Megafire Manual

MEGAFIRE ® Gas/Oil Burners

Page 2603

Performance and Selection Data Packaged Internal Construction

Basic MEGAFIRE ® Burners include an air control shutter, fuel nozzles, mixing cone, pilot and provision for UV scanner in one compact package. Combustion air is provided by either an integral centaxial (IB) in-line blower or via an (EB) external blower. A differential air pressure (see page 2604) must be provided for cataloged capacities. IB version is used for negative to balanced combustion chamber pressures. For back pressure or over-fire applications, use EB version and external blower.

“EB” External Blower version Combustion Air Inlet 1/2" NPT Oil Inlet

1/4" NPT Lifting Lug Comb. Air Test Conn.

5/8" (.625) dia. Mounting Holes

Observation Port Main Gas Inlet

3/4" NPT Atomizing Media Inlet

Access Plate

Pilot Inlet Plate

Stainless Steel Discharge Sleeve

Alternate Air Inlet Positions

“IB” In-Line Blower version Lifting Lug

Lifting Lug

1/2" NPT Oil Inlet

End View Into Face of Burner Stainless Steel Castable Refractory

Combustion Air Inlet Same Mtg. as Discharge Sleeve

Main Gas Inlet

Access Plate 3/4" NPT Atomizing Media Inlet

1/4" NPT Comb. Air Test Conn.

Flame discharge is through a stainless steel combustion sleeve (1100°F (593°C) maximum chamber temperature) or a refractory block (1600°F (870°C) (870°C) maximum chamber chamb er temperature) temperatur e) complete with seal and support housing. Piloting is by an independent, spark-ignited, raw gas pilot. Burner mounting uses an integral mounting flange, but additional support MUST be provided. Combustion air control is accomplished with a built-in air shutter, connected via control cable, cabl e, to a fuel control valve (Maxon MICRO-RATIO ® Valve). The “XC” version utilizing external control of air and fuel is also available.

8/97


Optional Block/Seal & Support Assembly

Pilot Inlet Plate

Suitable fuels include natural gas, propane, or #2 oil at 50 SSU viscosity or less. Atomizing steam or air is required at 60 PSIG for oil firing. Simultaneous gas and oil firing is possible, up to the total rated capacity of a MEGAFIRE ® Burner. A complete system utilizing MEGAFIRE ® Burners also includes gas, oil, and atomizing media pipe trains and a control panel.


Page 2604

Performance and Selection Data MEGAFIRE® Burners Maximum Capacity (Btu / hr) Turndown Ratios Fuel Pressures required at burner inlet Pilot Gas Inlet Pressure Combustion Air

15M

30M

45M

15,000,000

30,000,000

45,000,000

Natural Gas or Propane

15 to 1

15 to 1

1 5 to 1

#2 Oil

10 to 1

10 to 1

1 0 to 1

Natural Gas

22" wc

26" wc

38" wc

#2 Oil

70 psig

70 psig

60 psig

Propane

8.8" wc

10.4" wc

15.2" wc

Natural Gas, Propane, or #2 Oil

(range) 100k – 300 kBtu / hr

0.5 – 5" wc

(SCFM) [1]

2750

6000

9500

2.9" wc

2.9" wc

3.3" wc

@ EB transition inlet

4.4" wc

5.1" wc

9.9" wc

SCFM Air @ 60 psig

20

37

72

lbs / hr Steam @ 60 psig

58

109

207

Direct Drive 230 / 460 / 3 / 60

3

5

10

Length (in feet)

9

15

21

3.5

4

4

40 lbs.

50 lbs.

60 lbs.

87

88

89

Combustion Air Differential Pressure @ test connection upstream of air shutter (IB and EB versions) Total Combustion Air Pressure Required (EB version only) Atomizing Media (for oil firing option) IB Blower Horsepower Approximate Flame Dimension

Diameter (in feet)

Force (pounds) required to open air shutter with combustion air on (refer to Bulletin 7000-Control Valves for torque required to operate control valve set Noise Levels (IB burner only) [2]

dBA

[1]The SCFM shown is based on the IB fan curves at the known differential through the burner with the air shutter fully open. For both IB and EB versions, combustion air must be provided at differential pressure (burner over combustion chamber) for cataloged burner capacities. [2] Silencers are available to reduce noise levels to below 80 dBA

To select your MEGAFIRE ® Burner, specify: 1. 2.

