater Switch on
2. Circuit Breakers
closed
3. Oil Thermostat set
and working
4. Heating Element
working
I.Oil Thermostat
2. Warp Points
HOT WATER
OIL HEATER
1.OH
Thermostat
2. Pump - Motor

1.OJI
Thermostat
STEAM HEATER
1 . Steam Pressure
Gauge - Boiler
-2psi
2. Oil Thermostat
3. Steam Trap
4. Steam Regulator
1. Oil Thermostat
2. Steam Regulator
54
-------
TROUBLESHOOTING THIS PARTICULAR SYSTEM
CORRECTING OIL TEMPERATURE:
TROUBLESHOOTING
CHECKS FOR:
HEATERS ON THIS SYSTEM
COLD OIL
OIL TOO HOT
55
-------
TROUBLESHOOTING SUMMARY-GENERAL
FLAME READING: Based on normal oil flow.
INCORRECT
FLAME

HOW
INCORRECT
POSSIBLE
CAUSE

CHECKS
TO
MAKE

rrJJ
/M^ -ytS^~^L,
Lni£ ^^r
i-j — '

FLAME AWAY FROM
BURNER

Too much Primary Air

Primary Air
shutter, linkage.
fan

,-Jj . 3 .
t\> ,^^-^^^Jl
j-^> ^S^
H '

SMOKY FLAME

Not enough air

Primary Air
shutter, linkage

Secondary Air
Windbox, linkage
Stack Damper

n n^
\ j| > ^/^—^^^
^n ^^^^
,-j — i

FLAME TOO LONG

Too much oil
Incorrect cup
position

Oil Valves
Burner Cup

INCORRECT
FLAME

HOW
INCORRECT
POSSIBLE
CAUSE
CHECKS
TO
MAKE

H -1

FLAME TOO WIDE
Too little primary
air; Incorrect cup
position
Primary Air
shutter, linkage,
fan
Burner Cup

T-* '

SPARKY FLAME
Oversized bits of
oil and carbon
Cup - Clean,
possible
adjustment

n^
njnl^ ^f^=^^=^
1 s\ r""" -^*~*5. ^ y ^~
,J 1

PULSATING FLAME
Oil amount incorrect
Uneven oil flow
Too little air
Oil Temperature
Oil Pressure
Air Supplies

56
-------
TROUBLESHOOTING THIS PARTICULAR SYSTEM
FLAME READING: Based on normal oil flow.
INCORRECT
FLAME
HOW
INCORRECT
FLAME AWAY FROM
BURNER
SMOKY FLAME
FLAME TOO LONG
POSSIBLE
CAUSE(S)
CHECKS
TO
MAKE
INCORRECT
FLAME
HOW
INCORRECT

POSSIBLE
CAUSES(S)
CHECKS
TO
MAKE
FLAME TOO WIDE
SPARKY FLAME
PULSATING FLAME
57
-------
On the following pages is a short glossary of words that apply to
your boiler. This is for future reference. YOU DON'T HAVE TO
DO ANYTHING ON THESE PAGES.

If you ever want to check on what a word means that has to do
with the boiler, look here for its meaning.

GLOSSARY
A
ATOMIZE

ATOMIZING CUP

B
BOILER FIRETUBES
BREECHING

BTU
To break into tiny bits or mist.

Cone in the burner assembly which spins the oil into a mist
for burning.
Tubes through which the heat from the furnace flows to
heat the water in the boiler.

Connection (channel or pipe) from boiler to stack.

British Thermo Unit; the amount of heat necessary to raise
the temperature of 1 Ib. of water 1 ° F at or near
maximum density.
BURNER COVER
BURNER CUP

BURNER HINGE

BURNER MOTOR

C
CHECK VALVES

CIRCUIT BREAKER

COMBUSTION
Cover which should be used over burner opening when
burner is swung out (venturi cover). Failure to cover
opening might cause refractory to be damaged from cold
air shock.

Atomizing cup; cup which spins the oil into a fine mist for
burning.

Joint(s) on which the burner can be swung away from the
main boiler assembly.

Motor providing the power to spin the atomizing cup.
A valve permitting oil to flow in one direction only; used
to prevent oil from returning to the tank when the pump
shuts down.

Device for the automatic interruption of an electrical
circuit when a problem occurs.

Burning; the interaction of oil with oxygen In air ac-
companied by a well defined flame releasing heat.
CONDENSATE
Water formed by cooling steam.
-------
D
DAMPER

DIAPHRAGM

DIPSTICK

DRAFT

DRAFT CONTROLS

E
EMISSION

F
FAN CASING

FIREBOX

FLAME ROD

FLAME SCANNER

FLASH POINT

FLUE GAS
Device which checks or regulates the draft (air) flow.

Flat disk of metal or rubber which bends in response to
pressure changes.

Long stick used to measure the depth of a liquid.

Air flow caused by chimney effect or by a blower (fan).

Ways of regulating the air flow.
Undesirable combustion products such as smoke, soot,
SO2 etc.
The fan cover which permits access to the fan.

The furnace; where combustion takes place.

Sensor inserted in the flame to establish and monitor
proper ignition.

Sensor to establish or monitor proper ignition based on
presence of ultra-violet rays; purple peeper.

Temperature (determined by laboratory test) which indi-
cates the fire safety of the fuel.

Products of burning fuel.
FLUE GAS
TEMPERATURE

FUEL NOZZLE
Temperature of gases as they leave the boiler.
Fitting at the end of the oil supply line which distributes
the oil into the cup.
GRAVITY (specific)
The comparison of the ratio of the weight of a gallon of oil
to a gallon of water; measured in degrees API (American
Petroleum Institute); low gravity indicates heavy oil.
60
-------
H
HEATERS
Equipment which raises the oil to the required tem-
perature for pumping, flow, and burning; boiler systems
are equipped with an electric header and a steam or hot
water oil heater.
IGNITION

IMPINGEMENT
The act of lighting fuel; light-off.

When flame touches refractories so as to impair com-
bustion.
J
JUMPER
Means for cutting an electrical control out of the circuit.
LATCH-OUT SWITCH

LOUVERS

LOW WATER CUT-OFF
Safety switch; device which protects the boiler by shutting
down the system in the event of flame failure.

Movable, multiple panels for controling air flow.

Automatically shuts off the burner when the water in the
boiler is too low.
M
MAGNETIC OIL VALVE
MASTER CONTROLLER
(programmer. Pro-
jector Relay)

METERING VALVE
MODULATING MOTOR

MODULATION
Control which starts and stops oil from entering the
atomizing cup.

Device on the main panel board which starts and stops the
burner safely.
Automatic oil flow valve connected to the Primary and
Secondary air dampers so that burner operation can be
modulated.

Motor that drives the linkages to oil and air valves.

Automatic matching of the burner oil input with the
correct air flow to meet the heating demands of the
building.
61
-------
0
OIL PRESSURE

OIL PRESSURE GAUGE

OIL TEMPERATURE
INTERLOCK
OIL TRANSFER PUMP

PARTICULATES

PHOTO CELL
The force required to move the oil.

Instrument used to measure oil pressure.

Thermostatic control set to prevent the burner from
operating until the oil reaches the proper viscosity for
good combustion.

Motor driven pump providing the pressure required to
move oil from the tank to the burner.
Any solid or liquid (other than water) which is so small as
to be capable of being carried by the wind or suspended in
air.

The sensor which proves the presence of a flame, thus
insuring a safe light-off.
PILOT

POST-PURGE

POUR POINT

PRE-PURGE
PRESSURE RELIEF
VALVE

PRIMARY AIR SHUTTER
PSI

PULSATING
A gas burner used to light the main oil burner.

Continuing burner fan operation after the flame is shut off
in order to clean any residual oil or gas vapors remaining in
the boiler.

Measure of the effect of temperature on the ability of oil
to flow; is measured by cooling the oil until it just moves.

Burner fan operation before ignition to insure absence of
combustion vapors in the boiler.

Valve set at a pressure to permit the oil to return to the
tank when not needed to meet the burner need.

Adjustable, automatic means of controling the primary air
to the burner.

Pounds per Square Inch — a unit of pressure.

Rhythmic changing of the flame shape.
62
-------
R
RATIO
REFRACTORY
The relation of one substance to another; in boilers the
relation of the right amount of air to the right amount of
oil is the proper air/oil ratio.

Special brick lining for the firebox in the boiler.
RELAY

RESET

RESIDUAL

RINGELMANN CHART

ROTARY CUP
Part of control system used to transfer electrical impulses.

Generally refers to the main overriding safety control
valve; must be manually turned back on in the event of
automatic shutdown.

Refinery term for the end product of oil processing;
descriptive word for #6 oil.

Chart used to measure the severity of air pollution by how
dark the smoke is.

Polished brass cone in burner which spins to atomize the
oil.
SAFETY CONTROL
SENSORS

SCHEMATIC DIAGRAM
SECONDARY AIR

SECONDARY AIR
DAMPER

SEDIMENT

SEQUENTIAL DRAFT
CONTROLLER

SMOKE ALARM
Parts of the safety system located in the firebox and used
to prove the existence of flames.

A diagram drawn to show the proper order and relation of
things rather than how they actually look.

Air supply around the burner flame from the windbox.

Damper on the windbox usually in the form of louvers to
control secondary air flow.

Undesirable residues in oil.

A regulator in the breeching which adjusts stack draft.
Device in the breeching which responds to smoke by
setting off an alarm.
63
-------
SOLVENT

SPINNING CUP

STRAINERS

SUCTION BELL
Organic liquid used for cleaning; usually kerosene or
Stoddard's solvent.

The atomizing cone in the burner.

Large and fine mesh sieves in the oil lines which remove
residue.

Device in the storage tank where a limited amount of oil is
heated for pumping.
TRIAL FOR IGNITION
Time period provided to complete the ignition cycle;
normally about 10 seconds. If ignition does not take place
within this time, the boiler shuts down (some systems
permit a second trial).
V
VACUUM GAUGE

VISCOSITY
An oil pressure gauge on the oil line (on inlet side of
pump) which indicates clogging of oil line.

A measure of the ability of oil to flow.
w
WINDBOX
A louvered cover designed to permit modulation of the
secondary air flow.
64
-------
Section 2
THE BASICS OF
BOILER OPERATION AND MAINTENANCE
1. IS YOUR BOILER ROOM IN GOOD SHAPE?
Get your upgraded boiler room off to a good start and keep it clean!
DOORS MUST
LOCK
OIL SLICKS
GONE
GAUGES EASY
TO READ
JOOLS PUT
AWAY
AIR INTAKES
CLEAN
GARBAGE
CLEANED UP
Keep strangers out
Floor dry —
no puddles or oil slicks
Clean instruments
You're bound to get
in a cluttered room
hurt
Never block
outside air intakes
No mess
To be sure you've got it, fill in the blanks below:
must lock.
slicks gone.
easy to read.
put away.
intakes clean.
cleaned up.
Write the first letter of the first word of each sentence in this space:
Check your answers
65
-------
66
Answers to Exercise 1: D O G T A G
See if DOGTAG will help you remember the six rules for keeping your boiler room in shape. Write
them below.
Check and correct your answers
from preceding page, then go
to next exercise.
-------
2. CHECK THESE THINGS EVERY DAY

To keep the boiler running right you'll need:

- FUEL in the tank
- WATER in the boiler
— OIL hot enough to flow and burn properly
FUEL
You should check your fuel gauge every day, especially in winter. Keep a five-day supply on hand.
Draw a needle on the fuel gauge below showing a five-day supply of oil for you in winter (refer to
Boiler Handbook you've started).
What is your fuel supplier's
telephone number:
— Go on to next page
67
-------
WATER
Check the water level by looking at the gauge glass on the outside of the boiler. If the gauge glass
registers half full or more, there is enough water; add water if the glass registers under half.
CIRCLE THE CORRECT WORD under each gauge glass below:
L. 1' II

' *'x/v
/ t'
l \ f
m

ill
1 IIIIUII
Water
OK/NEEDED
Water
OK/NEEDED
L
Water
OK/NEEDED
1. OK
2. NEEDED
3. OK
You would have to add water to the second glass only, one and three are OK. When you need water,
what do you do?
Turn on feed pump:
Other:
Open city water valve:
(describe)
Go to next page
68
-------
OIL TEMPERATURE (in electric heater)

Low-sulphur oil — like the kind you are burning now — atomizes at lower temperatures but still
must be heated.

What is the atomization temperature you now use?
Here is an electric heater (with cap removed):
OIL TEMPERATURE THERMOSTAT
(set at atomizing temperature)
COLD OIL INTERLOCK
(set 15° below atomizing temperature)
CHECK EVERY DAY:
Thermostat — puts oil into burner at right temperature
Cold Oil Interlock — shuts burner down if oil is not hot enough
1. At what temperature should your oil temperature thermostat be set?
2. At what temperature should your cold oil interlock be set?
What are the three things to check each day? 3.

