ENGINEERING & INSTALLATION MANUAL

Transcription

1 MIURA LX BOILER 170/15 PSI Design ENGINEERING & INSTALLATION MANUAL C APPROVED LX & LXL - HIGH EFFICIENCY LOW NO SERIES MIURA BOILER WEST, INC. x * IN OUR CONTINUING EFFORT TO IMPROVE OUR PRODUCT, INFORMATION IN THIS MANUAL MAY BE CHANGED WITHOUT NOTICE OWNER SHALL MAINTAIN THIS MANUAL IN LEGIBLE CONDITION FOR FUTURE REFERENCE PUBLICATION REVISED MARCH 2000 ENGINEERING REVISED FEBRUARY 2000

2 L.V.C. SECTIONAL VIEW LX BOILER SECTIONAL VIEW ECONOMIZER THIS ILLUSTRATION IS FOR EXAMPLE ONLY. INTENDED FOR COMPONENT IDENTIFICATION ONLY. ACTUAL BOILER WILL VARY DEPENDING ON MODEL SELECTED AND OPTIONS INSTALLED STEAM PRESSURE SENSOR (PRIMARY BOILER CONTROL) LIQUID VOLUME CONTROLLER (PRIMARY PUMP CONTROL) LOW FIRE PUMP CONTROL HIGH FIRE PUMP CONTROL LOW WATER CUTOFF BLOW DOWN PIPING HIGH LIMIT STEAM PRESSURE SWITCH BACK UP CONTROL PRESSURE SWITCH PRESSURE GAUGE FORCED DRAFT BLOWER AND MOTOR STEAM OUTLET STEAM/MOISTURE SEPARATOR COMBUSTION AIR DAMPER MAIN GAS INLET FLAME VIEW PORT PILOT BURNER BURNER CASTABLE THERMOCOUPLE VENT WATER SAMPLE VALVE INSPECTION PORT A.S.M.E. SAFETY VALVE SECONDARY WATER PUMP CONTROL BLOW DOWN PIPING STEAM OUTLET LOW BUBBLE CUT OFF INSULATION FLUE GAS OUTLET DRAIN AUTO SURFACE BLOWDOWN FEED WATER INLET Figure 1 LX-50SG Sectional View Cut Away CONDUCTIVITY SENSOR INSPECTION PORT

3 List of Illustration Figures List of Tables iv iv 1 SECTION ONE - INTRODUCTION FEATURES CODE AND REGULATORY AGENCIES NATIONAL REGULATORY ORGANIZATIONS MIURA BOILER STEAM GENERATORS Inspector Briefing STANDARD EQUIPMENT GUARANTEE DEFINITIONS AND SYMBOLS ABOUT THIS MANUAL 8 2 SECTION TWO - SPECIFICATIONS 9 3 SECTION THREE - INSTALLATION SPECIAL INSTALLATION UNLOADING ASSEMBLING Feed Water Pump Feed Water Control Valves BOILER POSTITIONING AND ANCHORING Boiler Proper Economizer Installation STEAM PIPING FEED WATER SYSTEM PIPING FEED WATER PUMP Feed Water Control Valves Piping Flushing SAFETY RELIEF VALVES, INSTALLATION BLOW DOWN PIPING FUEL SUPPLY ARRANGEMENTS Gas Piping ELECTRICAL INSTALLATION Panel Layout Boiler Interface Capabilities CLEARANCES VENTILATION STACKS AND BREACHING 33 4 SECTION FOUR - OPERATION SAFETY FEATURES AND OPERATING CONTROLS Low Water Volume Cut-Off OOverheat Monitor Temperatre Scale Monitor Temperature High Pressure Limit Cut-Off 38 ii

4 4.1.5 Misfire False Signals Power Overload Air Pressure Fuel Gas Pressure ROUTINE BOILER OPERATION Preparation Before Start-Up Start-Up Blow Down Bottom Blow Down Automatic Bottom Blow Down (Option) Shutdown Cautions During Operation Extended Shutdown Carry Over Make-Up Water Make-Up Water Maintenance Check Water Specifications 45 5 SECTION 5 - MAINTENANCE MAINTENANCE AND CLEANING SCHEDULE TROUBLE SHOOTING Honeywell Flame Controller and Annunciator Messages Physical Problem and Corrective Action OPERATING DISCIPLINES RECOMMENDED SPARE PARTS LIST 49 iii

5 LIST OF ILLUSTRATION FIGURES Figure 2 Nitrous Oxide Emissions vs. Load 2 Figure 3 Boiler Lifting and Handling Points 14 Figure 4 Feed Water Pump Foundation and Installation 15 Figure 5 Pump Base Mounting Holes 15 Figure 6 LX Series Boiler Base Plate 16 Figure 7 Economizer Mounting 17 Figure 8 Steam Line and Trap Arrangement 18 Figure 9 Recommended Feed Water Piping Arrangement 19 Figure 10 Boiler Safety Valve Installation 24 Figure 11 Economizer Safety Relief Valve Installation 24 Figure 12 Blow Down Piping Arrangement 25 Figure 13 Double Blow Down Isolation Valve Options 25 Figure 14 Typical LX Series Gas Train and Vent Points 27 Figure 15 Main Gas Pressure Regulator Vent Piping 28 Figure 16 Pilot Gas Regulator Vent Line Connection 28 Figure 17 Gas Pressure Switch Connection 28 Figure 18 LX Series Boiler Electrical Connection 30 Figure 19 LX Series Terminal Strip Connections 30 Figure 20 Boiler Control Panel with MIURA XJ1 Intelligent Steam Manager 31 Figure 21 Stack Design 35 Figure 22 Stack Installation 35 Figure 23 Stack and Economizer Bolting Dimensions 36 Figure 24 Water Volume Control Illustration 37 LIST OF TABLES Table 1 Specifications for LX(L)-50(S)G 9 Table 2 Specifications for LX(L)-100(S)G 10 Table 3 Specifications for LX(L)-150SG 11 Table 4 Specifications for LX(L)-200SG 12 Table 5 Specifications for LX-300SG 13 Table 6 LX Series Feed Pump Foundation Dimensions 16 Table 7 Main Steam Outlet Valve Size 17 Table 8 Feed Water Pump Suction Strainer Size 19 Table 9 Feed Water Pump Recommendations 21 Table 10 Blow Down Piping Sizes 24 Table 11 LX Gas Piping Sizes 26 Table 12 Boiler Minimum Clearance Requirements 32 Table 13 Boiler Ventilation Requirements 33 Table 14 Floatless Switches and Probes 37 Table 15 Boiler Water Chemistry Specifications 45 Table 16 Maintenance and Cleaning Schedule 46 Table 17 Motor Service and Lubrication Schedule 46 Table 18 Physical Problem and Corrective Action Chart 47 iv

6 1 SECTION ONE - INTRODUCTION Muira Boiler Co., Ltd. began North American activities in 1988 when the manufacturing plant in Brantford, Ontario, was established. Their engineering department developed procedures to meet ASME codes and listing approval from IRI/FM, UL, and pre-approval for the SCAQMD (Southern California Air Quality Management District). The United States corporate sales office, Miura Boiler West, Inc., was established and has developed relationships with national, state, and city inspectors and agencies. The North American network consists of branches in Chicago, Los Angeles, and Ontario. The parent company, Miura Boiler, Ltd. in Japan, is the leading manufacturer of boilers and other thermal equipment in the Pacific Rim holding more than 55% of the market. With factories in five countries, production now exceeds 14,000 units per year. As a result of design necessities in Japan, such as limited space and total dependence on foreign energy, the MIURA STEAM BOILER has been engineered as a highly efficient, vertical water tube, once-through forced-flow design. The MIURA Boiler features a compact unit with a low-water content and is designed to run with a minimum amount of maintenance with simple push-button controls. Operation is quiet, radiant heat losses are minimal, and steam quality is second to none. Miura Boilers are often installed in a multiple boiler network. MIURA Boilers, along with the patented MIURA Multiple Installation panel, allow appropriate horsepower to be brought on and off line quickly to meet sophisticated production needs with maximum fuel economy. The 35-year, field-proven Miura Advantage is the ability to reach full output steam from cold start in less than five minutes using the least amount of energy and having the lowest environmental impact. The high efficiency Miura Boiler has won numerous awards from engineering societies and gas associations because it is a compact, safe, cost-effective boiler. 1.1 FEATURES Miura Boiler, Co., Ltd. developed the new Low NOx Boiler by using the most advanced technical methods. The flat-shaped burner and the rectangular-shaped boiler vessel are uniquely designed for the LX. The LX boiler has a very compact design. In general, the LX series can double steam output in the same space of an existing boiler room. The LX series needs only one-half of the space required for a conventional fire tube design for new construction plants. It is known that the temperature of the combustion flame should be less than 3,272 F to prevent NOx formation. Generally, the combustion flame will have some high temperature areas generating NOx. Miura engineers have calculated the temperature distribution in the combustion and heat exchanging areas. From theoretical analysis and rigorous testing the designed temperature distribution is homogeneously less than 3,272F. The burner surface is made as large as possible, and the furnace volume as small as possible, to optimize the combustion process. As a result, the LX has NOx emissions of less than 20 PPM at 3% converted O 2 and maintains CO levels less than 100ppm (see Figure 2). Miura s emissions meet and exceed all current North American NOx regulations. 1