Quantity Size – 15M = 15,000,000 Btu/hr (maximum) – 30M = 30,000,000 Btu/hr (maximum) – 45M = 45,000,000 Btu/hr (maximum) 3. Fuel and atomizing media – Gas: If other than natural or propane gas, provide: Specific fuel and/or analysis; Specific gravity, calorific value, and available pressure – Oil: If other than #2 oil, provide: Specific fluid and/or analysis; Specific gravity, calorific value, viscosity, temperature and available pressure – Atomizing media: Air – Volume and pressure Steam – Volume, temperature and pressure 4. Combustion chamber static pressure condition 5. In-Line (IB) or External (EB) Blower version – For “IB” version:

6. 7.

8.

9.

– Electrical specification for motor – For “EB” version: – Electrical specification for motor – Blower discharge position – Blower volume and pressure – For “XC” version (EB only): – Verify that control of combustion air/fuel gas and/or fuel oil is specified Discharge options – #310 stainless steel discharge sleeve, or – Refractory block with seal and support housing Control valve options – Standard cam version – Packaged control valve arrangement: Right-hand assembly, or Left-hand assembly Assembly arrangement options – Gas inlet position (Note: pilot/scanner always opposite side from gas inlet) – Air inlet position Accessory options – Connecting base & linkage for specific automatic control motor – Atomizing air train – Atomizing steam train – Light oil train – Gas train – Shut-off valve(s) – Control panel


Page 2605

Performance and Selection Data Performance Curves 15M MEGAFIRE ® – Natural Gas 25

16000 14000

. 20 c . w s e h c n i , 15 e r u s s e r P s 10 a G l a r u t a N 5

12000 10000

Flow

8000

Pressure

6000 4000

r u o h / t e e f c i b u c , w o l F s a G l a r u t a N

2000 0

0 Min 0

1

2

3

4

5

6

7

8

9

Max 11

10

Fuel Gas Control Valve Position

NOTE: The fuel gas pressures shown are measured at the fuel gas test connection downstream of the control valve at the gas manifold inlet flange. NOTE: The fuel gas control valve, represented on the x-axis of the above graph is a Maxon 3 inch “-M” style control valve. This valve is supplied in the 15M, 30M and 45M MEGAFIRE ® pre-assembled control valve/pipe train package.

15M MEGAFIRE ® – #2 Fuel Oil 70

120

60

100

g50 i s p , e r 40 u s s e r P l i 30 O l e u F20

80

Pressure

60

40

Flow

20

10 0 0 Min

r u o h / s n o l l a g , w o l F l i O l e u F

0 1

2

3

4

5

6

7

8

9

10

11 Max

Fuel Oil Control Valve Position

NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a Maxon 1/2" – O – 100 SYNCHRO oil valve. This valve is supplied in the 15M MEGAFIRE ® pre-assembled control valve/pipe train package.

8/97


Page 2606

Performance and Selection Data Performance Curves 30M MEGAFIRE ® – Natural Gas 25

30000

25000

. 20 c . w s e h c n i , 15 e r u s s e r P s 10 a G l a r u t a N 5

r u o h / t 20000 e e f c i b u c 15000 , w o l F s a 10000 G l a u t a N 5000

Flow

Pressure

0 Min Min 0

0 1

2

3

4

5

6

7

8

9

10

Max 11 Max

Fuel Gas Valve Position

NOTE: The fuel gas pressures shown are measured at the fuel gas test connection downstream of the control valve at the gas manifold inlet flange. NOTE: The fuel gas control valve, represented on the x-axis of the above graphs is a Maxon 3 inch “-M” style control valve. This valve is supplied in the 15M, 30M and 45M MEGAFIRE ® pre-assembled control valve/pipe train package.

30M MEGAFIRE ® – #2 Fuel Oil 60

250

50

200

g i s 40 p , e r u s s 30 e r P l i O l e 20 u F

r u o h / s 150 n o l l a g , w o l 100 F l i O l e u F 50

Pressure

Flow

10

0

Min 0 Min

0 1

2

3

4

5

6

7

8

9

10

Max 11

Fuel Oil Control Valve Position

NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a M axon 3/4" – O – 200 SYNCHRO oil valve. This valve is supplied in the 30M MEGAFIRE ® pre-assembled control valve/pipe train package.