4.
5.
Check and correct
your answers.
69
-------
1. atomizing temperature
2. 15° lower than thermostat
3. Fuel
4. Water
5. Oil Temperature
3. CLEAN YOUR SMOKE ALARM EVERT FEW DAYS
-AT LEAST ONCE A WEEK

Here's how your smoke alarm works:
Light in :
Stack
If light doesn't register on sensor ^

Alarm goes off as smoke must
be blocking light.
The Smoke Alarm is going off at the two stacks below. Only one is really smoking.

CIRCLE THE CORRECT WORDS UNDER THE STACKS - if there is a true alarm or a false alarm.
Dirt
Light M
Light If.;
TRUE/FALSE Alarm
TRUE/FALSE Alarm
The first picture shows what should happen with smoke. The light in the second picture does not
get through to the sensor because of dirt on the lens and the alarm goes off when there is no smoke!
What must you do frequently to keep a false alarm from
sounding? .

—Check and correct
your answer
70
-------
Answer to Exercise 3: Clean the smoke alarm lens.
4. REVIEW: DAILY BOILER TASKS
1. List the six things that keep your boiler room in good shape:
2. What three things must also be checked every day?
in the tank
in the boiler
hot enough to burn properly
3. On what piece of equipment must you check the settings of the oil temperature thermostat and
the cold oil interlock?
4. What happens if smoke alarm lens is dirty?_
Answers to Exercise 4:
1. Doors must lock
Oil slicks gone
Gauges easy to read
Tools put away
Air intakes clean
Garbage cleaned up
2. Fuel
Water
Oil
3. Electric Heater

4. False Alarm
71
-------
5. GETTING READY TO START

You may have to start a cold boiler. First look at the OIL PRESSURE GAUGE. It is networking
right if it shows a pressure reading when the system is off. Look at the gauges below.
CIRCLE THE CORRECT WORDS UNDER EACH.
SYSTEM OFF
SYSTEM OFF
1. Gauge IS/IS NOT working correctly.
2. Gauge IS/IS NOT working correctly
1. The first gauge above is out of order. If you replace this gauge, keep a spare on hand.
2. Gauge 2 is correct.

TWO SWITCHES TO THROW:
Two more things must be turned on and given time to work before you start. Study the diagram,
then answer the questions below:
1.
Large Systems
may have more
than one.
4
2.
Closest heater
to the burner.
»
FUEL OIL
PUMP
ELECTRIC
HEATER
BURNER
1. What piece of equipment gets the oil up to proper
burning temperature?
2. What piece of equipment moves the oil out of the tank to
the burner?
3. What 2 pieces of equipment must be turned on before you
can start the burner?
Check and correct
your answers.
72
-------
Answers to Exercise 5: 1) Electric Heater
2) Fuel Oil Pump
3) Heater & Pump
6. CHECK OUT THE BURNER

Burners on a manual stop/start schedule should be cleaned before shut-down and left with the
burner out of the furnace (with the furnace opening covered). Before starting up the burner again,
do these three things:
1. Inspect burner cup and clean if necessary.
2. Swing burner assembly into furnace.
3. Reset linkage, lock burner in position.
Correct linkage settings are important; they control the air/oil ratio. Mark the settings so that you
can reset them perfectly each time.

A. Study the three pictures. Write the number and description from above of the step it shows:
into furnace.
in position.
B. Answer these questions:

What do you get if the burner cup is dirty? _
What do you get if the air/oil ratio is wrong?
lock burner
clean if nescessary.
and
Check and correct
your answers .
73
-------
Answers to Exercise 6:
A. 2. Swing burner assembly back into furnace
3. Reset linkage, lock burner in position.
1. Inspect burner cup, clean if necessary
B. Smoke
Smoke
7. FIFTEEN MINUTES LATER

1. CHECK THE FLAME
Remember a good flame? CIRCLE GOOD or BAD under each flame, whichever is true:
GOOD/BAD
GOOD/BAD
GOOD/BAD
A good flame is a steady, orange one which fills the furnace but does not touch the walls, like the
middle one above.

2. CHECK OIL TEMPERATURE AND
3. CHECK OIL PRESSURE

vacuum
gauge
O
oil
pressure
it gauge
W 9 <^
oil
temperature
gauge
o - 1 iNlx
The oil temperature and pressure right for your boiler will depend on the oil you are using.
1. What instrument in the diagram checks oil
temperature?
2. What instruments in the diagram let you
check the oil pressure? (more than one)
74
-------
About 15 minutes after your boiler has been operating, what basic things should you check?
3.
4.
5.
If you find any of these out of line, you will follow troubleshooting guides that will appear later in
this program.
Check and correct
your answers
Answers to Exercise 7:

1. Oil Temperature Gauge (thermometers, aquastats)
2. Pressure Gauge, Vacuum Gauge
3. The Flame
4. Oil Temperature
5. Oil Pressure
75
-------
8. REVIEW: DAILY BOILER TASKS & COLD STARTS

1. What key word reminds you of the six checks you should make in the boiler room every day?

2. What two settings on the electric heater should be checked every day?

3. How many days fuel supply should you havi on hand at all times?

4. Check the in the boiler every day.

5. Before turning on the burner, check the gauge.

6. Before turning on the burner, what two pieces of equipment must be turned on?

7. What three things should be checked after the boiler has been running for 15 minutes?
Check and correct
your answers r—n
Answers to Exercise 8:

1. DOGTAG
2. Oil Temperature Thermostat, Cold Oil Interlock
3. 5 Days
4. Water
5. Oil Pressure
6. Fuel Pump, Electric Heater
7. Flame
Oil Temperature
Oil Pressure
76
-------
9. CLEANING THE CUP

The burner cup should be: CLEAN
UNDAMAGED
and SPIN PERFECTLY

Check the cup when it is HOT and the oil is still LOOSE. Plan a convenient time to do this every
few days, at least once a week.
OPENING THE BURNER - Remember accurate linkage setting.
WHEN DISCONNECTING
RIGID LINKAGE
Mark settings if necessary so
replacement is accurate.
After the burner is out, cover the opening. Cool air will weaken or crack the refractory walls.

NUMBER THE FOLLOWING in the correct order:
Swing burner out
Open latch
Cover burner opening
Disconnect twist plugs ("dogs") and linkage
1. How could you lose the proper air/oil ratio when cleaning
the cup? ,
2. How could you damage the refractory when cleaning the
cup?
Check and correct
your answers.
77
-------
1. by not marking the linkage
2. by not covering the furnace opening
CLEANING THE CUP
Use materials that will not scratch it.
1. Wipe cup with clean rag
and solvent.
3. Spin cup slowly by
hand to check for
wobble.
1

2. Remove deposits with a
wooden stick.
I
4. Check surface and edge
for nicks, scratches,
dents.
Wobble in the cup (3 above) often means that the shaft or cup is bent. Call Service.

A nick on the cup surface or edge (4 above), even small, will cause a problem in atomization. Call
Service.
1. Why must you use a clean cloth to clean the cup?
2. What do you do with a wooden stick?
3. How do you check for wobble?
4. Will a small scratch or nick on the edge cause a noticable
problem?
Check and correct
your answers
78
-------
1. A dirty cloth will scratch the cup
2. Remove deposits on cup
3. Spin cup slowly by hand
4. Yes
COMPLETE THE PROCEDURE FOR CLEANING THE CUP:
1.
with rag
and solvent.
2.
with wooden
stick.
3. Spin cup
to check
4.
for nicks,
scratches,
dents.
Check and correct
your answers.
79
-------
Cup Cleaning Procedure:

1. Wipe cup
2. Remove deposits
3. For wobble
4. Check surface and edge
CHECK IN AND AROUND CUP
CLEAN AIR AND OIL INPUT
AIR CONE -
Wipe around and scrape
off any dirt.
FUEL NOZZLE
If you have a fine mesh
strainer, clean the nozzle
in place. If not, remove
the nozzle and clean in
solvent.
Now, the burner is ready to go again.
Answer these questions with regard to your system:
1. What might collect in the fuel nozzle?
2. Is it sufficient to clean your fuel nozzle in place or must
you remove it?
3. What might collect in the air cone?
Check and correct
your answers.
80
-------
1. Dirt in the oil
2. Yes, if you have a fine mesh strainer, otherwise no
3. Dirt in the air or from the fan
CUP CLEANING REVIEW
1. The cup should be cleaned when it is (hot, cold).
2. In opening the burner to clean the cup, what two things should you be careful of to avoid smoke
and/or damage to your boiler?
3. Complete the four things to do or check in cleaning the cup?
1.
2.
3.
4.
with rag and solvent.
with wooden stick.
by spinning the cup.
for nicks, scratches.
4. What two other cup related things do you clean after cup cleaning?
Check and correct
your answers, r—»
Answers — Cup Cleaning Review

1. Hot
2. Mark your linkage settings
Cover the burner opening
3. Clean the cup
Remove deposits
Check for wobble
Check edge and surface
4. Fuel nozzle
Air cone around cup
81
-------
10. CLEAN OIL STRAINERS ONCE A WEEK
You need to keep your oil strainers clean, in order to have clean oil and a good flame.
Most systems have two strainers. They may be either single basket or double basket.
CIRCLE THE CORRECT WORDS UNDER EACH PICTURE:
oil to burner
li
oil from pump
1.SINGLE/DOUBLE BASKET
oil to burner
oil from pump
2.SINGLE/DOUBLE BASKET
Check and correct
your answers
1. Single

2. Double
You may have single baskets (as in the first picture), double baskets (as in the second picture) or
both.
How many strainers do you have?
Are they single or double basket?
82
-------
CLEAN EACH DIFFERENTLY
oil to burner
oil from pump
SINGLE BASKET CLEANING

1. TURN OFF OIL VALVE
2. SHUT DOWN BOILER
3. TAKE OUT BASKET and CLEAN
4. REPLACE BASKET
5. OPEN OIL VALVE
6. START BOILER
oil to burner
oil from pump
DOUBLE BASKET CLEANING

1. SWITCH OIL to empty basket
2. TAKE OUT DIRTY BASKET and CLEAN
3. REPLACE BASKET
(empty basket clean)
Answer these questions:

1. With what kind of strainer must you
shut down the oil flow and boiler?
2. With what kind of strainer can you keep
oil flowing while cleaning a basket?
3. How do you keep oil from being in the
single basket strainer while cleaning it?
4. Do you need to shut down your boiler to
clean your strainer(s)?
Check and correct
your answers.
83
-------
1. Single basket
2. Double basket
3. Turn off the preceding oil valve
4. Check your own answer
Clean strainers with a wire brush and solvent (kerosene). Place something under the strainer when
cleaning to avoid dripping oil on the floor.

Complete the procedure for cleaning the strainers below:
SINGLE STRAINER

1. Turn off valve.
2. Shutdown
3. Take out and clean.
4. Replace
5. oil valve.
6. boiler.

DOUBLE STRAINER

1. Switch to empty basket.
2. Take out dirty . and clean.
3. Replace
Check and correct
your answers.
84
-------
Single Strainer
Double Strainer
1. Turn off oil valve
2. Shut down system
3. Take out basket and clean
4. Replace basket
5. Open oil valve
6. Start boiler
1. Switch oil to empty basket
2. Take out dirty basket and clean
3. Replace basket
11. LUBRICATE EACH WEEK
Weekly lubrication is necessary for a smooth running system.
Check and lubricate if necessary:
EQUIPMENT
1. Burner Gear Case
2. Motors
3. Linkage Joints
PROCEDURE
Check oil level (visually or
with finger) and add oil if
reservoir not full
1 or 2 drops at oiling points
for bearings
1 or 2 drops
Answer the following questions:

1. What equipment usually has a lube oil level indicator showing if oil is needed?

2. Do not over oil bearings and joints. How much is needed?
3. List the equipment in your boiler system needing lubrication:
Check and correct
your answers.
85
-------
1. Burner Motor Gear Case
2. 1 or 2 drops
3. Check your own answers
12. WEEKLY MAINTENANCE SUMMARY
WEEKLY TASKS: CLEAN OIL STRAINERS
LUBRICATE
CIRCLE THE CORRECT underlined words below:
1. The boiler should/need not be shut down when cleaning a single basket oil strainer.
2. In a double basket oil strainer the oil is always flowing through one/both of the baskets.
3. You may need to lubricate:gear case/all motors/switches on control panel/linkage joints.
Check and correct
your answers.
86
-------
1. should
2. one
3. gear case/all motors/linkage joints
13. HOW ARE YOUR TUBES CLEANED?

If you have an automatic soot blower you can easily blow your tubes. If not, they must be cleaned
manually.

If you clean manually, check every month and punch the tubes when soot builds up about 1/8 inch.
CLEANING METHOD
Automatic Soot
Blower
Manual Cleaning
INSPECT
Every two
weeks
Every month
PERFORMED BY
Boiler Operator
Boiler Operatory/
Contract Maintenance
1. How are your tubes cleaned?
2. How often do you need to inspect them?
3. Who cleans your boiler tubes?
Check and correct
your answers.
87
-------
1. Automatic soot blower or by hand
2. Every two weeks (automatic), every month (manually)
3. Me or maintenance service
14. DO YOU HAVE AN AUTOMATIC SOOT BLOWER?
If you have an automatic soot blower, this page will give you the basics. If you don't have one, turn
to the next exercise.