7 All NOx Concentrations Converted to 3% Oxygen Content N O x C o n c Load % of Rated Boiler Capacity Figure 2 Nitrous Oxide Emissions Vs. Load 1.2 CODE AND REGULATORY AGENCIES There are a number of codes, standards, laws, and regulations covering boilers and related equipment that should be considered when designing a system. Regulatory requirements are dictated by a variety of sources and are all focused primarily on safety. The equipment shall be installed in accordance with the current regulations, codes, and specifications of the applicable city, county, state, and federal agencies. Authorities having jurisdiction should be consulted before installations are made. For more information on how the various rules affect boiler selection and operation, you may want to contact your local MIURA authorized representative or the engineering firm designing the boiler installation. Here are some essential rules to consider: The boiler industry is tightly regulated by the American Society of Mechanical Engineers (ASME) and the ASME codes, which control boiler design, inspection, and quality assurance. In most states, the boiler pressure vessel must have an ASME stamp. (Deaerators, economizers, and other pressure vessels must also be ASME stamped.) The insurance company insuring the facility or boiler may dictate additional requirements. Boiler manufacturers provide special boiler trim according to the requirements of the major insurance companies. Special boiler trim items usually pertain to added safety controls. Some industries, such as food processing, brewing, or pharmaceuticals, may also have additional regulations that have an impact on the boiler and the boiler room. UL and /or ASME-CSD1 specifications may be required. State or local authorities may require data on the boiler controls or basic design criteria. Most areas have established a maximum temperature at which water can be discharged to the sewer. In this case, a blow down separator after cooler is required. Most state, local, or provincial authorities require a permit to install and /or operate a boiler. Additional restrictions may apply in non-attainment areas where air quality does not meet the national ambient air quality standards, and emission regulations are more stringent. Be sure to investigate this before buying a boiler. For all new boilers with inputs over 10 Million Btu/Hr, U.S. Federal emission standards apply, including permitting and reporting procedures. A full-time boiler operator may be required. Operator requirement depends on the boiler s size, pressure, heating surface area, and volume of water. Boilers can be selected which minimize the requirements, either by falling under the requirements and being exempt, or with special equipment 2

8 with special equipment that gives the operator more freedom in the facility. Contact the local boiler inspector for details. Most states or provinces require an annual boiler inspection. There may be other requirements on piping as well. A partial list of agencies having jurisdiction over boiler installation and operation is given below. This list is comprehensive but by no means all-inclusive. United States Environmental Protection Agency A.S.M.E. Codes and Standards National Board Licensing Requirements American Gas Association Standards Underwriters Laboratories, Inc. Factory Mutual Insurers Industrial Risk Insurers Occupational Safety and Health Administration Food and Drug Administration Local, City, and State Fire Marshall State Boiler Inspection Division Division of Labor and Industry for the Local State or City Local Building and Construction Code Inspectors MIURA Boiler recommends contacting your actual insurance provider as well as the utility companies for assistance in identifying and complying with codes. 1.3 NATIONAL REGULATORY ORGANIZATIONS A.S.M.E. 345 East 47th Street New York, NY PHONE: (212) NATIONAL BOARD 1055 Crupper Avenue Columbus, OH PHONE: (614) ASME - C.S.D East 47th Street New York, NY PHONE: (212) N.F.P.A. P.O. Box 9146 Quincy, MA PHONE: (800) NATIONAL UNDERWRITERS 505 Gest Street Cincinnati, OH UNDERWRITERS LABORATORIES 333 Pfingsten Road Northbrook, IL PHONE: (847)

9 1.3.1 MIURA BOILER STEAM GENERATORS Inspector Briefing The Miura steam generator is an unfamiliar design to most inspectors in the field. The purpose of this section is to address common questions and familiarize the inspector with the Miura steam generator through a general overview of the design and operational characteristics. The Miura LX boiler design consists of straight water tubes between upper and lower rectangular headers. Both headers are encased in a cashable refractory, leaving only the tubes exposed to combustion gases. There is very little water and consequently very little energy stored in the steam generator. Water volume is exclusively in the tubes with only incidental bubbling in the upper header. Therefore, the LX design has no natural circulation such as a riser, down-comer effect common to natural circulation boilers. Water is forced into the bottom header and tubes by means of a feed water pump. The water is flashed into steam in the tubes, forming a dynamic bubbling system that cools the tubes. This bubbling action may be best described as a steam gradient, with more steam at the top of the tubes than at the bottom. Steam is accumulated in the upper header with a final separation in the external separator. Condensate dropped by the external separator is fed back into the lower header. Because of the steam gradient, there is no defined stream/water level and thus no sight glass. Special modifications are incorporated into the boiler construction and safety system to accommodate this. First, probes are inserted directly into the top of the tubes. One probe is long, for low water cut out; and one probe is shorter for feed water control (LX-300 models only). This water volume control relies on electrical resistance and the bubbling action is what cools the tubes. As the volume of water in the steam generator is consumed, there is less bubbling at the top of the tubes, increasing the amount of electrical resistance. Once the effective electrical resistance reaches a pre-determined level, a ten-second-time delay is tripped, after which the feed water pump is turned on. It continues to run until the bubbles re-establish effective contact with the probe. Should the water volume ever become so low as to lose effective contact with the low water cutout probe, the boiler will shut down. Secondly, probes are inserted into a water column on the side of the boiler. This water control system relies on a conventional electrical conductance system. When water contacts a probe, a circuit is formed. Three probes control the boiler feed; the short probe controls the pump in Low Fire, the medium-length probe controls the pump in High Fire. The long probe is the primary low water cut out. This safety can be confusing for the inspector who encounters the Miura steam generator in the field for the first time, because a water column typically equals a fixed water level. This is not true, however, for the Miura LX Series steam generator because of the low water content and the fierce boiling action of the steam gradient. This dynamic system is stabilized by a special modification of the water column to create an artificial level. The flanged pipe leading form the boiler body runs through the column with three holes drilled in the pipe to create an orifice effect. Yet, even with this orifice effect, the artificial level formed is not the level in the boiler; and oscillates - especially with load swings on the system. This oscillation is normal and is directly proportional to the volume of water in the boiler tubes Either of these feed water control systems can operate without the other for proper feed water control. However, the combination of these two systems provides for double low water safety and is called the two-way water volume control system. Thirdly, thermocouples are attached directly to the tubes. The thermocouples measure the temperature of the tube and will shut the boiler down if a low water volume condition is detected due to insufficient bubbling, dry fire, or if scale build-up is detected. Scale formation is monitored directly by the rise in tube surface temperature because of lower heat transfer rates. This temperature sensing method can detect a formation of scale of less than 1/64 and will shut down the boiler. The early detection of scale formation is an important factor in maintaining a high efficiency boiler. According to the US National Bureau of Standards, ¼ of scale build up on heating units requires up to 55% more energy to attain the same temperature. Other methods of detecting scale, such as a 4