Page 2607

Performance and Selection Data Performance Curves 45M MEGAFIRE ® – Gas 30

45000 40000

25

. c . w s e h20 c n i , e r u s 15 s e r P s a G10 l a r u t a N 5

r u 35000 o h / t 30000 e e f c i b 25000 u c , w o 20000 l F s a 15000 g l a r u t 10000 a N

Flow

Pressure

5000 0 Min 0 Min

0 1

2

3

4

5

6

7

8

9

10

11 Max Max

Fuel Gas Valve Position

NOTE: The fuel gas pressures shown are measured at the fuel gas test connection downstream of the control valve at the gas manifold inlet flange. NOTE: The fuel gas control valve, represented on the x-axis of the above graphs is a Maxon 3 inch “-M” style control valve. This valve is supplied in the 15M, 30M and 45M MEGAFIRE ® pre-assembled control valve/pipe train package.

45M MEGAFIRE ® – Oil 60

350

300

50

r

250 u o

g i s 40 p , e r u s s 30 e r P l i O l e u20 F

200

Flow

150

Pressure

100

10

0 Min 0

h / s n o l l a g , w o l F l i O l e u F

50

1

2

3

4

5

6

7

8

9

10

0 Max Max 11

Fuel Oil Valve Position

NOTE: The fuel oil control valve, represented on the x-axis of the above graph is a Maxon 1" – O – 400 SYNCHRO oil valve. This valve is supplied in the 45M MEGAFIRE ® pre-assembled control valve/pipe train package.

8/97


Page 2608

Dimensions 15M EB MEGAFIRE ® Combination Burners – Right Hand Arrangement 48.44 36.63 30.0 1/4" NPT 16.5 Comb. Air Test 1/2" NPT Conn. Oil Inlet

Combustion Air Inlet

7.13

Lifting Lug


28.69 19.44

9.88

27.656 dia. 29.656 dia.

15.0 21.03 dia.

19.28 dia.

Observation Port

16.76 Main Gas 2.0 Inlet


Access Plate

Pilot Inlet Plate


22˚ 22˚


15M EB MEGAFIRE ® Combination Burners – Left Hand Arrangement 48.44 36.63


30.0 Lifting Lug


16.5

9.88

19.44


Access Plate

28.69

7.0

15.0

27.656 dia. 29.656 dia.

21.03 dia.

19.28 dia.

Observation Port

16.76


22˚

Main Gas Inlet


22˚

Gas Pressure Test Connection

17.0 dia.

2.0

1/2" NPT Oil Inlet


Pilot Inlet Plate

22

15˚ 15˚

19.0 dia. 12.0 dia. outside

9/16" (.562) dia. 12 holes


4" ANSI raised face 150# slip-on welding flange w/2.688 lg. 4" NPT Sch. 40 pipe Bolt holes to straddle centerline

Main Gas Inlet


Page 2609

Dimensions 15M IB MEGAFIRE ® Combination Burners – Right Hand Arrangement 56.94 36.63

16.5

Lifting Lug

1/2" NPT Oil Inlet


28.69

30.0

19.44

Lifting Lug 27.656 dia.

9.88


29.656 dia.

16.76

24.03 dia.

19.28 dia. 22˚

Main Gas Inlet Access Plate

2.0

1/4" NPT Comb. Air 3/4" NPT Test Atomizing Conn. Media Inlet

22˚


Pilot Inlet Plate

15M IB MEGAFIRE ® Combination Burners – Left Hand Arrangement 56.94

9.88


36.63 30.0 Access 16.5 Plate 1/4" NPT Lifting Comb. Air Lug Test Conn.

Lifting Lug

28.69


19.44

27.656 dia.

19.28 dia.

29.656 dia.

24.03 dia.