Blow your tubes during daylight hours, while the boiler is running, and about once every two
weeks.

Start the AIR COMPRESSOR and let it reach the 50 #- 100 # range. The SMOKE ALARM
should be turned off and the AIR CONTROL VALVE opened for the system to blow
automatically.

The smoke alarm is turned off because soot blown from the tubes would set it off when you don't
want it to.
Number these steps in the right order:
Start air compressor
Blow tubes (open air valve)
Turn smoke alarm off
Turn smoke alarm on
Shut off air compressor
Check and correct
your answers.
88
-------
1 Start air compressor
_3_ Blow tubes (open air valve)
_2^ Turn smoke alarm off
_5_ Turn smoke alarm on
4 Shut off air compressor
15. PUNCHING THE TUBES
Either you or contracted maintenance will clean or punch tubes.
GETTING READY:
1. CLOSE DAMPERS manually or set draft control at zero.
2. SHUT DOWN THE SYSTEM 1/2 hour before cleaning.
3. COVER BURNER with heavy cloth or canvas.
4. PROVIDE TRASH CANS lined with plastic or paper bags for soot.
Which of the above (1, 2, 3, 4) is particularly important when you realize:
1. That tubes and clean-out doors are often located directly
over the burner.
2. The difficulty in handling loose soot.
3. That the boiler is hot inside!
4. Moving air in the tubes will send billows of soot through
the clean-out door when it's open.
Check and correct
your answers.
89
-------
1.1
2. 4
3. 2
4. 1
Clean your boiler tubes with a WIRE BRUSH attached to a VACUUM LANCE, carefully pulling the
soot toward you into a lined trash can. Avoid getting soot into the stack, breeching or burner.
Number manual tube cleaning steps in the right order:
Clean tubes and close cleanout door.
Tie necks of can liners and put out for removal.
Getting Ready — shut burner down 1/2 hour before cleaning
close dampers
cover burner
provide trash cans with liners
Remove cloth from burner; put equipment away.
Check and correct
your answers
90
-------
J_
3
16. TUBE CLEANING REVIEW

AUTOMATIC SOOT BLOWING STEPS:
1. Start air compressor
2. Turn off smoke alarm
3. Blow tubes (open air valve)
4. Shut off air compressor
5. Turn smoke alarm on

MANUAL TUBE CLEANING STEPS:
1. Getting Ready: Shut burner down 1/2 hr. before cleaning
close dampers
cover burner
provide trash cans with liners
2. Clean tubes and close clean-out door
3. Remove cloth from burner; put equipment away
4. Tie necks of can liners and put out for removal

LIST THE STEPS YOU TAKE when cleaning your tubes:
91
-------
OPERATION AND MAINTENANCE SUMMARY

Below is a summary of the tasks included in this section.
They are listed in your Boiler Handbook for future reference.

BOILER ROOM CLEAN-UP
Doors must lock
Oil slicks gone
Gauges easy to read

Tools put away
Air intakes clean
Garbage cleaned up

DAILY CHECKS
1. FUEL in the tank
2. WATER in the boiler
3. HEATER SETTINGS - Oil Thermostat and Cold Oil Interlock

FREQUENT CLEANING
1. SMOKE ALARM LENS
2. ATOMIZING CUP
Getting
Ready
1. Disconnect twist plugs and linkage
2. Open latch
3. Swing burner out
4. Cover burner opening
11. Clean cup with rag and solvent
2. Remove deposits with wooden stick
3. Spin cup to check for wobble
4. Check cup surface and edge for nicks

Other J1. Clean fuel nozzle
Checks \2. Clean air cone around cup
92
-------
STARTING A COLD BOILER
Getting
Ready
[1. Check oil pressure gauge
2. Turn on fuel oil pump
3. Turn on electric heater
Check
Burner
!1. Inspect cup, clean if necessary
2. Swing burner into place
3. Reset linkage, lock in burner
After fi. Flame
Start <2. Oil Temperature
Checks (3. Oil Pressure

WEEKLY MAINTENANCE

1. CLEAN OIL STRAINERS
SINGLE BASKET

1. Turn off oil valve
2. Shut down boiler
3. Remove basket and clean
4. Replace basket
5. Open oil valve
6. Start boiler
DOUBLE BASKET

1. Switch oil to empty basket
2. Remove dirty basket and clean
3. Replace basket
2. LUBRICATE WHERE NEEDED
MONTHLY MAINTENANCE
1. CLEAN BOILER TUBES
93
-------
SUMMARY

These questions review the important things in this section:
1. What basic supply should you check in the boiler each
day? (Without it the boiler cannot operate.)

2. What basic supply to the burner should you check each
day? (Without it the burner cannot operate.)

3. What should you check each day to be sure of good oil
flow and proper burn?

4. What should you clean frequently to guard against a false
smoke alarm?

5. Which heater do you need to turn on and heat up when
starting a cold boiler?

6. What piece of equipment moves the oil and must be
turned on when starting a cold boiler?
7. What instruments let you check the oil temperature?

8. What does the oil pressure gauge and the vacuum gauge
let you check?

9. When cleaning the atomizing cup, should you use a
wooden or metal stick to scrape off deposits?

10. Will a 1/4" or smaller nick on the cup surface hurt
proper atomization?
94
-------
11. What will you prevent by using a clean cloth with solvent
in cleaning the cup?

12. When cleaning the cup, what are you checking for when
you give it a spin?

13. Dirt build-up should be removed from what two places
in and around the cup?
14. Must the oil flow be turned off when cleaning a single
basket strainer?

15. Must the oil flow be turned off when cleaning a double
basket strainer?

16. What should be done about once a week to be sure that
motors and linkage joints operate smoothly?

17. Should boiler tubes be cleaned on the average of once a
week, once a month, or once a year?

18. What are the two methods or ways of cleaning the boiler
tubes?
Check your answers.
95
-------
ANSWERS TO REVIEW QUESTIONS

1. water
2. oil
3. oil temperature
4. smoke alarm lens
5. electric heater
6. pump
7. oil temperature gauges
8. oil pressure
9. wooden
10. yes
11. cup damage (scratches, poor atomization, smoke)
12. wobble
13. fuel nozzle in cup
air cone around cup
14. yes
15. no
16. lubrication
17. once a month
18. manual cleaning
automatic soot blower
-------
Section 3
TROUBLESHOOTING BOILERS;
CORRECTING OIL TEMPERATURE
1. SMOKE: WHAT TO DO

WHEN THE SMOKE ALARM GOES OFF

INCORRECT OIL TEMPERATURE IS THE BIGGEST CAUSE OF SMOKE. Check this first.

Correct temperature depends on the oil being used.

Look at the temperature gauge NEAREST THE BURNER. It should MATCH your ATOMIZING
TEMPERATURE.
Suppose that:
Atomizing temperature = 160 F.

All oil temperature gauges are working.
CIRCLE THE CORRECT WORD(S) UNDER EACH DIAGRAM.
60F
I
fl ,-
f t*
Temp. He
Gauge

90> I
Burner h
X .. irVT"*-
— i Sr ^vl IN \s
— c \^L>-L|>
ater Temp.
Gauge
Oil Temperature IS/IS NOT correct.
130F
160F
o
L
Burner
t
Temp.
Gauge
Electric

Heater
Temp.
Gauge
Oil Temperature IS/IS NOT correct.
In the first diagram, the oil nearest the burner IS NOT correct. It is 70° below atomizing
temperature. This means an oil heating problem. The oil temperature is A—OK in the second
diagram.

What is the biggest cause of
a smoking boiler? _____
— Check your answer.
97
-------
Incorrect oil temperature
If the oil temperature is wrong, locate the trouble spot by checking the OIL TEMPERATURE
AT EACH HEATER. In a line of several heaters, trouble in the first may throw them all off.

What is normal for your heaters is in your Boiler Handbook.

Suppose these temperatures are normal for the heaters below:
Tank Heating Coil Output 10° F
Hot Water Oil Heater Output - 130 F
Electric Heater Output - 160 F
The Oil Temperature Gauges are working.
100F 110F 125F /"
III Fpfr*
s \ _f
Hot Water Electric -*
Oil Heater Heater Burner

100F I30F 170F
1 1 1
£} -i— , £} Cj ^v
Hot Water Electric
Oil Heater Heater

frfi
LJ-LP
Burner
1. Which heater is not heating the oil cor-
rectly?
2. Which heater is not heating the oil cor-
rectly?
— Check your answers.
98
-------
1. Hot Water Oil Heater (too cold)
2. Electric Oil Heater (too hot)
A SMOKE ALARM!
1. What is the biggest cause of
smoke?
2. Which oil temperature gauge
should you look at first?
3. If the oil temperature is wrong, check each
individual . . .
— Check your answers.
99
-------
1. incorrect oil temperature
2. one nearest the burner
3. heater
2. ELECTRIC HEATER-COLD OIL
If the electric heater isn't heating - check TWO BASICS to be sure it is on!
HEATER
SWITCH
ON
CIRCUIT BREAKERS CLOSED
CONTROL BOARD
n an
a an
a a
ELECTRIC SUPPLY
Know which
circuit each
breaker monitors.

Your Electric Heater switch may be on your control board or on the Electric Heater. The circuit
breaker location varies with each situation.
1. If the circuit breaker is open or switch off, will
the electric heater work?
2. Where is your electric heater switch?
3. Where are the fuses or circuit breakers on your
system?
— Check your answers.
TOO
-------
1. No
2. Check your own answer
3. Check you own answer
If the Electric Heater is on - check the TEMPERATURE CONTROL.
Electrical
Connection
THERMOSTAT
WORKING
Thermostat
ELECTRIC HEATER
Cold Oil
Interlock
CONTROLS SET
CORRECTLY
I
The thermostat should be set at the atomizing temperature with the cold oil interlock 15° lower.

The oil should change temperature when the thermostat setting is changed if the thermostat is

working.

You or service may replace the thermostat if it is broken.
If the thermostat is working, what should
happen when you turn it up?
— Check your answer.
101
-------
oil gets hotter
CHECK OFF (»/) the three troubleshooting steps seen so far: (cold oil in electric heater).
HEATER SWITCH ON?
CIRCUIT BREAKERS closed?
TERMPERATURE CONTROLS set correctly and working?

If you don't find the trouble, check the HEATING ELEMENT before calling service. It will no
doubt be replaced by service if broken.
135 F
ELECTRIC HEATER
150 F
Did the oil temperature go up in this heater?
If the temperature goes up (as above), you know the HEATING ELEMENT IS WORKING.
What do you do if you find the heating
element not operating?
— Check your answer.
102
-------
call service for replacement
COMPLETE THE TROUBLESHOOTING STEPS for COLD OIL in the ELECTRIC HEATER.
1. Heater.
2.
3.
4
on.
breakers closed.
controls set correctly and working.
element working.
These all appear on the previous page. Check your answers and correct them if necessary.
SOME SMOKING BOILERS!

Below are two smoking boilers caused by cold oil coming from the Electric Heater. Beside each
write what the probable problem is. Assume the correct atomizing temperature to be 170 F. All
oil temperature gauges are working.

Switch
Onfl
"xV
140F jA-
Thermostat
Fuses J
OK

Switch
Onfl -\
170F \
Thermostat*'
Fuses
nK
Ulx

?1
II oi

[

91
loi,
)

25
\
V

30
^
lil

j
ELECTRIC
HEATER
r

3
ELECTRIC
HEATER

I
*.

"1_

-»

1 —

140F
9
T

130F
9
> F

1. PROBLEM:
2. PROBLEM:
103
-------
ANSWERS TO COLD BOILER PROBLEMS:

1. Thermostat needs to be reset.
2. Heating element not working.
3. ELECTRIC HEATER -OIL TOO HOT

Two things could be causing the Electric Heater to over heat.

1. THERMOSTAT — Is it set correctly? Is it working properly?

2. WARP POINTS (inside the thermostat) - Are they sticking together? If they are, they must
be replaced (by you or service).

If these two checks don't solve the problem, call service.

.ANSWER THESE QUESTIONS (assume oil temperature gauge OK):

1. What instrument shows that there is a hot
oil problem in the Electric Heater?
2. When you first find hot oil in the Electric
Heater, what control setting should be
checked?

3. Have your warp points ever been replaced?

If so, who did it?
104
-------
1. Oil temperature gauge after the Electric Heater
2. Oil thermostat
3. Check your own answer
When you get hot oil in the Electric Heater, what two things should you check before calling
service?
1.
2.
Check and correct
your answers
1. Thermostat (reset or repair)
2. Warp Points
HANDBOOK SUMMARY
TURN TO PAGE 54 .YOUR BOILER HANDBOOK.

On Page 54 is a summary of how to Troubleshoot Cold and Hot Oil in the heaters. Use this as
reference.