10 pressure gage on the discharge of the feed water pump, are much less sensitive. The MIURA XJ1 Intelligent Management microcomputer automatically adjusts the alarm settings for the scale monitor based on current boiler steam pressure and boiler firing rate. The boiler will not operate should any low water safeties fail. Only through tampering could the boiler operate without safeties and develop a dry fire condition. Even in the unlikely event this condition should ever be created, by the time the tubes superheat enough to destroy the tensile strength of the metal, the amount of energy contained in the remaining water is so small that the possibility of a pressure explosion is negligible. The Miura Steam Generator design has been used for more than thirty-five years with over 200,000 units presently in operation worldwide. There is no record of ANY pressure vessel explosions. Steam is produced within five minutes from cold start-up and selected tubes can be visually inspected through two-inch openings located on the top and bottom headers. A complete inspection is typically accomplished in a thirty-minute period. All Miura steam generators are annotated as a forced flow steam generator (with no fixed steam or water level) on the pressure vessel s P-3 form and registered with the National Board. The complete packaged steam generator is listed with UL as a standard and can be built to IRI, FM and /or ASME-CSD1 at customer request. Please note that all flanges and fittings identified in this manual as 150# ASA comply with ASME/ANSI standard B16.5. The 150# stamping refers to a standard classification not Maximum Allowable Working Pressure (MAWP). As specified in Table A-361 of ASME codes, Section I, 1995 edition, the MAWP for 150# flanges is 205 psig for saturated steam service and 170 psig for Boiler Feed and Blow-off line service. This specification matches the 170 psig for saturated steam service and 170psig for Boiler Feed and Blow-off line service. This specification matches the 170psi MAWP rating of the MIURA boiler. Miura is dedicated to reliable and safe operation of its steam generator through sound engineering principles and years of in-the-field experience. Please contact us at our Chicago office at (847) or the Los Angeles office at (626) should you have any further questions or comments. 5

11 1.4 STANDARD EQUIPMENT As a fully Packaged Forced Draft Steam Boiler, the LX series receives complete operational testing at our factory to ensure trouble-free installation. (Service Parts are non-proprietary.) The LX has the following items as standard equipment: Boiler Design is UL Approved and Labeled A.S.M.E. S Stamped. A.S.M.E.-CSD-1, IRI, or FM available Mounted Control Panel - Wired with All Necessary Components (No Main Disconnect Provided) Micro Processor Based Integrated Burner Controller - Records Five Most Recent Faults For Recall. 31-Day Operating and Fault History Reporting Available by Modem Link with MIURA Factory Level Service Department. Remote Monitoring of Boiler Performance and Trouble Shooting Available as an Option Gas Meter Available as an Option for Measuring Actual Steam Production Computer Interface Capability (Requires Optional Equipment) Service Parts are Non-Proprietary Centrifugal Forced Draft Blower and Motor Combustion Air Proving Switch Automatic Combustion Air Damper and Motor Flame Safeguard Control with UV Flame Sensor Thermocouples on Water Tubers to Prevent Overheat Condition due to Low Water Volume or Scale Build Up Dual Ultra Violet Flame Detectors on LX-300 Fan Screen Dust Warning Two Independent Water Volume Controls & Low Water Cut Off Safety Devices, plus Manual Reset Liquid Volume Control Column and Bottom Blow Down Valves High and Low Steam Pressure Switches, Plus an Independent High-Pressure Safety Requiring Manual Reset Gas Regulator with Threaded Connections for Main Burner and Pilot Flame High and Low Gas Pressure Switches Dual Pilot Gas Solenoid Valves for Natural Gas Dual Fluid Actuated Main Gas Valves and Plugged Leak Test Port (Vent Valve Optional) External Steam Separator Ports for Direct Visual Inspection of Internals Main Stream Outlet Globe Valve (Optional) A.S.M.E. Approved Safety Relief Valves for Boiler (Option for LXL) and Economizer (If Installed) Intermittent Surface Blow Down System with Strainer and Manual Shut Off Valve High and Low Fire Rate Operating Hours Display with Start Cycle Aggregate and Five-Fault History and Display Heavy Duty Galvanized Economizer ( S Series) Completely Enclosed Heavy Gauge Casing Steam Pressure Gauge Installed Multi-Stage Feed Water Pump and Motor with Stainless Steel Impellers and Ceramic Bearings (Optional) 6

12 1.5 GUARANTEE: Refer to warranty documents for specific details. SIX-MONTH labor warranty from boiler start up may be available, contact Local Sales and Service representa tives for details. This labor warranty covers routine inspection and repairs at the job site. Travel and lodging expenses are not covered except within local representative service area. ONE YEAR Standard warranty for parts from boiler commissioning date or 18 months from shipping date, whichever occurs first. Express shipping cost for overnight or next day delivery of parts is not included. Damage to the boiler or parts of the boiler after leaving the factory is not covered. Parts replaced under this warranty must be returned to MIURA. If the failed part is not returned, the customer will be charged for the new item. SEVEN-YEAR limited factory warranty on pressure vessel against material or workmanship defects. 1.6 DEFINITIONS AND SYMBOLS Note, Caution, and Danger are used throughout this manual with the following definitions and symbols. NOTE: Note indicates an area or subject of special merit, emphasizing either the product capabilities or common errors in operation or maintenance. CAUTION: Caution indicates possible damage to equipment. It also indicates any condition or practice, which, if not observed or remedied, could result in damage or destruction of the equipment. DANGER: Danger indicates any condition or practice, which, if not observed, could result in personal injury or possible death. CAUTION: All steam engines require proper water treatment. This treatment is mandatory from the time the MIURA BOILER is started. Failure to follow the recommended water treatment and maintenance procedures could shorten the life (as well as the efficiency) of the boiler. None of the Miura warranties cover repair due to improper water treatment. 7

13 1.7 ABOUT THIS MANUAL This manual is written to support engineering and mechanical contractor firms. Some basic information is given for the operator and maintenance personnel. More specific information on operation and maintenance of the unit is given in the MIURA OPERATION AND MAINTENANCE MANUAL. If a question about boiler installation is not contained in the text of this manual and is not answered by one of the drawings, please call the MIURA representative or the company offices in Chicago or Los Angeles. We will be glad to help. This manual is available on disk for Microsoft Word 2000 and Word 95/97. In addtion, detailed drawings are available on disk in Auto CAD 14 files. If computer copies are desired, please contact the Chicago Office of MIURA Boiler. A small fee is required for shipping and handling. MIURA BOILER CO., LTD. (Factory) 8 Copernicus Boulevard Brantford, Ontario Canada N3P 1Y4 PHONE: (519) FAX: (519) Canada@ miuraboiler.com MIURA BOILER WEST, INC. (Chicago Office) 600 Northgate Parkway, Suite M Wheeling, IL PHONE: (847) FAX: (847) Chicago@miuraboiler.com MIURA BOILER WEST, INC. (LA Office) 1945 South Myrtle Avenue Monrovia, CA PHONE: (626) FAX: (626) LA@miuraboiler.com 8

14 2 SECTION TWO - SPECIFICATIONS ITEM Boiler Type Boiler Horsepower Rating Maximum Working Pressure Equivalent Output Heat Input Heat Output Efficiency (Fuel to Steam) Heating Surface Area Operational Water Content Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Emissions, Gas Fired Main Steam Outlet Safety Valve Outlet for LX Safety Valve Outlet for LXL Feed Water Inlet Fuel Gas Inlet Automatic Surface Blow Down Manual Bottom Blow Down Chimney Diameter Flame Detector Overheat Protection Table 1 Specifications for LX(L)-50(S)G UNITS LX-50 G LX-50 SG NO ECONOMIZER WITH ECONOMIZER Multiple Water Tube, Once Through, Forced Flow, Steam Boiler BHP PSIG LB/HR BTU/HR BTU/HR % FT² GAL LBS LBS Inches 2,066,000 1,674, ,500 3,150 3 Position Step Burner HIGH-LOW-OFF Forced Draft, Pre-Mixed Burner Electric Spark Ignited Interrupted Gas Pilot 460, or 230V, 3 Phase, 60 HZ KVA KW (HP) 7.0 for LX (5.1 for LXL) 2.25 (3.0) SCFH 2,058 1,960 PSIG 3-5 (Natural Gas or Propane) SCFH 27,600 23,600 26,300 22,400 FT/S F Max. 100 PPM CO Max. 20 PPM NOx (Corrected to 3% O 2 ) 2 for LX and 4 for LXL 1 1/4 2 1/ (LX) 150 (LXL) 1, /4 1 1/2 3/8 1,969,000 1,674, ,070 3,840 One 1/4 1 & 2 1/ Ultraviolet Flame Eye Sensor Low Water Cut-Off & High Temperature (Water Tube) Cut-Off NOTE: i) Equivalent output is calculated from and at 212 F (100 C) Feed Water to 212 F steam. ii) Gas consumption based on Natural Gas with High heating 1004 BTU/SCFH when operating at 70 psig (10 for LXL). iii) Thermal effi ciencies are based on high heating values of fuels. iv) Flue gas temperature & velocity are calculated for Natural Gas with 68 F Feed Water. v) LX and LXL have the same specifi cations except as noted above. 9