16.76

Stainless Steel Discharge Sleeve 22˚

22˚

Pilot Inlet Plate Gas Pressure Test Connection

Main Gas Inlet 1/2" NPT Oil Inlet

22˚


Main Gas Inlet

8/97


2.0


Page 2610

Dimensions 30M EB MEGAFIRE ® Combination Burners – Right Hand Arrangement 58.94


36.63 30.0 16.5 3/4" NPT Oil Inlet

10.9

35.5

Lifting Lug


26.25

15.5

42.31 dia. 19.0 33.63 dia.

27.06 dia.

Observation Port

23.08

Main Gas Inlet


Access Plate

2.0



Pilot Inlet Plate

40.31 dia.

22˚


22˚

30M EB MEGAFIRE ® Combination Burners – Left Hand Arrangement 58.94 36.63 30.0 16.5

35.5



26.25

15.5

Lifting Lug


10.9

42.31 dia.

19.0

27.06 dia.

33.63 dia.

23.08

Stainless Steel Discharge Sleeve Alternate Air Inlet Positions

Pilot Inlet Plate 22 ˚

22˚

Gas Pressure Test Connection

22˚

3/4" NPT Oil Inlet

Access Plate

Main Gas Inlet

2.0


21.25 dia.

11˚ 11˚


Main Gas Inlet

23.5 dia. 9/16" (.562) drill thru 16 holes

16.0 dia. outside



Page 2611

Dimensions 30M IB MEGAFIRE ® Combination Burners – Right Hand Arrangement 61.94 36.63 30.0 16.5 3/4" NPT Oil Inlet


35.5

Lifting Lug


26.25

15.5

42.21 dia.

36.63 dia.

27.06 dia.

23.08

Main Gas Inlet 1/4" NPT Comb. Air Test Conn.

2.0


Access Plate

40.31 dia.

Pilot Inlet Plate

22˚


22˚

30M IB MEGAFIRE ® Combination Burners – Left Hand Arrangement 61.94 36.63 30.0 35.5


26.25

15.5

16.5 1/4" NPT Comb. Air Test Conn.

Lifting Lug

Lifting Lug


42.31 dia.

27.06 dia.

36.63 dia.

23.08 40.31

Stainless Steel Discharge Sleeve 22˚

22˚

Pilot Inlet Plate Gas Pressure Test Connection


3/4" NPT Oil Inlet

22˚


Main Gas Inlet

8/97

Access Plate

Main Gas Inlet 2.0


Page 2612

Dimensions 45M EB MEGAFIRE ® Combination Burners – Right Hand Arrangement 60.94 36.63

Combustion Air Inlet 16.5

3.0 Access Plate Lifting Lug

1" NPT Oil Inlet

12.9

37.49 5/8" (.625) dia. Mounting Holes

28.25

15.5

46.78 dia.

21.48

31.43 dia.

37.59 dia.

Observation Port

23.38

44.78 dia.


Main Gas Inlet

22˚


22˚

Pilot Inlet Plate

2.0



45M EB MEGAFIRE ® Combination Burners – Left Hand Arrangement 60.94 36.63


30.0 Access Plate Lifting Lug

37.49 5/8" (.625) dia. Mounting Holes

28.25

15.5

16.5 1/4" NPT Comb. Air Test Conn.

12.9

46.78 dia.

21.48

31.3 dia.

37.59 dia. Observation Port

25.38

44.78 dia. Alternate Air Inlet Positions

22˚

22˚


Main Gas Inlet Pilot Inlet Plate Gas Pressure Test Connection

2.0 3/4" NPT Atomizing Media Inlet

25.0 dia.

22˚ 9˚ 9˚

27.5 dia. 9/16" (.562) drill thru 20 holes

20.0 dia.



Main Gas Inlet


Page 2613

Dimensions 45M IB MEGAFIRE ® Combination Burners – Right Hand Arrangement 65.94 36.63 30.0 Lifting Lug

16.5 1" NPT OIl Inlet


37.49

Lifting Lug

28.25


15.5

46.78 dia.

31.43 dia.

41.59 dia.

25.38

Main Gas Inlet Access Plate

2.0

44.78 dia.

Stainless Steel Discharge Sleeve Pilot Inlet Plate


22˚

22˚


45M IB MEGAFIRE ® Combination Burners – Left Hand Arrangement 65.94 36.63 30.0

37.49


Lifting Lug

28.25

1" NPT 1/4" NPT Oil Inlet

15.5

Lifting Lug

Comb. Air Test Conn.