IF YOU HAVE AN ELECTRIC HEATER, TURN TO PAGE 55 IN THE BOILER HANDBOOK.

Write ELECTRIC HEATER at the top of the first column on the table, under "Heaters on this
system".

Under Electric Heater, list the COLD OIL CHECKS and HOT OJL CHECKS YOU HAVE JUST
LEARNED,
105
-------
4. COLD OIL FROM THE HOT WATER OIL HEATER
If you get COLD OIL from the HOT WATER OIL HEATER, check -

1. THERMOSTAT on heater for incorrect setting or breakage.
To check for breakage, change the thermostat setting, wait, and see if it
changes the oil temperature.
2. WATER PUMP and its MOTOR
If you have them, check out what you can and call service if they are not
operating.

Oil cannot be heated without these two essentials.

1. Which of the above parts determines the
temperature of the oil?
2. Which of the above delivers hot water to
heat the oil?
— Check your answers.
106
-------
1. Thermostat
2. Pump, Motor
On this diagram CIRCLE the parts you would check if you had COLD OIL coming from the

HOT WATER OIL HEATER.
Temp.
Gauge Tnermostat

O 4* J
-oil
HOT WATER OIL HEATER
If none of these adjustments solve the problem — call service.
— Check your answers.
107
-------
Temp.
Gauge jhet^ostat
c
HOT WATEH OIL HEATER
5. HOT WATER OIL HEATER - OIL TOO HOT
There is only one check to make before calling service if you get hot oil here.
THERMOSTAT Check for correct setting or if it is out-of-order.
1. Does your system use a hot water oil
heater?
2. What is the normal thermostat setting for
your hot water oil heater?
— Check your answers.
108
-------
1. Check your own answer
2. You should have this in your Boiler Handbook,
1. If you find HOT OIL in your HOT WATER OIL HEATER, what should you check before

calling service?
2. If you find COLD OIL in your HOT WATER OIL HEATER, what should you check before

calling service?
Check and correct
your answers
1. Thermostat
2. Thermostat
Pump, Motor
HANDBOOK SUMMARY

TURN TO PAGE 55,YOUR BOILER HANDBOOK.

Write HOT WATER OIL HEATER at the top of the second column if you have one. In this
column, WRITE THE COLD AND HOT OIL TROUBLESHOOTING CHECKS just covered.
109
-------
6. COLD OIL FROM THE STEAM HEATER
You may have a Steam Oil Heater. CHECK THESE PARTS if you find COLD OIL there.
2. THERMOSTAT
working,
-rrfoil-.
STEAM HEATER
1. STEAM PRESSURE GAUGE
On boiler
Approx. 2 psi
If the STEAM PRESSURE in the boiler is all right, check the THERMOSTAT for your correct
setting.

ANSWER THESE QUESTIONS:

1. What instrument tells you if you have
steam in the boiler or not?
2. What is the approximate boiler steam
pressure that you need to heat oil? (see
gauge above)

3. If you get cold oil in your Steam Heater,
what are the first two things to check?
— Check your answers.
110
-------
1. Steam Gauge
2. 2p.s.i.
3. Steam Gauge, Thermostat
Here are two more checks to make if you get cold oil.
4. STEAM REGULATOR
Working
THERMOSTAT

Oil
STEAM HEATER
3. STEAM TRAP
Water drops
discharging
periodically
STEAM PRESSURE GAUGE
The heater discharges condensate (water drops) normally through the STEAM TRAP. If it is

discharging steam, something is out-of-order.

The Thermostat is connected to the STEAM REGULATOR and regulates it. Check it for proper
operation.

If these steps don't solve cold oil in the STEAM HEATER, call service.
1. How can you tell that the steam trap is working
satisfactorily?
2. What device does the thermostat control to let the
right amount of steam into the heater?
— Check your answers.
Ill
-------
1. Water drops discharge periodically
2. Steam Regulator
LABEL THE FOUR CHECKS to make on a steam heater delivering cold oil.
2.
•-•> oil
STEAM HEATER
Check your answers.
112
-------
1. Steam pressure in boiler
2. Thermostat
3. Steam Trap
4. Steam Regulator
Below are two Steam Heaters with cold oil problems. WRITE WHAT SEEMS TO BE THE
PROBLEM BESIDE EACH.

Suppose that: Normal operating temperature for the steam heater is 125 F and the oil

temperature gauge is working.
2psi
115 F
'STEAM PRESSURE
_auge GAUGE
water discharge OK
1. PROBLEM:
2psi
100 F
'Ga3eSTEAMPRESSURE
fcauge GAUGE
water discharge OK
*New Thermostat
working properly
2. PROBLEM:
Check your answers.
113
-------
1. Reset thermostat to 125 F
2. Steam Regulator may need repair or replacement
7. STEAM HEATER-OIL TOO HOT
CHECK THESE TWO THINGS to solve a hot oil problem.

2. STEAM REGULATOR - can reduce steam by adjusting screw.
i

]=:
1. THERMOSTAT — may need to be reset, repaired, or replaced.
STEAM HEATER
If these two steps don't solve the problem, call service.

1. What do you always check when you have a

temperature problem with a heater?

2. Too hot may mean too much steam. Where do you

check steam going into the heater?
— Check your answers.
114
-------
1. Thermostat
2. Steam Regulator
There are two checks to make if you get HOT OIL in the STEAM HEATER. LABEL THEM on

the diagram below.
1.
STEAM HEATER
4- -

-------
STEAM HEATER REVIEW
Listed below are the COLD and HOT OIL TROUBLESHOOTING STEPS for the STEAM
HEATER - COMPLETE THEM.

COLD OIL - STEAM HEATER

CHECK:
1.
2..
3.

4.
periodically.
Gauge on the boiler.
on heater. It should be set correctly and working.
to see that only drops of water are discharging
. to see that steam is going into the heater properly.
HOT OIL - STEAM HEATER
CHECK:
1.
2.
should be set correctly and working.
should be admitting steam properly.
— Check your answers.
116
-------
Answers to Steam Heater Review

COLD OIL:
1. Steam Pressure Gauge on boiler
2. Thermostat on Heater
3. Steam Trap — drops of water periodically
4. Steam Regulator — steam into heater
HOT OIL: 1. Thermostat
2. Steam Regulator
HANDBOOK SUMMARY

TURN TO PAGE 55 .YOUR BOILER HANDBOOK.
Write STEAM HEATER at the top of the last column on the table if you have one. In this
column, WRITE THE COLD AND HOT OIL TROUBLESHOOTING CHECKS just covered.

This completes the basic cold/hot oil checks to make before calling service.

Use BOILER HANDBOOK PAGES 54-55 for reference if you get an oil temperature problem.
117
-------
SUMMARY
These questions review the important things in this section:
1. What is the biggest cause of a smoking boiler?
2. If you get smoke, what is the first thing to
check?

3. What gauge right after a heater tells you if there
is an oil temperature problem there?

4. Is the proper atomizing temperature determined
by the^ji you use or the burner you have?

5. What is one of the first things you always check
on any heater when there is an oil temperature
problem?

6. If you have an open circuit or blown fuse, what
will be the temperature problem in the electric
heater?

7. What heater has to be actually turned on in
order to heat the oil?

8. What electric heater setting should match the
oil atomizing temperature?

9. What instruments will tell you if the heating
element in the electric heater is working?

10. What points inside the electric heater thermo-
stat should be checked if you get hot oil
there?

11. If the atomizing temperature is 150 F and
your electric heater thermostat is set at 160 F,
what would you do?
118
-------
12. What should be checked in the case of cold oil
in the hot water oil heater to be sure the
heater is getting hot water to heat the oil?

13. What is the one check you make on the hot
water oil heater whether the oil is too hot or
too cold?

14. What do you need in the boiler in order to get
steam in the steam heater?

15. What instrument measures how much steam is
in the boiler?

16. Through what is condensate (drops of water)
discharged from the steam heater?

1?. What instrument is connected to the thermo-
stat and regulates steam going into the steam
heater?

18. If the oil is too hot in the steam heater, what
two instruments should be checked?
19. If all troubleshooting checks are made and an
incorrect oil temperature problem is not
solved, what should be done?
— Check your answers.
119
-------
ANSWERS TO REVIEW QUESTIONS:

1. incorrect oil temperature
2. oil temperature
3. oil temperature gauge
4. oil
5. thermostat
6. cold oil
7. electric heater
8. thermostat
9. oil temperature gauges on each side of heater
10. warp points
11. reset thermostat to 150 F
12. pump
13. thermostat
14. steam pressure
15. steam pressure gauge
16. steam trap
17. steam regulator
18. thermostat
steam regulator
19. call service
120
-------
Soction 4
TROUBLESHOOTING BOILERS;
FLAME READING
1. FLAME AWAY FROM THE BURNER
Most boilers have a peephole. Through it you can see the flame.
Look at this flame.
CIRCLE THE CORRECT ANSWER:
This flame is: A. too close to the burner.
B. too far away from the burner.
B is correct. The most likely reason is that the flame above is being pushed off the burner by
TOO MUCH PRIMARY AIR.

The PRIMARY AIR SHUTTER (regulated by LINKAGE) is taking in too much air. If you know how to set
the Primary Air Shutter, adjust it carefully. The correct air/oil ratio is the key to good flames and -
burning. If you don't know a lot about it, call service.

Check the parts below which may need adjustment to correct a flame off the *•

Primary Air Shutter
Primary Air Linkage
Secondary Air Damper
-------
Primary Air Shutter
V Primary Air Linkage
Secondary Air Damper
LOOK AT THIS FLAME.
1. How does this flame not look right?
2. What should you suspect when you get a flame like this?
— Check your answers.
-------
1. too far away from burner
2. too much primary air
2. SMOKY FLAME

A Smoky Flame (unstable and flickering) means NOT ENOUGH AIR. Check the three parts of the primary
air system.

PRIMARY AIR
FAN
LINKAGE
SHUTTER
The PRIMARY AIR SHUTTER and LINKAGE can be lubricated and cleaned but change the setting only if
you have been taught to do it accurately on your system.

You know how your FAN should sound. Blades may need to be cleaned; belts may need to be tightened.

CIRCLE THE PARTS ON THE DIAGRAM THAT YOU CAN KEEP CLEAN AND IN GOOD WORKING
ORDER.
Answer these questions:
1. Do smoky flames come from too much or too little air?
2. When you get a smoky flame, first check the
air.
— Check your answers.
110
-------
1. too little
2. primary
If the Primary Air is all right, check —

SECONDARY AIR

The Windbox may not be delivering enough air. LABEL THE LINKAGE and DAMPER on the lines in
the diagram.
T.n
WIND |
BOX
outside air
Linkage must be set properly and lubricated to move easily. It should clear the floor when in the lowest
position.
The damper should be clean.
1. If you get a smoky flame, what do you check after the primary air?
2. What equipment must be set and move easily to deliver secondary
air?
— Check your answers.
-------
1. Secondary Air
2. Linkage, Damper
SMOKY FLAME-NOT ENOUGH AIR
1.
A.
On the diagram, LABEL THREE SOURCES OF AIR to check when you get a Smoky Flame -
PRIMARY AIR
SECONDARY AIR
STACK DAMPER
B.
The STACK DAMPER should move freely and not be blocked. You may or may not adjust this damper,
but you can keep it lubricated and clean.
1. Is your stack damper manual or automatic?
2. What can you do to keep the stack damper in good condition?
— Check your answers.
125
-------
PRIMARY AIR
pC
SECONDARY AIR
\| DAMPER
B.
1. Check your own answer
2. clean it, lubricate it
Here are two incorrect flames.
CIRCLE the correct answers beside each diagram.
This flame is: AWAY FROM THE BURNER
SMOKY
A cause is: TOO MUCH AIR
NOT ENOUGH AIR

Troubleshooting
Checks: PRIMARY AIR
SECONDARY AIR
STACK DAMPER
This flame is: AWAY FROM THE BURNER
SMOKY

A cause is: TOO MUCH AIR
NOT ENOUGH AIR

Troubleshooting
Checks: PRIMARY AIR
SECONDARY AIR
STACK DAMPER

— Check your answers.
126
-------
ANSWERS TO PREVIOUS PAGE.
.n
This flame is: AWAY FROM THE BURNER
A cause is: TOO MUCH AIR
Troubleshooting
Checks: PRIMARY AIR
This flame is: SMOKY

A cause is: NOT ENOUGH AIR

Troubleshooting
Checks: PRIMARY AIR
SECONDARY AIR
STACK DAMPER
-------
HANDBOOK SUMMARY
TURN TO PAGE 56.
Here is an incorrect flame summary for your future reference.

NOW, LOOK AT PAGE 57 in the HANDBOOK.

Here is your own table of incorrect oil flames. Under each flame is space to write a probable cause of the
flame, and some Troubleshooting Checks.