15 ITEM Boiler Type Boiler Horsepower Rating Maximum Working Pressure Equivalent Output Heat Input Heat Output Efficiency (Fuel to Steam) Heating Surface Area Operational Water Content Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Emissions, Gas Fired Main Steam Outlet Safety Valve Outlet for LX Safety Valve Outlet for LXL Feed Water Inlet Fuel Gas Inlet Automatic Surface Blow Down Manual Bottom Blow Down Chimney Diameter Flame Detector Overheat Protection Table 2 Specifications for LX(L)-100(S)G UNITS LX-100 G LX-100 SG NO ECONOMIZER WITH ECONOMIZER Multiple Water Tube, Once Through, Forced Flow, Steam Boiler ,450 4,133,000 3,938,000 3,348,000 3,348, BHP PSIG LB/HR BTU/HR BTU/HR % FT² GAL LBS LBS KVA KW (HP) SCFH PSIG SCFH Inches 5,300 4,910 3 Position Step Burner HIGH-LOW-OFF Forced Draft, Pre-Mixed Burner 13.0 for LX (12.3 for LXL) 7.5 (10) 4,120 3, (Natural Gas or Propane) 55,200 52,500 47,200 44,900 FT/S F Max. 100 PPM CO Max. 20 PPM NOx (Corrected to 3% O 2 ) 2 (6 for LXL) 2 2 1/2 x Electric Spark Ignited Interrupted Gas Pilot 460, or 230V, 3 Phase, 60 HZ 1 2 3/8 6,070 5,470 1 & 2 1 & 2 1/2 x Ultraviolet Flame Eye Sensor Low Water Cut-Off & High Temperature (Water Tube) Cut-Off NOTE: i) Equivalent output is calculated from and at 212 F (100 C) Feed Water to 212 F steam. ii) Gas consumption based on Natural Gas with High heating 1004 BTU/SCFH when operating at 70 psig (10 for LXL). iii) Thermal effi ciencies are based on high heating values of fuels. iv) Flue gas temperature & velocity are calculated for Natural Gas with 68 F Feed Water. v) LX and LXL have the same specifi cations except as noted above. 10

16 ITEM Boiler Type Boiler Horsepower Rating Maximum Working Pressure Equivalent Output Heat Input Heat Output Efficiency (Fuel to Steam) Heating Surface Area Operational Water Content Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Emissions, Gas Fired Main Steam Outlet Safety Valve Outlet for LX Safety Valve Outlet for LXL Feed Water Inlet Fuel Gas Inlet Automatic Surface Blow Down Manual Bottom Blow Down Chimney Diameter Flame Detector Overheat Protection Table 3 Specifications for LX(L)-150SG UNITS LX-100 SG WITH ECONOMIZER Multiple Water Tube, Once Through, Forced Flow, Steam Boiler (LX) 15 (LXL) 5,175 5,908,000 5,022,000 BHP PSIG LB/HR BTU/HR BTU/HR % FT² GAL LBS LBS ,600 8,950 3 Position Step Burner HIGH-LOW-OFF Forced Draft, Pre-Mixed Burner Electric Spark Ignited Interrupted Gas Pilot 460, or 230V, 3 Phase, 60 HZ KVA 19.2 HP 15 SCFH 5,880 PSIG 3-5 (Natural Gas or Propane) SCFH 78,800 67,300 FT/S 28.7 F 270 Max. 100 PPM CO Max. 20 PPM NOx (Corrected to 3% O 2 ) 3 (LX) and 8 (LXL) 1 & 2 1/2 One 1 & 2 x 4 Inches 1 2 3/ Ultraviolet Flame Eye Sensor Low Water Cut-Off & High Temperature (Water Tube) Cut-Off NOTE: i) Equivalent output is calculated from and at 212 F (100 C) Feed Water to 212 F steam. ii) Gas consumption based on Natural Gas with High heating 1004 BTU/SCFH when operating at 70 psig (10 for LXL). iii) Thermal effi ciencies are based on high heating values of fuels. iv) Flue gas temperature & velocity are calculated for Natural Gas with 68 F Feed Water. v) LX and LXL have the same specifi cations except as noted above. 11

17 ITEM Boiler Type Boiler Horsepower Rating Maximum Working Pressure Equivalent Output Heat Input Heat Output Efficiency (Fuel to Steam) Heating Surface Area Operational Water Content Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Emissions, Gas Fired Main Steam Outlet Safety Valve Outlet for LX Safety Valve Outlet for LXL Feed Water Inlet Fuel Gas Inlet Automatic Surface Blow Down Manual Bottom Blow Off Chimney Diameter Flame Detector Overheat Protection Table 4 Specifications for LX(L)-200SG UNITS LX-100 SG WITH ECONOMIZER Multiple Water Tube, Once Through, Forced Flow, Steam Boiler (LX) 15 (LXL) 6,900 7,876,000 6,695,000 BHP PSIG LB/HR BTU/HR BTU/HR % FT² GAL LBS LBS ,000 9,200 3 Position Step Burner HIGH-LOW-OFF Forced Draft, Pre-Mixed Burner Electric Spark Ignited Interrupted Gas Pilot 460, or 230V, 3 Phase, 60 HZ KVA 19.2 for LX (15.9 for LXL) HP 15 SCFH 7,850 PSIG 3-5 (Natural Gas or Propane) SCFH 105,000 89,000 FT/S 18.8 F 270 Max. 100 PPM CO Max. 20 PPM NOx (Corrected to 3% O 2 ) 3 (LX) and 8 (LXL) 1 & 2 1/2 One 1 & 2 x 4 Inches 1 1/4 2 3/ Ultraviolet Flame Eye Sensor Low Water Cut-Off & High Temperature (Water Tube) Cut-Off NOTE: i) Equivalent output is calculated from and at 212 F (100 C) Feed Water to 212 F steam. ii) Gas consumption based on Natural Gas with High heating 1004 BTU/SCFH when operating at 70 psig (10 for LXL). iii) Thermal effi ciencies are based on high heating values of fuels. iv) Flue gas temperature & velocity are calculated for Natural Gas with 68 F Feed Water. v) LX and LXL have the same specifi cations except as noted above. 12

18 ITEM Boiler Type Boiler Horsepower Rating Maximum Working Pressure Equivalent Output Heat Input Heat Output Efficiency (Fuel to Steam) Heating Surface Area Operational Water Content Operational Weight Shipping Weight Combustion Control Combustion System Ignition System Power Supply Max. Electrical Consumption Blower Motor Output Fuel Consumption Fuel Supply Pressure Flue Gas Volume (Wet) Flue Gas Volume (Dry) Flue Gas Velocity Flue Gas Temperature Emissions, Gas Fired Main Steam Outlet Safety Valve Outlet Feed Water Inlet Fuel Gas Inlet Automatic Surface Blow Down Manual Bottom Blow Off Chimney Diameter Flame Detector Overheat Protection Table 3 Specifications for LX-300SG UNITS LX-300 SG WITH ECONOMIZER Multiple Water Tube, Once Through, Forced Flow, Steam Boiler ,350 11,824,000 10,050,000 BHP PSIG LB/HR BTU/HR BTU/HR % FT² GAL LBS LBS ,200 12,200 3 Position Step Burner HIGH-LOW-OFF Forced Draft, Pre-Mixed Burner Electric Spark Ignited Interrupted Gas Pilot 460, or 230V, 3 Phase, 60 HZ KVA 31.6 HP 25 SCFH 11,770 PSIG 3-5 (Natural Gas or Propane) SCFH 157, ,700 FT/S 16.6 F 270 Max. 100 PPM CO Max. 20 PPM NOx (Corrected to 3% O 2 ) 4 One 1 & 2 x 2 1/2 1 1/4 Inches 2 1/2 3/8 x 2 1 1/4 26 Two Ultraviolet Flame Eye Sensors Low Water Cut-Off & High Temperature (Water Tube) Cut-Off NOTE: i) Equivalent output is calculated from and at 212 F (100 C) Feed Water to 212 F steam. ii) Gas consumption based on Natural Gas with High heating 1004 BTU/SCFH when operating at 70 psig (10 for LXL). iii) Thermal effi ciencies are based on high heating values of fuels. iv) Flue gas temperature & velocity are calculated for Natural Gas with 68 F Feed Water. 13