46.78 dia.

41.59 dia.

31.3 dia.

25.38

44.78 dia. 22˚


22˚ Gas Pressure Test Connection

Main Gas Inlet Pilot Inlet Plate

Access Plate

2.0 3/4" NPT Atomizing Media Inlet

22˚

4" ANSI raised face 150# slip-on welding flange w/2.688 lg. 4" NPT Sch. 40 pipe Bold holes to straddle centerline

Main Gas Inlet

8/97


Page 2614

Dimensions Oil Gun Assembly

Name

Combustion Air Test Connection

Lifting lugs to be in upright (or 12 o'clock) position regardless of air, oil or gas inlet rotation

B 5 5 2 9 3

T S E T

R I A N O I T S U B M O C

FLAME DETECTOR

Blower Lifting Lug

PILOT SPARK IGN.

See pilot detail below

Main Gas

ATOMIZING MEDIA

Mounting feet to be in down (6 o' clock) position regardless of air, oil or gas inlet rotation

Atomizing Air/Steam

OIL

Oil

MEGAFIRE ® Raw Gas Pilot No Gaps

Note: Oil gun assembly must seat solidly against mixing cone

Sight Port

Pilot Gas Connection

UV Scanner Connection Spark Ignitor

Suggested Block Mounting for Seal & Support Blocks Metal Wall

Refractory Cast or Block Fiber Blanket Wrapping Block 1" minimum

Burner Block with Stainless Support Sleeve

Maximum chamber temperature ratings for discharge options: SS discharge sleeve – 1100°F (593°C) Refractory block discharge – 1600°F (870°C)


Page 2615

Dimensions Refractory Block/Seal & Support Assembly 15M MEGAFIRE ® Burner 5/8" (.625) 16 holes

27.656 dia.

25.0

5.875 9.875

29.656 dia.

30M MEGAFIRE ® Burner

34.0

42.312 dia.

40.312 dia. 5/8" (.625) 16 holes

8/97

12.0 16.0


Page 2616

Dimensions Refractory Block/Seal & Support Assembly 45M MEGAFIRE ® Burner 5/8" (.625) holes 16 required

38.5

46.781 dia.

44.781 dia.

11.5 15.5


Page 2617

MEGAFIRE ® Burner Accessories (Dimensions in Inches)

#2 Light Oil Pipe Train

6

7

7 8

4 1 Inlet

5 1

3

¡

Flow

¡

2 6 7

Assembly includes: 1 3/4" ball valves 2 1" filter 3 3/4" oil pressure regulator 4 1/4" needle valve 5 Oil pressure gauge (0-160 PSIG)

8

Low pressure switch (5-150 PSIG) 3/4" Series 8730 shut-off valves (ordered separately; assembled into pipe train as shown) High pressure switch (5-150 PSIG)

Atomizing Air Pipe Train 4

5 3

1 Inlet

¡

Flow

2

Assembly includes: 1 3/4" ball valves 2 3/4" air filter 3 3/4" air regulator with (0-160 PSIG) gauge 4 Low pressure switch (5-150 PSIG) 5 3/4" solenoid valve

8/97

1 ¡


Page 2618

MEGAFIRE ® Burner Accessories (Dimensions in Inches)

Atomizing Steam Pipe Trains (maximum temperature 300°F) Note: Field site insulation will be required.

5 3

8

6

4

7 1

1 2 Inlet

¡

Flow

¡

Assembly includes: 1 1" ball valves 2 1" strainer 3 Thermometer (30-300°F) 4 1" pressure regulator 5 Low pressure switch (50-150 PSIG) 6 1" solenoid valve 7 1/4" needle valve 8 Steam pressure gauge (0-100 PSIG)

Pipe Train #2 Light Oil Atomizing Steam Atomizing Air

Size

Length

Height

Depth

Minimum Inlet Pressure

3 / 4"

76"

23"

13"

75 PSIG

1"

56"

22"

8"

100 PSIG

3 / 8"

38"

22"

5"

75 PSIG

Maximum Inlet Pressure 150 PSIG

Megafire Manual

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