WRITE IN A CAUSE AND TROUBLESHOOTING CHECKS UNDER "FLAME AWAY FROM THE
BURNER" AND "SMOKY FLAME." Use Page 127 in this book for reference.
After completing this work, go on to the next page.
128
-------
3. FLAME TOO LONG
HITS THE WALL - SMOKY TIPS
Magnetic
Oil
Valve
Metering Valve [—| p-|
~1 I A 1 1
CUP WRONG POSITION
If there is TOO MUCH OIL going into the burner, there will be too much flame (too long) in the firebox.

Your upgraded system should have the OIL VALVES shown above. The Metering Valve is set by the oil
representative; you should change it only if you have been trained on your system.
ANSWER THESE QUESTIONS:
1. Too much oil may give you what kind of flame?
2. On the diagram, two
regulate the oil flow.
— Check your answers.
-------
1. too long
2. valves
WRITE ONE CAUSE OF A LONG FLAME on the line in the diagram:
Magnetic
Oil
Metering Valv
CUP WRONG POSITION
Check your answer on the preceding page.

If the CUP is set OUT FROM THE BURNER too far, it will extend the flame and cause it to hit the wall.
REPLACE THE CUP CORRECTLY EACH TIME YOU CLEAN IT.
ANSWER THESE QUESTIONS:
1. In addition to oil valves what device shown on the diagram must be set correctly
for a good flame?
2. Are you responsible for correct cup position?
— Check your answers.
130
-------
1. cup
2. yes
Magnetic
Metering Valve Oil Valve
When your smoke alarm goes off, you may see a flame like the one above in your firebox.
1. What is wrong with the flame above?
2. What are two causes of this incorrect flame?
3. What instruments may be adjusted to correct it?
— Check your answers.
131
-------
1. too long
2. too much oil, wrong cup position
3. oil valves, cup
4. ANOTHER BAD FLAME
CIRCLE THE CORRECT WORD under the diagram:
Flame is too
NARROW/WIDE
The flame may become too wide like the one above if the AIR CONE AROUND THE CUP is NOT
STRONG ENOUGH. Or, the CUP could be in the WRONG POSITION.
ANSWER THESE QUESTIONS:
1. You may get a wide flame if there is not enough:
A. PRIMARY AIR
B. SECONDARY AIR
2. What must be in the proper position to atomize a good flame?
— Check your answers.
132
-------
1. A. Primary Air
2. cup
Primary Air Fan
Primary Air Shutter'
Two causes of a WIDE FLAME have been considered.
1. What equipment would you check to troubleshoot TOO LITTLE
PRIMARY AIR? (see diagram)
2. If the Primary Air is OK, what other equipment would you check to
troubleshoot a wide flame?
— Check your answers.
133
-------
1. Primary Air Shutter
Linkage
Primary Air Fan
2. cup
When your smoke alarm goes off you may see a flame like the one above.
1. How is the flame above incorrect?
2. What are two common causes of this type of flame?
3. What equipment would you check to correct it?
— Check your answers.
134
-------
1. too wide
2. not enough Primary Air
cup in wrong position
3. Primary Air Shutter, Linkage, Fan, Cup
Below are two incorrect flames.
CIRCLE the correct answers beside each diagram.
This flame is:
TOO LONG
TOO WIDE
Some causes are: TOO MUCH OIL

TOO LITTLE
PRIMARY AIR
CUP IN WRONG
POSITION
Troubleshooting
Checks: PRIMARY AIR
OIL VALVES
CUP
This flame is:
TOO LONG
TOO WIDE
Some causes are: TOO MUCH OIL
TOO LITTLE
PRIMARY AIR
CUP IN WRONG
POSITION

Troubleshooting
Checks: PRIMARY AIR
OIL VALVES
CUP
— Check your answers.
13
-------
ANSWERS TO PREVIOUS PAGE:
This flame is: TOO LONG
Some causes are: TOO MUCH OIL

CUP IN WRONG
POSITION
Troubleshooting
Checks: OIL VALVES
CUP
This flame is: TOO WIDE
Some causes are: TOO LITTLE
PRIMARY AIR

CUP IN WRONG
POSITION
Troubleshooting
Checks: PRIMARY AIR
CUP
HANDBOOK SUMMARY

TURN TO VOUR BOILER HANDBOOK, PAGE 57.

COMPLETE INCORRECT FLAME COLUMNS 3 and 4 with the information you have just learned.
Use this page for reference.
136
-------
5. "SPARKY" FLAME
Here are small areas where too much oil is burning and bits of burning carbon can be seen. They do not look
like electric sparks but are spots where extra oil or carbon is burning.
BURNING OIL
GLOBS or BITS
of CARBON
When this happens the CUP may be either DIRTY, DAMAGED, or in the INCORRECT POSITION. If
cleaning and adjusting the cup doesn't help, call service.
1. "Sparks" in the flame could be bits of burning
or
2. What can you do to try to correct a "sparky" flame?
— Check your answers.
13;
-------
1. oil or carbon
2. clean and adjust the cup
J-f
K 7
1. Why is the flame above not a good flame?
2. What could be causing this flame?
3. What do you check to troubleshoot this flame?
138
— Check your answers.
-------
1. has "sparks" in it
2. oil globs or carbon
3. cup (clean or adjust)
6. PULSATING FLAME

A pulsating flame is one that changes in rhythm - large, small, large, small, etc. It is likely to be noisy.

Three possible causes you may be able to correct:

WRONG AMOUNT OF OIL
UNEVEN OIL FLOW
NOT ENOUGH AIR

CIRCLE the correct words under the picture.
To troubleshoot this flame, check the
AIR/OIL/CUP
As there are many causes of a pulsating flame, it is difficult to troubleshoot. If the air and oil checks you
will learn don't stop pulsation, call service.
What are two oil problems which may cause a pulsating flame?
— Check your answers.
139
-------
wrong amount of oil
uneven oil flow
Two checks concerning oil:
1.
Oil Pressure
Gauge
2.
Oil Temperature
Gauge
What should the oil temperature closest to the burner be on your system? _
What should your oil pressure gauge read?
You have this information in your Handbook. Checking OIL TEMPERATURE and troubleshooting OIL
HEATERS was covered in the last section.

OIL PRESSURE checks will be taken up on the next page.

1. What is wrong with the flame above?
2. What two oil gauges do you check in troubleshooting it?
— Check your answers.
140
-------
1. Pulsating flame
2. Oil Temperature Gauge
Oil Pressure Gauge
If OIL PRESSURE is the problem, it will be TOO HIGH.
IF HIGH
CHECK
Oil
Pressure Pressure
Oil Strainer
v_^
« Oil
uauye
9

Relief 1 ,_,
Valve I
\ 1 I— i i
^ oil 1
' Ull
Strainer ' — 1
\0))
t°n
Return to tank
d
ON THE DIAGRAM:

CIRCLE THE PART that sends excess oil back to the tank.

PUT CHECKS (V} ON THE PARTS that clean the oil but could become dirty and clogged.

If the PRESSURE RELIEF VALVE doesn't send enough oil back to the tank, it should be adjusted by
service. A clogged line, perhaps at the STRAINERS, will send the oil pressure up.
1. Where does the Pressure Relief Valve send excess oil?
2. Which of these can you probably take care of without calling service?
3. If you get high oil pressure, what two things should you check?
— Check your answers.
141
-------
1. to the tank
2. oil strainers
3. pressure relief valve
oil strainers
After checking the OIL TEMPERATURE and OIL PRESSURE, CHECK for TOO LITTLE AIR before
calling service.
CIRCLE PLACES TO CHECK FOR TOO LITTLE AIR ON THE DIAGRAM:
PRIMARY AIR,
W
SECONDARY AIR -V
To check for too little air, look at all four air sources above.
STACK DAMPER
OUTSIDE AIR
1. How is the flame above not a good one?
2. What are the areas to check? (CHECK THREE BELOW)
Oil Temperature
Cup Condition
Oil Pressure
Too Much Air
Too Little Air
3. How many air sources are there to check if you get a flame like the
one above?
142
— Check your answers
-------
1. Pulsating
2. JL_ Oil Temperature
Cup Condition
^L Oil Pressure
Too Much Air
*L_ Too Little Air
3. Four
PRESSURE
OIL RELIEF HEATERS
5TRAINERO VALVE
Oil tp tank
STACK -
DAMPER
SECONDARY
AIR
FOR EACH MAJOR AREA BELOW, WRITE THE PARTS FROM THE DIAGRAM THAT YOU SHOULD
CHECK BEFORE CALLING SERVICE.

PULSATING FLAME CHECKS:
1. OIL TEMPERATURE
INCORRECT
Check:
2. HIGH OIL PRESSURE
3. TOO LITTLE AIR
Check:
Check:
— Check your answers.
143
-------
ANSWERS TO PULSATING FLAME CHECKS:
1. OIL TEMPERATURE
INCORRECT
Check: Heaters
2. HIGH OIL PRESSURE
Check: Pressure Relief Valve
Oil Strainers
3. TOO LITTLE AIR
Check: Outside Air Supply
Primary Air
Secondary Air
Stack Damper
144
-------
Below are the last two incorrect flames presented. CIRCLE the CORRECT ANSWERS for each.
This flame is:
"SPARKY"
PULSATING
A cause is:
Troubleshooting
Checks:
WRONG AMOUNT OF OIL
BITS OF BURNING OIL
OR CARBON
UNEVEN OIL FLOW
TOO LITTLE AIR
CUP
OIL TEMPERATURE GAUGE
OIL PRESSURE GAUGE
AIR SUPPLY
This flame is:
"SPARKY"
PULSATING
Some causes are: WRONG AMOUNT OF OIL
i
BITS OF BURNING DIRT
OR OIL

UNEVEN OIL FLOW
Troubleshooting
Checks:
TOO LITTLE AIR

CUP
OIL TEMPERATURE GAUGE
OIL PRESSURE GAUGE
AIR SUPPLY
— Check your answers.
145
-------
ANSWERS TO PREVIOUS PAGE:
This flame is: "SPARKY"
A cause is:
BITS OF BURNING OIL
OR CARBON
Troubleshooting
Checks: CUP
This flame is: PULSATING
Some causes are: WRONG AMOUNT OF OIL
UNEVEN OIL FLOW
TOO LITTLE AIR
Troubleshooting
Checks:
OIL TEMPERATURE GAUGE
OIL PRESSURE GAUGE
AIR SUPPLY
146
-------
HANDBOOK SUMMARY
TURN TO PAGE 57.
COMPLETE THE LAST TWO INCORRECT FLAME COLUMNS with the information you have just
learned. Use page 146 in this book for reference.
This completes some basic flame checks should your smoke alarm go
off. If a problem occurs which these pages have not covered or if the
problem is not easily solved, call service.
-------
REVIEW QUESTIONS
1. When the smoke alarm goes off, what is the key to troubleshooting
after checking the oil temperature?
Under each, write what is incorrect about the flames below:
2.
3.
4.
5.
6.
14ft
-------
8. If the flame is pushed away from the burner, the cause is often too
much air.

9. Even though you may not make adjustments, what can you do to
shutters and linkage to keep them working well?

10. What are three main areas (other than outside air) to check when you
get a smoky flame and there is not enough air?

11. A flame that is too long or too wide could be the result of an
incorrect position.

12. Is it too much or too little primary air that can cause a flame to be too
wide?

13. What could be in the oil that may cause "sparks" in the flame?
14. What burning supply often needs adjustment to correct a pulsating
flame?

15. What two gauges should you first check when you get a pulsating flame?

16. Assuming normal oil flow, what basic supply usually needs adjustment
when you get smoke?

17. If oil temperature adjustment and flame reading don't enable you to
solve a smoke problem, what should you do?
— Check your answers.
149
-------
ANSWERS TO REVIEW QUESTIONS:

1. the flame
2. flame away from the burner
3. smoky flame
4. too long
5. too wide
6. "sparky" flame
7. pulsating flame
8. primary
9. clean and/or lubricate
10. primary air
secondary air
stack damper
11. cup
12. too little
13. oil globs or carbon bits
14. oil
15. oil temperature gauge
oil pressure gauge
16. air
17. call service
150
-------
Part 2
THE PROPER OPERATION
AND MAINTENANCE
OF FLUE FED INCINERATORS
-------
Section 5
INCINERATORS;
BASIC PARTS AND FUNDAMENTALS
1. INCINERATORS
In the past, incinerators have belched out smoke and fly ash. To combat this health and property hazard.

New York City has passed upgrading laws. These include:

I. INCINERATORS UPGRADED - INCLUDING SCRUBBERS

II. OPERATORS TRAINED IN RUNNING UPGRADED EQUIPMENT
Some smoke and fly ash are unavoidable. Keep emissions at a minimum by keeping your INCINERATOR

CLEAN and in GOOD CONDITION.
CHECK ( V ) what you can do to keep down incinerator pollution:
.1. Take this course in proper incinerator operation.