19 3 SECTION THREE - INSTALLATION 3.1 SPECIAL INSTALLATION The MIURA LX series, in the 50 to 150 BHP sizes are designed to allow installation through a standard 36 x 84 door. The LX-200SG and LX-300SG will not fit through a standard personnel door. This feature can be a large cost savings to the customer. The cost savings is a direct result of reduced construction charges by allowing installation of the boiler through a standard door rather than disassembling a wall of the boiler room. In addition, the MIURA boiler can use a standard freight elevator to allow installation above or below the ground floor. This allows the customer to save the cost of crane service. If the boiler is to be installed through an existing doorway, the Steam Separator on all models must be removed at the job site. This will require a hydrostatic test on re-assembly before the boiler is certified. If a boiler arrives at the job site and installation plans have changed, the boiler can easily be disassembled in the field to fit through the door. All other joints requiring disassembly are standard flanges with gaskets or NPT threaded pipe. 3.2 UNLOADING For transportation the LX boiler will be disassembled and shipped in separate crates as follows: Boiler Proper. Optional Economizer (S series) on some models. LXL (Low pressure) models will ship with the vertical moisture separator serarately. Optional Feed Water Pump Assembly. The LX-100/150/200/300SG will ship with the Economizer Pre-mounted on the boiler foundation. NOTE: Electric parts may be packaged in a separate container as warranted by their nature or options selected by the customer. Figure 3 is for illustration only. Details will vary. The boiler proper and economizer have lifting lugs as shown in Figure 3: Shipping weights are as listed on specification table. LX/LXL - 50 LX/LXL LX/LXL - 150SG LX/LXL - 200SG LX-300SG Economizer Lifting Lugs are 1 Lifting Lugs (2) 1 (2) 1 3/8 1 3/8 Figure 3 Boiler Lifting and Handling Points. 14

20 Th LX series boiler may be unloaded from the transport truck using a forklift. However, if a forklift is used, precautions should be taken to ensure that th eboiler does not tip over. The boiler is top heavy and the weight is not centered. Because of the many cariables involved such as model, size of forklift and size of the loading dock, MIURA is not able to recommend a specific method of unloading the boiler. As a general starting point, the boiler center of gravity will be the midpoint of the two lifting lugs. Securing the top of the boiler to the forklift with a chain or similar methods is strongly recommended. The LX-100/150/200/300SG is shipped with the Economizer bolted to the Boiler and Boiler Skid. CAUTION: All boiler prices are F.O.B. the factory at Brantford Ontario. This means that MIURA Boiler West, Inc. is not responsible for damage to the boiler occurring during shipping. We strongly recommend a thorough inspection of all boiler shipments at place of delivery. This inspection should include photographs of the boiler and ancillary equipment packing crates. If any damage is found, do not release the driver or unload the equipment until a satisfactory arrangement is made with the shipping company to cover the damage. MIURA Boiler makes reasonable effort to ensure that no vibration or shock damage will occur. However, if such damage occurs and is not discovered and noted at the time of delivery, MIURA Boiler is not responsible to pay for the cost of repairs and any damaged parts will not be under warranty. 3.3 ASSEMBLING Feed Water Pump OPTIONAL EQUIPMENT All feed water pump foundations, if used, should have four (4) 5/8 holes for 1/2 anchor bolts. See Figure 4 and Figure 5. Place the feed water pump on a foundation and tighten mounting bolts. The foundation and strainer are not provided by MIURA. Note that pump should be located under or close to feed water tank. See Figure 9 and Table 6. FROM FEED WATER TANK B A C D 4 HOLES 1/2 8 for LX HOLES 5/8 for Anchor Bolts E PUMP BASE (example) Figure 4 Feed Water Pump and Installation Figure 5 Pump Base Mounting Holes 15

21 MODEL DIMENSION (IN INCHES) A B C D E OVERALL HEIGHT LXL-50/ / / /8 LXL-150/ / / /4 LX / / /8 LX / / /8 LX-150/ / / LX / / /4 Table 6 LX Series Feed Pump Foundation Dimensions 3.32 Feed Water Control Valves In the application where the customer does not want to operate the feed pump in frequent start/stop cycles, other options are available. Again, the feed system operates in a simple On-Off manner. If control valves are used, they MUST be quick acting, within 5 seconds. MIURA Boiler recommends Ball Valves with pneumatic actuators (preferred) or electric actuators (acceptable). Note that the pneumatic actuators operate in 1 second open to shut and the electric actuators are 5 seconds open to shut. Refer to sections 3.6 and for detailed discussion and suggestions. Electric feed water control valves are available as an option on all boiler models. 3.4 BOILER POSITIONING AND ANCHORING Boiler Proper Mark boiler center line and boiler foundation corners on foundation. Recommended foundation is 6 concrete slab. Re-enforcement of slab is not necessary if floor is solid. The boiler foundation dimensions are given on BOILER ASSEMBLY OUTSIDE VIEW drawing. Clearances are listed in Table 12. All LX model boilers have four (4) anchor bolt holes for 5/8 anchor bolts. After positioning, anchor the boiler to the foundation. See Figure 6. LX-LXL-20/100/150/200 Base Plate Figure 6 LX Series Boiler Base Plate LX-300 Base Plate 16

22 3.4.2 Economizer Installation (OPTIONAL EQUIPMENT) 1. This section does not apply to LX-G or LXL-G boilers. These models do not include an economizer. 2. Flue gas flanges must be sealed. Adjust the economizer as necessary to match the boiler flange by using the four adjusting bolts mounted on economizer base plate. 3. Adjustment of the economizer to the boiler may result in loss of vertical alignment of the economizer outlet flue. This will be compensated by flue gas stack. 4. Install and tighten bolts for flange between boiler and economizer. When boiler to economizer joint is tight, place shims under economizer base and bolt to foundation slab. 5. See Figure The LX-100/150/200/300SG is shipped from the factory with the economizer mounted to boiler and skid. 7. All economizers have a 2 drain hole on the bottom. The drain is intended to allow any condensation from the economizer tubes or rainwater accumulation to drain from the boiler. The drain can be piped to a floor drain if desired. If necessary to prevent flue gas entry into the boiler room, a J shaped water trap may be installed. This should only be necessary in boiler installations where flue draft exceeds the MIURA specifications. LX/LXL-50 LX/LXL-150/200 LX/LXL Bolt 16 Bolt 12 Bolt ECONOMIZER SIDE (4) Height Adjusting Bolts 3/4 BOILER SIDE Figure 7 Economizer Mounting DANGER: INSTALLER AND OPERATOR MUST IDENTIFY EMERGENCY SHUT-OFF DEVICES TO INCLUDE POWER SWITCH, MAIN GAS AND WATER COCK. 3.5 STEAM PIPING BOILER MODEL Table 7 Main Steam Outlet Valve Size OUTLET CONNECTION LXL-50 2 NPT LXL # ASA FLANGE LX NPT LXL # ASA FLANGE LX-150/LX # ASA FLANGE LXL-150/LXL # ASA FLANGE LX # ASA FLANGE 17 BOILER MODEL * Safety valves for LXL boilers are optional equipment from MIURA. OUTLET CONNECTION

23 MIURA Boiler recommends a check valve between the boiler outlet valve and the header isolation valve. Install the main steam check valve horizontally to prevent condensate build up above the check valve. MIURA boilers do not have a manhole. All openings into the waterside of the pressure vessel are 2 standard pipe plugs. Consequently, most jurisdictions do not require a NON RETURN VALVE in multiple boiler installations. Therefore, less expensive standard globe valves may be used instead of the Non-Return stop-check type. Contact the local boiler inspector for verification of local code requirements. Install the horizontal piping with sufficient slope and condensate drainage to prevent water accumulation in process steam supply piping. Recommended slope is 1 for every 200 to 300 horizontal pipe run. For piping runs of more than 50 feet, consideration should be given to expansion joints in the steam piping to minimize piping stress on the boiler and process equipment as a result of thermal expansion of the steam piping. When the amount of condensate return is insufficient to maintain feed water tank or hotwell tank temperature, a pre-heater steam system may be installed if desired. A feed water pre-heat system in NOT required for the MIURA boiler. However, a pre-heat of the feed water reduce the amount of oxygen in the feed water and therefore the amount of oxygen scavenging chemicals required. For installations where a De-Aerating tank is installed, if expected condensate return is expected to exceed 50% of boiler capacity, a separate condensate surge tank may be required. Install a steam condensate drain trap on the main stream header to remove condensate prior to distribution to process steam lines. All low points in the steam piping should also have a condensate removal trap installed. This will minimize the chances of damage caused by water hammer or poor temperature control of the process due to water slugs in the steam system. Standard steam system practice is to install a steam trap every 75 feet of piping run. See Figure 8 for system diagram and Table 7 for outlet valve connections. Steam Outlet Steam Header Condensate Return LX Series Steam Trap Feed Water Tank Figure 8 Steam Line and Trap Arrangement 18

24 3.6 FEED WATER SYSTEM PIPING Table 8 Feed Water Pump Suction Strainer Size WATER INLET CONNECTION AND FEED WATER PUMP STRAINER SIZE LXL-50 LX/LXL-100 LX/LXL/150/200/300 3/4 NPT 1 NPT 1 1/4 NPT Vent Condensate Return Feed Water Tank LX Series Softener Chemical Pump Feed Water Pump MIURA BOILER Figure 9 Recommended Feed Water Piping Arrangement NOTE: Prior to installing pump, softener, and other equipment, review applicable instruction books For the recommended system, refer to Table 8 and Figure 9 for the following discussion. Zero PPM hardness and daily sampling are required at feed water tank. Use a test kit with a minimum sensitivity of one ppm. Do not connect the hard water line to condensate return line. Install softener in series. Dual units are recommended. Do not use a float-actuated make-up water control valve. Such a system may result in low flow rates through softener resulting in channeling of ion exchange medium. Use a make-up water control system that will only allow specified flow through the softener. The rule of thumb is ½ GPM minimum flow for each cubic foot of resin in the softener tank. Consult Chemical Treatment Company for specifics. Test cocks for individual softener and feed water tank water quality testing are recommended. NOTE: To properly size the water softener, raw water hardness and conductivity, make-up water volume, boiler operating hours and water iron content are important factors. For details and assistance please contact your nearest MIURA representative or Boiler Water Treatment Chemical Company. Collect condensate from process as feasible. Return condensate to feed water tank. Do not connect any piping that would allow hardness or product to enter feed water tank. Thermal insulation is recommended for all piping between feed water tank and the Boiler to conserve heat. 19

25 Install the feed water pump under or near the feed water tank. The suction pipe should be adequately sized and configured to minimize friction losses. MIURA requires at least six feet of water above the suction of the pump to prevent cavitation. Use a gate valve in the feed water pump suction line. Avoid high points in the pump suction piping that would allow air to collect and result in loss of pump priming. Run all drains and overflows to floor level or well with inspection capability. CAUTION: DO NOT ALLOW THE PUMP TO RUN DRY. DO NOT ALLOW THE PUMP TO VAPOR LOCK. SEVERE AND IMMEDIATE DAMAGE TO THE PUMP WILL RESULT. Chemical feed can be made to feed tank and or feed water line. Most MIURA Boilers are provided with a set of DRY contacts through terminal strip connections 30 and 34. These wires connect a Normally Open contact on the feed water pump magnetic contactor. MIURA recommends wiring the chemical injection pumps through this contact. This allows the chemical injection pumps to operate only when the feed pump is running. This type of operation allows the chemical company to adjust chemical usage directly to the boiler water usage. Due to the very small water content of the boiler any difference between chemical injection rate and steaming rate will result in erratic chemistry control. Operating the chemical pumps concurrently with the feed pump will provide a more consistent use of chemicals. Chemical Treatment procedures should be based on recommendations of reputable Boiler water chemical treatment Company. NONE of the MIURA Boiler Warranties include damage to the pressure vessel due to corrosion, sludge, or formation of scale. Dual pump feed water systems are available as an additional option. Insulation of the feed water piping is recommended between the condensate return tank and the boiler. Some jurisdictions require a pressure gage on the discharge of the pump. Follow all local regulations. 3.6 FEED WATER PUMP (NOT INCLUDED WITH BOILER UNLESS ORDERED FROM MIURA) CAUTION: The feed water pump is vital to satisfactory operation of your new MIURA Boiler. Review this section carefully for pump selection criteria if the customer has chosen to purchase a pump from other than MIURA. All pumps, regardless of the manufacturer, require a positive pressure on the pump suction to prevent cavitation damage to the pump. Any damage to the pump resulting from installation errors or cavitation is NOT covered by MIURA. NOTE: Ensure the height of the water level in the feed water tank is sufficient to prevent cavitation of the feed water pump under normal operating conditions. As an example, the LX-300 boiler using the GRUNDFOS model CR8-100U pump will require at least 6 feet of water height above the pump suction connection if the feed water temperature is at the boiling point. In general, MIURA Boiler recommends installing the feed water supply tank as high as possible in the boiler room to prevent any possibility of feed water pump damage due to cavitation. Specifically, MIURA Boiler requests that the water level in the pump supply tank be AT LEAST 6 Feet vertically ABOVE the pump suction flange. If necessary to achieve six-foot vertical height, the pump may be installed in a pit and piping arranged as necessary. NOTE: The MIURA Boiler is a unique design. Common pump sizing criteria do not apply. 20

26 Danger: Improper sizing of the feed water pump will severely impact the performance of the MIURA Boiler. Under-sizing of the pump, either by flow or by pressure will result in frequent Low Water Alarms and Boiler Lockouts. If this condition is allowed to continue, the Manufacturer s Warranty on the pressure vessel DOES NOT COVER any tube damage that may result. Review and FOLLOW the pump sizing criteria below and this condition will not occur. MIURA Boiler recommends that a pump be purchased with the boiler rather than using an existing pump. The reason for this is that MIURA Boilers run with intermittent feed water pump operation. MIURA Boilers start the feed pump on call for water and turn it off when call for water stops. This is due in part to the boiler having no fixed steam/water level to maintain and in part as a side effect of the pressure vessel design. Some boilers use a modulating feed water control system such as McDonnell Miller float valves and operate the pump continuously. This is done partly because of a fixed steam/water level and mostly to reduce thermal stresses on the boiler shell that result from the introduction of relatively cold water to the hot boiler. The MIURA Design Advantage eliminates the need for this type of system. MIURA simply turns the pump on and off as needed based on actual boiler steam demand. This allows the pump to always run at optimum efficiency and prevents pump-overheating problems. The MIURA Boiler is designed, tested, and CERTIFIED to operate this way. Experience has shown there is no advantage to operating a MIURA Boiler with a modulating feed water control system. Therefore, if a pump other than that provided by MIURA is used, the following selection criteria are provided: Size the pump to deliver Twice (2X) or preferable Three times (3X) the steady state evaporation rate of the boiler. This flow MUST be delivered to the boiler at a pressure AT LEAST 30-psi ABOVE the Boiler operating pressure. Also, ensure that the pump motor is able to handle frequent start/stop cycles without overheating the motor windings. For example, an LX-300 operating at 100% capacity for one hour will evaporate 10,350 pounds of water (at 0 psig) each hour. This is the steady state evaporation rate. Converting this evaporation rate to gallons per minute gives 21.6 gpm. As a result, MIURA recommends a pump capable of providing at least 43.2 gpm. If the boiler is operating at 150 psi, the pump should deliver between 43.2 and 64.8 gpm at 170psi. The GRUNDFOS CR8-100U, which is the pump recommended, will provide 54 gpm under these conditions. MIURA recommends a pump equivalent to the GRUNDFOS pumps listed below for each boiler model. MIURA BOILER MODEL Table 9 Feed Water Pump Recommendations GRUNDFOS PUMP MODEL MOTOR HORSE POWER PUMP CAPACITY DESIRED LXL-50/100 CR2-40U 1 hp 8/16 GPM LXL-150/200 CR4-40U 1.5 hp 23 GPM LX-50 CR2-100U 3 hp 8 GPM LX-100 CR2-120U 3 hp 6 GPM LX-150 CR4-120U 5 hp 30 GPM LX-200 CR4-120U 5 hp 26 GPM LX-300 CR8-100U 7.5 hp 46 GPM 21