.2. Keep the incinerator clean and in good condition.
— Check your answer.
153
-------
/
2.
2. INCINERATOR PARTS
HERE ARE SOME BASIC INCINERATOR PARTS. LOOK THEM OVER.
f- FAN
TEMPERATURE CONTROL --^=

CYCLING TIME CLOCK--

GAS BURNER

INCLINED
HEARTH
CHARGING
HOPPER DOOR--»,
CHARGING FLUE
CHARGING FLUE GATE
OVERFIRE AIR
-- FLUE GAS FLOW
GRATE --4.-W-.-Vl

UNDERFIRE AIR --»

ASH PIT '
— SETTLING TANK
SUMP
FURNACE
154
-------
Answer these questions using the opposite diagram:
1. As the garbage is put through the hopper door and
falls down the charging flue, what device holds it
until firing time?

2. Name the two air supplies to the incinerator.

3. What timing device controls the incinerator?

4. How hot the fire is, is regulated by what control?

5. What kind of a burner provides the required
incinerator temperature?

6. What major part cleans the incinerator gases by
circulating them through water?

7. What is at the bottom of the scrubber which lets
you drain or clean the settling tank?
— Check your answers.
155
-------
1. Charging flue gate
2. Overfire air
Underfire air
3. Cycling time clock
4. Temperature Control
5. Gas Burner
6. Scrubber
7. Scrubber sump
3. BURNING
A burn needs three things:
1. GARBAGE
2. AIR
3. IGNITION AND HEAT - the burner
Good combustion needs a FAST, HOT FIRE. For this to happen the garbage, air, draft, and burner must be
controlled. The CYCLING TIME CLOCK is set and at the proper time these three are automatically
brought together for burning.
FIRST-GARBAGE
*-- CHARGING FLUE
CHARGING FLUE GATE —•»
CYCLING TIME CLOCK
f Garbage collects. Gate
opened automatically by
clock at firing time.
Gate remains closed
during burn cycle.
156
-------
MAKE THE FOLLOWING MARKS ON THE DIAGRAM:

- WRITE "HOPPER" where the tenants deposit their garbage.

— PUT A CIRCLE around the part that holds the garbage until firing time.

— UNDERLINE THE NAME of the part that controls the movement of the gate to drop the garbage
onto the hearth,

— WRITE "FIRE" in the chamber where the fire takes place.
— Check your answers.
157
-------
ANSWERS TO PREVIOUS PAGE:
- CHARGING FLUE
CYCLING TIME CLOCK
CHARGING
FLUE GATE
158
-------
Study this diagram and answer the questions
OVERFIREAIR
Openings in pipe permit regulation .,_.__
FAN->g^_>J
Air thrust (Blower) aids burning — - - ~1? j * *
CYCLING TIME CLOCK - -I-
Air freely flows in under grate > ^
UNDERFIRE AIR
Remember that the CYCLING TIME CLOCK regulates all major equipment,
1. Which is turned on and off by the time clock,
Overf ire Air or Underfire Air?
2 Which is produced by a fan and blown into the
incinerator, Overf ire Air or Underfire Air?
3. Which air to the incinerator is not turned on by
the time clock, but is free flowing?
4. What device starts the fan for Overfire Air?
— Check your answers.
159
-------
1. Overfire Air
2. Overfire Air
3. Underfire Air
4. Cycling Time Clock
This is how GARBAGE and AIR get into the incinerator.
LABEL THE DIAGRAM:
5. Cycling Time Clock
6. Overfire Air (and Fan)
7. Underfire Air
8. Draw a line showing the
path of the garbage.
1. Hopper Door
2. Charging Flue
3. Charging Flue Gate
4. Grate
For good combustion, be sure there is a good basic air supply to the incinerator room.
— Check and correct
your answers.
160
-------
ANSWERS TO PREVIOUS PAGE.
HOPPER DOOR -> '
CHARGING FLUE GATE
OVERFIRE AIR FAN
CYCLING TIME CLOCK -
UNDERFIREAIR
CHARGING FLUE
161
-------
IGNITION AND HEAT - THE BURNER
For a hot, fast burn the three parts below must be working properly.
Set to maintain
1400°-1600° fire.
TEMPERATURE CONTROL
Starts burner -» CYCLING TIME CLOCK
GAS BURNER
Ignites Garbage;
provides more heat
if needed.
ANSWER THESE QUESTIONS:
1. What starts the burner at firing time?
2. What ignites the garbage (starts the fire)?
3. What instrument monitors the fire temperature?
— Check your answers.
162
-------
1. Cycling Time Clock
2. Gas Burner
3. Temperature Control
The burning chamber is closed off when the Charging Flue Gate closes. It closes after dropping garbage to
the grate. It stays closed during the burn and collects garbage for the next burn.

PUT THE NAMES OF THESE PARTS ON THE DIAGRAM:

1. This starts the burner (also controls garbage and air)
2. This ignites the garbage
3. This keeps the fire between 1400F -1600 F.
\J Check and correct your diagram by the previous page.
CIRCLE THE CORRECT WORDS:
A good incinerator burn is HOT/WARM and SLOW/FAST.
— Check your answer.
163
-------
HOT and FAST
4. AFTER THE BURN
You are probably no longer surprised at the junk that ends up in your incinerator.
Here is the area to clean after the burn, when the incinerator is COOL.
FIRE DOOR >
CLEAN OUT DOOR
GRATE
PIT
1. Where will cans and bottles be left after the burn?

2. Where will the ashes fall during and after the
burn?

3. Through what door would you clean the grate?

4. Through what door would you remove ash that
had fallen through the grate?
— Check your answers.
164
-------
1. On the grate
2. Pit under Grate
3. Fire Door
4. Clean out door
5. BURNING REVIEW

1. What three things are needed for a burn?
2. What device controls these three to start the burn?
3. What part holds the garbage, then opens to allow
it to fall into the burning chamber?
4. Name the two air sources to the fire chamber.
5. What piece of equipment ignites the garbage?
6. What device monitors the burn for correct
temperature?
7. What two places need to be cleaned after the fire
is out?
ANSWERS 1- Garbage 4. Overfire Air
Air Underfire Air
Ignition (Burner) 5 Gas Burner

2. Cycling Time Clock 6. Temperature Control
7 firatp
3. Charging Flue Gate
Ash pit under Grate
165
-------
6. SCRUBBING THE GASES

New York City upgrading standards require all incinerators to have a SCRUBBER. As the garbage is burned
the EXHAUST GASES ARE CLEANED BY BEING WASHED VIGOROUSLY WITH WATER before going
out the Stack.
Here is a basic Scrubber diagram.
A -- AUTOMATIC BY-PASS DAMPER
Spray Nozzles
LI
'.- AUTOMATIC DRAFT CONTROL
IMF
— SETTLING TANK
Incinerator
166
-------
Answer these questions as to how the Scrubber works:

1. Gases from the burning refuse are pulled into the Scrubber by:

A. a pump
B. overfire air supply
C. fan induced draft

. 2. The dotted area on the diagram represents:
A. Quiet water to let the fly ash settle.
B. Churning water to wash the fly ash from the gases.

3. Are gases cleaner at Point A on the opposite diagram or Point B?
— Check your answers.
16
-------
L 1.
_B_ 2.
3-
V- AUTOMATIC BY-PASS DAMPER
.--f- AUTOMATIC DRAFT CONTROL
Gases are moved by a FAN and controlled by a DAMPER and DRAFT CONTROL. Normally the
AUTOMATIC DRAFT CONTROL valve is left in the open position to allow the gases to pass into the scrubber
The purpose of the automatic draft control is to maintain a low uniform draft in the incinerator.
When the scrubber is temporarily shut down for cleaning or maintenance or an emergency such as water
failure, the AUTOMATIC BY-PASS DAMPER is adjusted so that gases are directed past the scrubber and up
the stack without being cleaned.
MATCH the devices with what they do:
Automatic By-Pass Damper
Automatic Draft Control
Fan
A. Pulls gases from the Scrubber water and out the flue.
B. Directs gases from the burn on out the flue without going
through the Scrubber.
C. Directs gases from the burn into the Scrubber.
168
-------
_B Automatic By-Pass Damper
JC^ Automatic Draft Control
A Fan
On the diagram, LABEL THESE PARTS:

AUTOMATIC BY-PASS DAMPER
AUTOMATIC DRAFT CONTROL
FAN
DRAW A LINE SHOWING THE PATH OF FLUE GASES
STRAINER
169
-------
FAN
- AUTOMATIC BY-PASS DAMPER
\ AUTOMATIC DRAFT CONTROL
WATER LINE
STRAINER
170
-------
The water in the Scrubber is churning vigorously — DIRT and ASH SETTLE in the TANK at the bottom.
Answer these questions with one of the LETTERS FROM THE DIAGRAM BELOW:
1. At what point does water enter the scrubber?
2. At what point does water leave the scrubber?
3. What letter indicates the Settling Tank where dirt will collect?
r\

r~L-
— Check your answers.
WATER LINE
STRAINER
17
-------
_A 2.
B 3.
7 ASH CATCHERS
ASH in the scrubber will either
1. SETTLE in the tank, or be
2. CARRIED OUT THE WATER LINE with the water.
Little ash will go up the stack.
When the BY-PASS DAMPER is OPEN all the ash floats freely up the stack. The gases do not go through
the scrubber.
SEE THREE ASH CATCHERS BELOW:
1. SPARK ARRESTOR
By-Pass Damper
SETTLING .
• TANK
!•<
2. SUMP
—t- 3. WATER LINE STRAINER
172
-------
Answer these questions with a part from the diagram:
1. Where do you clean out the settling tank?
2. What filters ash from the water as it leaves the
tank?
3. What is the only device which will stop large
burning material when the by-pass damper is
open?
— Check your answers
17:
-------
1. Scrubber Sump
2. Water Line Strainer
3. Spark Arrester
On the diagram below, LABEL THE ASH CATCHERS:
SUMP
WATER LINE STRAINER
SPARK ARRESTOR

n i
[
i — \-

fc .
CHECK YOUR ANSWERS ON PAGE 172.
Which of these can you clean?
— Check your answer.
174
-------
all of them
8. SCRUBBER REVIEW
Below is an outline of an Incinerator-Scrubber. In it LABEL OR MARK THE FOLLOWING:
Automatic By-Pass Damper
Automatic Draft Control
Scrubber Settling Tank
Fan
Sump
Water Line Strainer
Spark Arrester
DRAW ARROWS showing the path of the flue gases.
PUT "X" on three ASH CATCHERS.
Check and correct
your answers.
175
-------
ANSWERS TO PREVIOUS PAGE:
SPARK ARRESTOR
FAN
AUTOMATIC BY-PASS DAMPER
AUTOMATIC DRAFT CONTROL
^ SETTLING TANK
SUMP
WATER LINE STRAINER'
176
-------
9. MULTI-CHAMBER INCINERATORS
In many systems, gases pass through one or more SEPARATION CHAMBERS AFTER THE BURN. Large
residue falls here before gases go into the scrubber.
WRITE "S" IN THE SEPARATION CHAMBERS ABOVE.
WRITE "X" WHERE large ash will fall.
There are two Separation Chambers above. There may be as many as four. The floors should be cleaned
regularly.
Does your system have Separation Chambers?
If so, how many?
177
-------
10. ROOF SETTLING CHAMBERS
Some systems have a ROOF SETTLING CHAMBER. ASH settles here before gases go out into the air.
CIRCLE THE CORRECT WORDS:

The roof settling chamber is A/B/C above.
It is useful when the scrubber IS/IS NOT operating
178
— Check your answer:
top of next ft
-------
Answers
The roof settling chamber is on the roof - B opposite. If the by-pass damper is open (scrubber NOT operating),
the roof chamber will collect most large ash.
Do you have a Roof Settling Chamber?

If so, do you clean it regularly?
— Go on to the next page.
179
-------
11. MULTIPLE CHAMBER REVIEW
TIJ
Name the chambers indicated by the letters above:
B
180
-------
A. Burning Chamber
B. Separation Chamber
C. Roof Settling Chamber
1. Are the materials collected in B and C mostly fine
ash or relatively large particles?

2. Which chamber cleans gases before the scrubber?

3. Which cleaning chamber is important when the
scrubber is not in use?
— Check your answers.
181
-------
1. large particles
2. B - Separation Chamber
3. C - Roof Settling Chamber
DOUBLE FLUES
Some incinerators have DOUBLE FLUES. So far only single flues have been shown.
LOOK AT THESE DIAGRAMS.
X
S\\~*^~-~J»-J
t
•
9
i i
B
182
-------
ANSWER THESE QUESTIONS WITH "A" or "B."
1. Which is a single flue?
2. Which is a double flue?
3. Which uses the same flue for garbage going down and gases going up?
4. Which uses separate flues for garbage and gases?
Check and correct
your answers
A 1-
B. 2.
A 3.
B. 4.
Separate flues are a big advantage. Tenants can put garbage in the hopper any time without the danger of
hot gases and flying ash.

Separate flues are shown in B and questions 2 and 4 above.

Single flue hoppers should automatically lock during burning. This is very important for safety and should
be checked regularly.