27 These pumps are available through MIURA, and if purchased with the boiler, they may be provided with an optional mounting foundation as described below. MIURA recommends installing a feed water suction strainer of at least 20 mesh. Install a strainer one size larger than pump suction piping. Pump flange kits are included with the pump from MIURA if the pump option is purchased from MIURA. Also, install an isolation valve on the supply side of the strainer to allow cleaning the strainer without draining the feed water supply tank. The suction side isolation valve and feed water strainer are NOT provided by MIURA and must be installed in order to include the pump in the One-Year Parts Warranty. The One-Year Warranty applies to the pump ONLY if it is purchased through MIURA. Water is automatically fed to the boiler from the feed tank by traveling through a manual shut off valve, Y type strainer, pump, economizer (if equipped), then through two (2) check valves to the bottom header to the internal water distribution tube. Grundfos series C multi-stage centrifugal pumps installed in accordance with the manufacturer s instruction booklet will operate efficiently and provide years of service. The pumps are water lubricated and do not require any external lubrication or inspection. The motors will require periodic lubrication as noted in the maintenance schedule section. The pump is a close coupled, multistage high-pressure centrifugal type. Pump models vary with the horsepower of the boiler. CAUTION: UNDER NO CIRCUMSTANCES SHOULD THE PUMP BE OPERATED FOR ANY PRO- LONGED PERIOD OF TIME WITHOUT FLOW THROUGH THE PUMP. Dry operation of the pump can result in motor and pump damage due to overheating. A properly sized recirculation flow fitting may be obtained from Grundfos and installed to prevent this damage if the pump is run with an isolation valve shut. On a boiler equipped with an Economizer, the economizer safety relief will open to provide flow if the boiler feed isolation valve is shut during pump operation. Grundfos Installation and operating instructions specify the number of start/stop cycles for the pumps. MIURA Boiler operations exceed these values. The number of start/stop cycles in conjunction with the short running times in our application is approved by Grundfos and MIURA Boiler engineering sections and will not result in motor overheating problems. For detailed installation data, refer to GRUNDFOS installation and operating instructions that were supplied with the pump. The pump is in a separate crate from the boiler. Before starting the pump after initial installation or maintenance, please check the following: All piping connections are tight and the pipes are adequately supported. Any isolation valves on the suction of the pump are open. Pump is primed and vented through the vent fitting located at the top of the pump. Open main power disconnects. Remove the coupling guard and rotate the pump shaft to be certain it turns freely. Replace the coupling guard. Insure that all feed water isolation valves are open. Shut the main power disconnect to the boiler. While observing the top of the pump, cycle the boiler ON-OFF switch located on the front of the boiler. This will start the pump and allow verification of the direction of rotation. Direction of rotation is counterclockwise when viewed from the top. The pump will not run if the control switch is in the OFF position. 22

28 3.7.1 FEED WATER CONTROL VALVES In the application where the customer does not want to operate the feed pump in frequent start/stop cycles, other options are available. Again the feed system operates in a simple On-Off manner. If control valves are used, they MUST be quick acting (within 5 seconds). MIURA Boiler recommends Ball valves with pneumatic actuators (preferred) or electric actuators (acceptable). Note that pneumatic actuators operate in 1 second open to shut and the electric actuators are 5 seconds open to shut. Refer to sections 3.6 and 3.7 for detailed discussion and suggestions. Electric feed water control valves are available as an option on all boiler models. DANGER: ANY PROPORTIONAL VALVE ACTIVATOR OR CONTROL VALVE MUST BE FULLY OPENED OR CLOSED WITHIN 5 SECONDS, OR IT IS NOT ACCEPTABLE AND WILL CANCEL ALL WARRANTIES PIPING FLUSHING After installation is completed, flush all water piping before the boiler is fired. MIURA is not responsible for damage to stuck open check valves that result from debris in the piping. 3.8 SAFETY RELIEF VALVES INSTALLATION ITEM LX-50 LX-100 LX-150 LX-200 LX-300 Boiler Safety Valve Outlet Boiler Safety Valve Outlet LXL Economizer Safety Valve Outlet 1 1/4 2 1/ /2 x 2 2 1/2 4 x 2 2 1/2 4 x 2 2 1/2 x 2 NA 1 NPT Drip pans should be used for boiler safety valves. Miura does not supply drip pan elbows with the boiler. Water that collects in the elbow and valve body after the valve lifts, any rain water or valve leakage should be drained off and not allowed to stagnate. Failure to drain the water may result in valve corrosion or water hammer if the valve lifts. This arrangement is shown in Figure 10. The optional economizer is also equipped from the factory with a safety valve. The installation is illustrated in Figure 11. The economizer safety valve may not be required to be piped to the roof depending on local codes. Piping should be directed to a floor drain or other collection point as specified by the local codes concerning boiler wastewater. If a deaerator is used, the water discharged by this safety may be near the boiling point and could cause a potential for personnel injury. Arrange the piping accordingly. 23

29 To Roof Slip on to the Drip Pan Elbow Drip Pan Elbow Union Safety Relief Valve Vent Pipe Support Union/Flange 1 NPT Safety Relief Valve for Economizer Open Drain to Floor/Waste Drain Figure 10 Boiler Safety Valve Installation 3.9 BLOW DOWN PIPING Figure 11 Economizer Safety Relief Valve Installation MIURA BOILER MODEL Table 10 Blow Down Piping Sizes LVC BLOW OFF OUTLET BOTTOM BLOW OFF OUTLET AUTOMATIC BLOW DOWN OUTLET LX-50/100/150/200 1 NPT 1 NPT 3/8 NPT & LXL-50 LXL-100/150/200 1 NPT 1 NPT 3/8 NPT LX NPT 1 1/4 NPT 3/8 NPT X 2 DANGER: Be sure to install blow down piping separately from overflow and drainage piping. Piping shall be arranged to prevent any possibility of boiler water splashing and causing personnel injury. All piping subject to pressure from the boiler during blow down must be securely anchored to prevent piping vibration and shock during blow down of the boiler. Due to the large number of different piping arrangements possible, MIURA recommends a maximum pressure for manual bottom blow down of 30psi. Information on piping sizes is given in Table 10. Note that the Automatic Surface Blow Down Line operates at full boiler pressure and temperature and, therefore, must be piped to the blow down tank. Do not allow siphoning back into the boiler from wastewater drains. Standard equipment includes on (1) quick operation type globe valve for blow down isolation. Double blow down isolation valves may be installed at customer request and as required by local regulations (See Figure 13) 24

30 Install an additional check valve between the automatic blow down solenoid valve and the blow down separator. (See Figure 12.) Check valve is not included with boiler. Blow down separator after cooler for boiler water may be supplied by MIURA Boiler at customer request. Insure local regulations for disposal of boiler wastewater are followed. In an installation where multiple boilers share a common blow down separator, install a check valve in the piping between each automatic and manual blow down isolation valve and the blow down separator. See Figure 12 as an example. In a situation where all blow down water is collected in a sump, size the sump for at least five times the operational water content of the boiler. This will allow collecting the boiler water and the cooling water used by the blow down separator. The operational water content is provided in the general specification tables. Follow all local regulations. To Roof Cooling Water From other Boiler From Intermittent Automatic LX SERIES BOILER L.V.C. Blow Down Tank Drain Bottom Blow Down Figure 12 Blow Down Piping Arrangement Option Valves From Bottom Blow and L.V.C. MIURA Standard Quick Operating Valve To Blow Down Separator Figure 13 Double Blow Down Isolation Valve Options 25

31 3.10 FUEL SUPPLY ARRANGEMENTS Gas Piping FUEL TYPE: Natural & Propane Gas SUPFPLY PRESSURE: 3-5 PSIG required at boiler regulator inlet at full firing rate and when boiler combustion is stopped. Installation of a pressure gage to monitor gas supply pressure is recommended. If the boiler is operated with propane fuel, MIURA Boiler STRONGLY recommends use of a vaporizer. Collecting the propane gas from the top of the tank is possible but not recommended due to variations in vapor space pressure depending on ambient air temperature. Also, ensure the vaporizer is sized for full boiler capacity even if the normal load is less than the maximum capacity of the boiler. This recommendation is based on the boiler operating at full rated fuel flow during the start up period. Table 11 LX Gas Piping Sizes ITEM LX-50 LXL-50 LX-100 LXL-100 LX-150 LXL-150 LX-200 LXL-200 LX-300 Gas Inlet Main Regulator Vent Pilot Regulator Vent Pressure Switch Vent Automatic Vent Valve (IRI Option) 1 1/2 NPT 2 NPT 2 1/2 NPT 1 NPT 1/4 NPT 1/8 NPT (One or Two Switches, Depending on Model) 3/4 NPT 1 NPT Use an approved reducing valve to meet the required specifications if the supply gas pressure is above 5 PSIG. Use an approved booster pump if necessary to meet the required minimum pressure specifications of 3PSIG. 3PSIG minimum is required at the inlet to the Fisher 133L regulator supplied with the boiler to ensure an adequate volume of fuel is available to support combustion during firing rate changes. Specifically, a change from burner Off to Low Fire, which is approximately 40% of rated fuel usage, occurs over a 13 second period. The fuel usage then goes from 40% to 100% rated consumption when the boiler goes to high fire. This change occurs in less than one second. Fuel consumption then changes from 100% to zero in less than one second when the boiler turns off. The Utility Gas regulator must maintain at least 3 PSIG and not exceed 5 PSIG under these conditions, and is to be installed as far away from the boiler regulator as possible. The maximum pressure of 5 PSIG is determined by Underwriter s Laboratory approval of the MIURA Gas train. Install a dirt pocket on Main gas inlet piping immediately up stream of boiler. NOTE: Maintain stamped gas supply pressure during operation. This pressure must be at the regulator supplied with the LX-Series boiler gas piping. If necessary, use larger pipe for long piping runs. Failure to maintain required gas flow rate and pressure will result in frequent boiler misfires! All main gas train piping to the burner is included, (with the exception of individual regulator and pressure switch vents). Do not attempt to change any part of this gas train without first consulting the nearest authorized MIURA dealer. Do not use any gas piping with a diameter smaller than the gas inlet piping to the boiler. 26

32 Use one reducing station to the boiler room. Do not use a separate reducing valve to supply each boiler. This would result in pressure oscillations that could result in boiler flame failures or momentary over firing conditions. Consult pressure regulator application engineers for correct sizing and regulator model selection. See specification tables for fuel consumption. The copper gas line to the pilot regulator is lined with Aluminum and does not require replacement in jurisdictions that prohibit use of copper tubing on natural gas piping. Two pressure switches, HIGH and LOW gas pressure, may be required to be vented to atmosphere outside the boiler room in some jurisdictions. Contact your local insurance provider and the Gas Company for specific requirements. Some jurisdictions may require the pilot gas regulator to be vented. See Figure 14 for a typical vent line arrangement and Figure 15, Figure16, and Figure 17 for connection points. Note that some boiler models may have ANTUNES RLGP-G 5~30 switches on the gas train which do not require venting to atmosphere. Gas vent lines, when manifolded, shall be connected to a common vent line having a cross-sectional area not less than the area of the largest vent line plus 50% of the areas of all the additional vent lines. An automatic solenoid operated automatic vent valve located between the main gas blocking valves may be required for insurance purposes and is an additional cost option to meet IRI specifications. Insure IRI is specified on the purchase order if necessary. Follow all local regulations. LX-300 Gas Train and Vent Connections are shown here. The smaller LX/LXL- 50/100/150/200 contain the same components arranged inside the boier casing. This drawing provides details to allow vent manifold connection in the field if appropriate for the customer location. Pilot Gas Regulator. Do not allow vent pipe to be kinked. This will result in pilot fl ame failures. Vent Manifold. Direct to outside boiler room as required by local regulations. This manifold and associated tubing is not provided by MIURA. High Gas Pressure Switch if required High Fire Solenoid Customer Gas Piping Main Burner Gas Regulator Low Gas Pressure Switch if required IRI Option Automatic Vent Valve MIURA provided Gas Train Figure 14 Typical LX Series Gas Train and Vent Points 27

33 To exterior vent 1 NPT Union Fitting Use drip leg or rain cap on vent line. Do not allow vent line to be blocked or to fill with rain water. Boiler operation will be adversely affected. Main Gas Regulator Figure 20 Main Gas Pressure Regulator Vent Piping To exterior vent. Do not allow line to be krimped. Frequent pilot flame failures will result. 1/4 aluminum pipe Pilot Gas Regulator Figure 21 Pilot Gas Regulator Vent Line Connection To exterior vent Gas Pressure Switch 1/4 Aluminum Tube Figure 22 Gas or Air Pressure Switch Connection 28

34 3.11 ELECTRICAL INSTALLATION ELECTRICAL TABLE NOTE: MIURA recommends that an additional alarm and warning light be installed in control room if possible. MODEL VOLTAGE (V) ELECTRICAL CONSUMPTION (KVA) WIRE GAGE (AWG) DISCONNECT AMPERAGE (A) LXL #10x3c+#10(G) #14x3c+#14(G) 15 LXL #6x3c+#10(G) #10x3c+#10(G) 30 LXL-200 & LXL #6x3c+#8(G) #10x3c+#10(G) LX #10x3c+#10(G) #14x3c+#14(G) 15 LX #6x3c+#8(G) #10x3c+#10(G) 30 LX-200 & LX #6x3c+#8(G) #8x3c+#10(G) LX #2x3c+#6(G) #6x3c+#8(G) 60 Other voltages are available by special order. Optional equipment such as the MIURA remote communications system or the MIURA Multiple Installation (MI) system must be wired as specified in the individual instruction books. After installation of the feed water pump, the motor must be wired to the boiler power distribution box using customer provided cables. If the pump is located some distance from the boiler, an emergency stop/start or disconnect switch may be required near the motor. For details of wiring, see individual wiring diagrams. Comply with local building electrical codes. See figure 18 for power box location and Figure 19 for terminal connection. Note that the boiler is supplied with a motor controller for the boiler feed water pump. The optional feed water pump should be powered from the boiler. If the pumps and motor controller were supplied with the de-aerator or hotwell tank, use the feed water pump motor contactor as the remote on-off switch for the pump. If the pump must be located remotely from the boiler, replace this wiring with appropriate conduit as required by local electrical codes. The pump should be located as close as possible to the water source to minimize risk of cavitation. 29

35 Figure 18 LX Series Boiler Electrical Connection LX/LXL-50/100 Power Box R S T G Terminal Strip 33W1 33WL TR CB4 CB2 88F T1 T2 T3 X1 X3 X4 X5 Tr CB4 CB2 88F 88W C1 88W 49F LX/LXL-150/200, 300 Junction Box LX/LXL-50/100, Boiler Control Box Layout LX-300SG units (typical) Power Source LX and LXL models under 300 BHP (typical) Power Box Feed Water Pump Feed Water Pump Figure 19 LX Series Terminal Strip Connections 30

36 All LX series boilers include as optional equipment a GRUNDFOS feed water pump. This pump is shipped in a separate crate form the boiler. All boilers include a motor controller and electrical overload pre-wired into the power box for the pump. If the pump is located at a distance from the boiler, use a connection box and comply with local wiring codes to run the wiring to the pump. Some installations, for example a pump located in a different room from the boiler, may require a local disconnect/emergency stop switch at the pump. In this situation, it is not necessary to provide an interlock between the pump and boiler to ensure that the local disconnect is shut. However, it is preferred to install a tank low water level cutout in the pump control circuit. This prevents the pump from running when the water has a low level to prevent dry running the pump. The boiler starts and stops the pump automatically as necessary to maintain the required water volume. If the pump does not start, the boiler safety circuits will shut down the boiler on low water volume and prevent damage. If desired, an indicating lamp may be installed near the boiler control panel to indicate that the local disconnect/emergency stop switch at the remote feed pump location is shut Panel Layout Display Window. Current Status and Information. CAUTION/WARNING Information Button (Push to read message before resetting Alarm) Menu/Setting Scroll Buttons Data Change/Set Button Alarm Reset Boiler Operation Switch/Circuit Breaker (to left of panel) Boiler Steam Pressure Boiler Combustion START/STOP Figure 20 Boiler Control Panel with MIURA XJ1 Intelligent Steam Manager 31