Do you have a Single or Double flue incinerator?
183
-------
PURGE DAMPER
£ GAS EMISSSION FLUE
CHARGING FLUE GATE
DOUBLE FLUE INCINERATOR
A PURGE DAMPER allows periodic cleaning of the Charging Flue. Garbage, grease and insects are burned
off by automatic sequence of the steps below:

TURN GAS BURNER ON
OPEN PURGE DAMPER
OPEN CHARGING FLUE GATE
SHUT DOWN SCRUBBER

Hot gases then go straight up the Charging Flue and clean it. Dotted line above show the path of these
gases.
184
-------
1. Waste gases normally go up which flue?

2. When cleaning the charging flue, hot gases are
directed up which flue?

3. A purge damper is needed in double flue
incinerators because:

A. It controls the draft.
B. It is needed to burn out the charging flue.
— Check your answers.
185
-------
1. Gas Emission Flue
2. Charging Flue
3. B
13. DOUBLE FLUE REVIEW
L
On the diagram —
LABEL the CHARGING FLUE
LABEL the GAS EMISSION FLUE
LABEL the PURGE DAMPER
DRAW A LINE showing the path of hot purge gases.
DRAW ARROWS showing the normal path of gases from the scrubbers.
CHECK YOUR DIAGRAM ON PAGE 184, correct it if necessary.
186
-------
HANDBOOK WRAP-UP

This completes the introduction to basic incinerator parts. Your system may not exactly match the
diagrams shown but it should be similar.

TURN TO YOUR INCINCERATOR HANDBOOK, PAGE 221.

PAGE 222 Basic parts and definitions are included here for your future reference.

PAGE 224 Here is a general incinerator outline. On it LABEL THINGS ABOUT YOUR
INCINERATOR THAT ARE DIFFERENT FROM THE EXAMPLE IN THIS LESSON.
(You may have a different type of Scrubber).

PAGE 225 RECORD THE STATISTICS OF YOUR SYSTEM HERE.
187
-------
SUMMARY
These questions review the important things in this section:
1. Is a good incinerator fire hot and fast or moderate
and slow?

2. What three basic ingredients are needed for an
incinerator fire?
3. What device is set to coordinate the burn (drop
the garbage, start the overfire air, start the
burner)?

4. What part of the incinerator actually holds the
garbage above the furnace until firing time?
5. Name the two direct air supplies to the fire?
6. Which can be regulated, Overfire Air or Underfire
Air?

7. What two places under the furnace collect waste
bottles, cans and ash?
188
-------
8. What major device should all incinerators have to
clean flue gases?

9. What circulates in the scrubber to clean the flue
gases?
10. Are flue gases pulled from the furnace into the
scrubber by the automatic draft control or
by-pass damper?

11. Are the flue gases directed out the flue without
going through the scrubber by the automatic
draft control or by-pass damper?

12. What is at the bottom of the settling tank which
collects dirt and must be cleaned regularly?

13. What device should be in the water line leaving
the scrubber to collect ash in the water?

14. What device pulls gases from the scrubber and
out the flue?
15. What are separation chambers used for?

16. A double flue incinerator is one that permits you
to switch garbage collection from one to the
other. (TRUE or FALSE)
-------
ANSWERS TO REVIEW QUESTIONS:

1. hot and fast
2. garbage
air
ignition (burner)

3. cycling time clock

4. charging flue gate

5. overfire air (blower)
underfire air

6. overfire air

7. grate
ash pit

8. scrubber

9. water
10. draft control

11. by-pass damper
12. sump

13. strainer

14. fan

15. cleaning the gases, collecting ash

16. False
190
-------
Section 6
INCINERATORS;
MAINTENANCE AND TROUBLESHOOTING
including your own INCINERATOR HANDBOOK

1. DAILY CLEANING
This section will cover tasks you should do each day to keep the system running smoothly
and maintenance tasks to be performed periodically. Also included are troubleshooting checks
to make before calling service should you get smoke.
Daily Cleaning reduces your chances of producing smoke. Your system will not work
smoothly if clogged with waste from burning.
Set a time each day to clean and check the incinerator. WAIT AT LEAST ONE HOUR after a
burn for the furnace to cool. SHUT DOWN THE SYSTEM by pushing the stop button. BELOW
ARE THREE PLACES to clean.
1. How long should you wait after a
burn to clean the incinerator?

2. From where would you clean cans,
bottles and other large waste mate-
rial?

3. From where would you clean most
of the ash?
SEPARATION CHAMBERS

— Check your answers.
191
-------
1. 1 hour or more
2. Grate
3. Ash Pit
On this diagram, MARK AN "X" on the number of SEPARATION CHAMBERS that you
have on your system. Leave this blank if you have none.
•> To Scrubber
You may also have a roof settling chamber. Some systems have the scrubber and chambers on
the roof.

Name the three places covered so far to
be cleaned each day.
— Check your answers.
192
-------
Grate
Ash Pit
Separation Chambers
2. DAILY SCRUBBER CLEANING
Be sure strainer is clean.
L
SETTLING TANK

SUMP
x Scoop out fly ash and sludge.
STRAINER
1. Where will most of the fly ash in
the settling tank collect?

2. What must be cleaned to prevent the
discharge water line from clogging?
After cleaning, be sure all incinerator doors are closed and turn the system back to automatic.
— Check your answers.
193
-------
1. sump
2. strainer
3. DAILY CLEANING REVIEW
ANSWER THESE QUESTIONS:

1. Name three places in the incinerator
(other than the scrubber) to clean
each day.
2. Name two places in the scrubber to
clean daily.
3. How long should you wait after a
burn to clean your system? .

CIRCLE THE CORRECT WORDS below:

4. Turn your system ON/OFF before cleaning.

5. After cleaning be sure to OPEN/CLOSE all incinerator doors.
ANSWERS 1. Grate
Ash Pit
Separation Chambers

2. Sump
Strainer

3. 1 hour

4. OFF

5. CLOSE
194
-------
4. DAILY CHECKS
In addition to cleaning, there are some DAILY CHECKS to make to keep major parts in good
working order.

CYCLING TIME CLOCK

ON THIS CLOCK, CIRCLE THE TIMES YOUR CLOCK IS SET to start a burn:
The clock is important as it brings together burning ingredients - garbage, air, ignition. If your
clock isn't working, call service to fix it.
Whom do you call for incinerator ser-
vice?
Do you have his number at a conven-
ient place for easy access?

Incinerator service agencies usually repair
all equipment.
What is the first daily check to make?
— Check your answer.
195
-------
Cycling Time Clock
5. FLUE GATE

Next, check the CHARGING FLUE GATE.

Assume the following for the cases below:
Time clock is set at 10:00 A.M. and is working.
Time is now 10:30 A.M.

CIRCLE THE CORRECT WORDS under each:
1.
Charging gate apparently
JAMMED/WORKING
2.
Charging Gate apparently
JAMMED/WORKING
196
-------
The first incinerator has started to burn and is OK. The second is jammed in the open
position. It could also jam closed or partially open.

If the charging gate becomes jammed, check to see if GARBAGE is BLOCKING the gate or
track. If not, the ACTUATOR PISTON may not be working. It is usually operated by water
pressure. If your basic utilities (electric supply, city water pressure) are OK, call service.

1. What two things should you check if
your charging gate becomes
jammed? .
2. Name two daily equipment checks
to make.
— Check your answers.
197
-------
1. Garbage blocking gate
Actuator Piston working
2. Cycling Time Clock
Charging Flue Gate
6. LAST TWO DAILY CHECKS:
BLOWER MOTOR
-OVERFIRE AIR
Sound normal?
GAS BURNER
Sound normal?
Spark Plugs connected?
Gas cock open?
You will normally not have problems with the above, but they are important. Be sure they are
in good working order.

1. What air source has movable parts
and should be checked daily?
2. What part is checked to confirm
dependable ignition?
— Check your answers.
198
-------
1. Blower - Overfire Air
2. Gas Burner
COMPLETE DAILY INCINERATOR CHECKS BELOW:
1. For the system to start on
time:
C
'c
4. Ignition equipment in
good order:
J
2. Garbage drops to burn
properly
N.
3. Air is getting to the fur-
nace:
— Check your answers.
19
-------
1. Cycling Time Clock
2. Charging Flue Gate
3. Overt ire Air Blower
4. Gas Burner
7. SCRUBBER-DAILY CHECKS

TWO SCRUBBER CHECKS:

1. WATER CIRCULATION - water moving vigorously; in and out at proper rate.

2. FAN AND MOTOR WORKING - gases taken from the scrubber and out the flue.

On the diagram WRITE THESE TWO on the appropriate lines.
200
-------
Water must circulate to clean the gases. The fan (at the top) pulls off gases for discharge. You
may have a WATER LEVEL GAUGE to monitor scrubber water.

1. Is there a water level gauge on your
system?
2. How does your scrubber circulate
the water (pump, draft pressure,
other)?

3. What equipment pushes Scrubber
gases out the flue which should be
checked daily?
— Check your answers.
201
-------
1. check your own answer
2. check your own answer
3. Fan (and motor)
8. REVIEW- DAILY CHECKS
COMPLETE THE DAILY INCINERATOR CHECKS.
1. Cycling
2. Charging
3. Overf ire Air —
4. Gas
5. Scrubber — Circulation
6. Scrubber — and Motor.

If you find any sign of trouble which you cannot easily fix, call service before it develops into
a major problem.

— Check your answers.
202
-------
1. Cycling Time Clock 4. Gas Burner
2. Charging Flue Gate 5. Scrubber - Water Circulation
3. Overf ire Air - Blower 6. Scrubber - Fan and Motor
This completes the DAILY CLEANING and CHECKING TASKS; they are summarized below.

DAILY CLEANING
1. Grate
2. Ash Pit
3. Separation Chambers
4. Scrubber Sump
5. Scrubber Water Line Strainer

DAILY CHECKS
1. Cycling Time Clock
2. Charging Flue Gate
3. Overf ire Air - Blower
4. Gas Burner
5. Scrubber - Water Circulation
6. Scrubber - Fan and Motor

THESE ARE INCLUDED IN YOUR INCINERATOR HANDBOOK, PAGE 226 FOR
FUTURE REFERENCE.
20
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9. PERIODIC MAINTENANCE
There are three cleaning tasks to be done periodically apart from the scrubber. These are:
1) ASH BUILD-UP, 2) CHARGING FLUE PURGE, and 3) SPARK ARRESTOR.

ASH BUILD UP

Even though you regularly clean ash from the floors of your system, there will be build-up on
the CHAMBER WALLS and LEDGES.

DRAW LINES ALONG SURFACES on the diagram which you should clean periodically.
I
To Scrubber
I
You should have indicated ALL INSIDE BURNING AND SEPARATION CHAMBER WALLS
AND LEDGES. You normally reach these through access doors.

How many chambers do you have to periodically clean for ash build-up?
204
-------
DOUBLE FLUE-PURGE CHARGING FLUE

This task is done only in the case of a double flue incinerator.

As garbage goes down the Charging Flue, a certain amount of GREASE collects on the
WALLS and attracts INSECTS.

Look at these flues -ANSWER THE QUESTIONS BELOW:
PURGE
DAMPER
CHARGING
FLUE GATE
B
*%
•E
1

t~^*_-k

I
*^_^--1_-t_^fc-^T--Y-

CHARGING
FLUE GATE
Which of the flues above has garbage
going down and gases going up?
Which flue walls would collect garbage
and insects which would not be burned
off with each burn?
Flue C has garbage and gases passing through and is cleaned with each burn. Flue A must be
cleaned by purging.
205
-------
Here's how to purge the charging flue:

1. PUT SYSTEM ON MANUAL CONTROL
2. TURN SCRUBBER OFF
3. OPEN BY-PASS DAMPER
4. OPEN PURGE DAMPER
5. OPEN CHARGING GATE
6. TURN GAS BURNER ON

In the list above, CIRCLE THE TWO DAMPERS to be opened for purging.

If the charging gate is not open, the hot gases cannot enter the ffue. You should have circled
by-pass and purge in the above list.

1. What provides heat (hot gases) for
purging?
2. What are the two maintenance tasks
seen so far to be performed periodi-
cally?
— Check your answers
206
-------
1. Gas Burner
2. Clean ash build-up
Purge charging flue
CLEAN SPARK ARRESTOR
Here are two spark arresters. ANSWER THE QUESTIONS under them.
Does A or B show a spark arrestor that
may interfere with flue gases? l

Does A or B show a spark arrestor that
is in good condition? 2

Name three maintenance tasks to be
performed periodically in your incin-
erator. 3
4
5
— Check your answers.
207
-------
1, Yes,B ( The second spark arrestor above needs to be cleaned with a wire brush. The build-up may
2. Yes, A \ interfere with some flue gases.
3. Clean ash build-up
4, Purge charging flue
5, Clean spark arrestor
10. SCRUBBER MAINTENANCE

All Scrubbers are different. There are three tasks you should perform periodically on yours no
matter what the type.

Before cleaning - TURN SCRUBBER OFF.

TWO PERIODIC CLEANING TASKS are on this diagram
SPRAY NOZZLES
— clean with wire brush
Make-up
Water Valve
j. SETTLING TANK
— drain, clean, partially refill
— turn scrubber on, check make-up
water valve and water control element
208
-------
1. What do you clean to be sure you
have a good water curtain?

2. What ash-collecting area should be
cleaned periodically in the scrubber?

3. What valve should be checked for
adequate water control?
— Check your answers.
209
-------
1. Spray nozzles
2. Settling tank
3. Make-up water valve
On the diagram, LABEL TWO SCRUBBER MAINTENANCE TASKS just considered.
BY-PASS DAMPER
— clean and lubricate
bearings if needed
O
CHECK AND CORRECT YOUR DIAGRAM using the diagram on page 208.

The THIRD SCRUBBER MAINTENANCE TASK is shown on the diagram above.

1. What damper should be periodically
checked for good operation?
2. What may need to be done to the
by-pass damper?
— Check your answers.
210
-------
1. By-pass damper
2. Cleaned and lubricated
11. SCRUBBER MAINTENANCE TASKS
On the diagram, LABEL THREE SCRUBBER MAINTENANCE TASKS just considered.
3.
A A A A A *
O
— Check your answers..
211
-------
3. Clean/lubricate by-pass damper
O
• 1. Clean spray nozzles
2. Clean settling tank
PERIODIC MAINTENANCE CHECKS FOR THE INCINERATOR/SCRUBBER ARE SUM-
MARIZED BELOW:

1. Clean Ash Build-Up from Walls
2. Purge Charging Flue
3. Clean Spark Arrester

4. Clean Spray Nozzles - Scrubber
5. Clean Settling Tank - Scrubber
6. Clean/Lubricate By-Pass Damper
These maintenance tasks are listed on page 226 of the Incinerator Handbook for your future
reference.
212
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12. TROUBLESHOOTING
Even a well-run incinerator produces smoke or odors at times. If this happens, check four
things which may help you solve the problem. If not, call service.

FIRST - CHECK THE SCRUBBER
FAN
Does it sound like
it is running properly?
WATER MOVING
Is the System
functioning properly?
If waste gases aren't being pulled from the scrubber, the by-pass damper will automatically
open and that means smoke. The gases cannot be cleaned if the water isn't vigorously cleaning
them.
1. If you get smoke, what do you
check to see if the gases are being
cleaned properly?

2. What two things can you check in
the scrubber for proper operation?
213
-------
1. Scrubber
2. Fan
Water
If the Scrubber is OK, check the OVERFIRE AIR and the CHARGING FLUE GATE.
CHARGING FLUE GATE
— Blocked by garbage
— Actuator piston working?
OVERFIRE AIR ,
— Blower operating?
The sound of the BLOWER generally tells you if it is operating properly. If the CHARGING
FLUE GATE is stuck, you may be able to remedy the situation without calling service.
214
-------
1. What could be stuck in an open or
closed position which may cause
smoke?

2. Which major air supply can cause
smoke if the blower is not working
properly?

3. What are three troubleshooting
checks to make in the incinerator
should you get smoke?
— Check your answers.
-------
1. Charging flue gate
2. Overfire air
3. Scrubber
Charging flue gate
Overfire air
3.
The last troubleshooting check before calling service —THE GAS BURNER. If the burner is
not running properly, smoke will probably result. A problem here generally means calling
service. You should check it out, however, as part of your information when calling service.

On the diagram below, LABEL THE FOUR TROUBLESHOOTING CHECKS to make before
calling service when you get incinerator smoke.
— Check these with the list on
the following page.
216
-------
INCINERATOR TROUBLESHOOTING CHECKS before calling service:
1. Scrubber
2. Overfire Air (Blower)
3. Charging Flue Gate
4. Gas Burner

These are included on page 226 of the Incinerator Handbook for your future reference.
INCINERATOR SUMMARY
DAILY CLEANING TASKS
1. Grate
2. Ash Pit
3. Separation Chambers
4. Scrubber Sump
5. Scrubber Water Line Strainer
DAILY CHECKING TASKS
1. Cycling Time Clock
2. Charginq Flue Gate
3. Overfire Air - Blower
4. Gas Burner
5. Scrubber - Water Circulation
6. Scrubber - Fan and Motor
PERIODIC MAINTENANCE
1. Clean Ash Build-up (all inside surfaces)
2. Purge Double Flue Incinerators-Charging Flue
3. Clean Spark Arrestor
4. Scrubber - Clean Spray Nozzles
5. Scrubber - Clean Settling Tank
6. Scrubber - Clean/Lubricate By-Pass Damper

TROUBLESHOOTING PROCEDURE
1. Scrubber
2. Overfire Air
3. Charging Flue Gate
4. Gas Burner
217
-------
14. REVIEW QUESTIONS

1. Where will most of the ash collect from
which it must be cleaned each day?

2. How often should the grate of the incin-
erator be cleaned?

3. From what two places in the scrubber
should you clean residue each day?
4. What is the minimum length of time
you should wait after a burn to clean
the incinerator?

5. What device should be checked daily to
be sure all burning ingredients are
brought together properly and on time?

6. What may become jammed which would
result in incomplete garbage drop or
firing chamber not being closed off?

7. Which air supply is most susceptible to
problems and should be checked each
day?

8. Should the gas burner be checked daily
or only periodically?

9. What scrubber part should be checked
each day to insure proper flue gas
removal?

10. The action of what basic scrubber
supply should be checked daily?

11. If separation chamber floors are cleaned
each day, ash build-up maintenance
tasks will not be necessary. (TRUE or
FALSE)
218
-------
12. In a double flue incinerator, what must
be done periodically to the charging
flue?

13. What device at the top of the stack
must be cleaned periodically?

14. What scrubber part should you clean
periodically to be sure you get a good
water curtain?

15. The scrubber settling tank should be
cleaned DAILY, PERIODICALLY,
YEARLY. (CHOOSE ONE)

16. What should be periodically done to the
by-pass damper?

17. If you get smoke, what gas cleaning
device should you first check?

18. What Overfire Air device should be
checked in the event of smoke?

19. When troubleshooting smoke in the
incinerator, should you check the Charg-
ing Flue Gate, Gas Burner, or both?
219
-------
ANSWERS TO REVIEW QUESTIONS:

1. ash pit
2. every day
3. sump
strainer
4. 1 hour
5. cycling time clock
6. flue gate
7. overfire air
8. daily
9. fan
10. water
11. False
12. purge it
13. spark arrester
14. water nozzles
15. periodically
16. cleaned and lubricated
17. scrubber
18. blower
19. both
220
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INCINERATOR HANDBOOK
This handbook will at first be used with Sections 5 and 6 of
the training program.

After it is completed, it will be a valuable reference in
keeping your incinerator in top operating condition.
CONTENTS

Parts - Definitions 222
Schematic 223
Reference Information 225
Maintenance - Troubleshooting 226
221
-------
PARTS-DEFINITIONS
HOPPER DOORS - Openings through which
tenants drop garbage.

CHARGING FLUE - Empty column that the
garbage falls through to the furnace.

CHARGING FLUE GATE - Gate across the
charging flue which collects the garbage. It
is opened and closed automatically by the
time clock.

OVERFIRE AIR - A fan and blower which
push air through a series of nozzles in a
pipe running into the furnace.

TEMPERATURE CONTROL - An automatic
control which turns the burner off/on to
maintain a 1400° 1600°F burn.

CYCLING TIME CLOCK- Device set to
activate various parts of the incineration
system at appropriate times.

GAS BURNER -14, Ignites the burn and
increases temperature if fire cools.

HEARTH - Steep incline which causes gar-
bage to form a pile for burning.

GRATE - Metal, louvered platform on which
garbage is burned.

FIRE DOOR - Door leading to the furnace.

UNDERFIRE AIR- Manually adjustable
louvers in the clean-out door which permit
air to pass in and up through the grate to
the burn.

CLEAN-OUT DOOR - Door to the ash pit.
AUTOMATIC BY-PASS DAMPER - Damper
which opens automatically when the scrub-
ber is off; draws flue gases past the
scrubber and out the flue.

AUTOMATIC DRAFT CONTROL- Regu-
lates furnace draft; draws flue gases into
the scrubber.

SCRUBBER - Device which cleans exhaust
gases by running them through a water
curtain before sending them out the flue.

WATER NOZZLES- Openings through
which the water is sprayed in the scrubber
to form a water curtain.

SETTLING TANK - Water tank at the base of
the scrubber.

SUMP - Outlet at base of settling tank where
residue taken from the gases settles.

STRAINER - Device in water pipe which fil-
ters out any residue in the discharge water
as it is recycled in the scrubber.

SCRUBBER FAN - Blower which takes the
clean flue gases from the scrubber and
directs them out the flue.

SPARK ARRESTOR - Wire screen cap over
the top of chimney which will catch any
large materials in the emission gases.'

PURGE DAMPER - Damper at top of charg-
ing flue on double flue inci nerator. Nor-
mally closed; opened to clean charging
flue.
222
-------
-4-— SPARh ARRESTOR
HOPPER DOOR »
CHARGING FLUE
GARBAGE
CHARGING FLUE GATE
OVERFIRE AIR

EMPERATURE CONTROL - -

CYCLING TIME CLOCK
GAS BURNER ^
HEARTH
FIRE DOOR
UNDERFIREAIR
CLEAN OUT DOOR
AUTOMATIC BY-PASS DAMPER
. - - WATER NOZZLES

<- - SCRUBBER

FLUE GAS FLOW
GRATE ---
SETTLING TANK
SUMP
STRAINER
AUTOMATIC DRAFT CONTROL
223
-------
224
-------
REFERENCE INFORMATION
Here is a place to list some basic information about your incinerator. You may have to complete
parts of this page at your incinerator.

COMPLETE THE ITEMS IN THE LAST COLUMN ON THE TABLES BELOW as they apply to
your system.

I. SETTINGS - You should be aware of these, even though they are seldom changed.
INSTRUMENT
Cycling Time Clock
Temperature Control - High & Low
SETTING

II. EQUIPMENT - Service may ask for this information if you call in a problem.
EQUIPMENT
Gas Burner
Scrubber
MAKE

MODEL NUMBER

III. PART SPECIFICATIONS - You may or may not replace these parts or know these sizes. If
not, leave this blank.
PART
Water Nozzles
Water Line Strainer
SIZE

IV. SERVICE - "Who to call" in the event of trouble.
NAME

PHONE

225
-------
INCINERATOR TASKS
MAINTENANCE-TROUBLESHOOTING
DAILY TASKS
CLEAN
1. Grate
2. Ash Pit
3. Separation Chambers
4. Scrubber Sump
5. Scrubber Water Line
Strainer
OPERATION CHECK
1. Cycling Time Clock
2. Charging Flue Gate
3. Overt ire Air - Blower
4. Gas Burner
5. Scrubber - water circulation
6. Scrubber - fan and motor
PERIODIC TASKS
MAINTENANCE CLEANING
1. Remove Ash Build-up - All inside surfaces
2. Purge Double Flue Incinerators - Charging Flue
3. Clean Spark Arrestor
4. Scrubber - Clean Spray Nozzles
5. Scrubber - Clean Settling Tank
6. Scrubber - Clean/Lubricate By-Pass Damper
TROUBLESHOOTING
TASKS
CHECK IN THE EVENT OF SMOKE
1. Scrubber
2. Overf ire Air
3. Changing Flue Gate
4. Gas Burner
226
EFA-450/9-76-001
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA - 450/9-76-001
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
WORKBOOK FOR OPERATORS OF SMALL BOILERS AND
INCINERATORS: A self-instruction text on the Proper
Opera.:p'on^andTMa]ntenance of Small Oil Fired^Boilers
y Crit
5. REPORT DATE
Date Issue March 1976
6. PERFORMING ORGANIZATION CODE
Incinerators; based on
Y. City Criteria
David Sage, Mariland Ruppart, C. George Segelar
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
1O. PROGRAM ELEMENT NO.
David Sage, Incorporated
200 Park Avenue
New York, New York 10017
1 1. CONTRACT/GRANT NC
68-02-0321
12. SPONSORING AGENCY NAME AND ADDRESS
Environmental Protection Agency
Office of Air and Waste Management
Office of Air Quality Planning and Strategies
Air Pollution Training Institute
Research Triangle ParR. N.C. 27711
13. TYPE OF REPORT AND PERIOD COVERED
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
16. ABSTRACT
A self-instructional workbook on the proper operation and maintenance of small
oil fired boilers and flue-fed incinerators. The intended audience; operators
in large metropolitan areas. Designed to provide fundamentals necessary to pass
city certification examination. Learner is provided information, questions, and
correct answers. Length of completion time is optional and is the choice of the
student. Environmental Protection Agency will not certify or offer certificates
of completion for the material. Use of this material is completely optional with
the cities. Based on New York City criteria.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS C. COS AT I Field/Group
18. DISTRIBUTION STATEMENT

Release Unlimited
19. SECURITY CLASS (This Report/
Not Classified
21. NO. OF PAGES

228
20. SECURITY CLASS I'Thy page)
Not Classified
22. PRICE
EPA Form 2220-1 (9-73)
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