Table of Contents
1.0 INTRODUCTION ......................................................................................................................................................................................................................................5
2.0 PRINCIPAL PARTS..................................................................................................................................................................................................................................6
2.1 DIMENSIONAL DRAWINGS ............................................................................................................................................................................................................9
3.0 TECHNICAL DATA.................................................................................................................................................................................................................................11
4.0 GENERAL REQUIREMENTS ................................................................................................................................................................................................................12
4.1 RELATED DOCUMENTS ...............................................................................................................................................................................................................12
5.0 WATER QUALITY ..................................................................................................................................................................................................................................13
5.1 ELECTRICAL ANODE PROTECTION SYSTEM...........................................................................................................................................................................13
6.0 LOCATION..............................................................................................................................................................................................................................................13
6.1 PLANT ROOM REQUIREMENTS ..................................................................................................................................................................................................13
6.2 GENERAL REQUIREMENTS.........................................................................................................................................................................................................13
6.3 CLEARANCES................................................................................................................................................................................................................................14
7.0 GAS SUPPLY .........................................................................................................................................................................................................................................14
7.1 SERVICE PIPES.............................................................................................................................................................................................................................14
7.2 METERS..........................................................................................................................................................................................................................................14
7.3 GAS SUPPLY PIPES......................................................................................................................................................................................................................14
7.4 BOOSTED SUPPLIES ....................................................................................................................................................................................................................14
7.5 PLANT-ROOM CONTROL VALVE ................................................................................................................................................................................................14
7.6 EQUIPMENT GAS SYSTEM LEAK CHECK..................................................................................................................................................................................14
8.0 FLUE HOOD ASSEMBLY LBF151 - LBF401 ........................................................................................................................................................................................15
8.1 UNPACKING THE FLUE HOOD ....................................................................................................................................................................................................15
8.2 FLUE HOOD INSTALLATION ........................................................................................................................................................................................................15
9.0 FLUE SYSTEM.......................................................................................................................................................................................................................................21
9.1 FLUE SYSTEM GENERAL REQUIREMENTS ..............................................................................................................................................................................21
9.2 APPROVED FLUE SYSTEM..........................................................................................................................................................................................................21
9.3 CONCENTRIC FLUE SYSTEM......................................................................................................................................................................................................22
9.3.1 HORIZONTAL CONCENTRIC FLUE FITTING DETAILS LBF81/121...................................................................................................................................22
9.3.2 VERTICAL CONCENTRIC FLUE FITTING DETAILS LBF81/121 ........................................................................................................................................23
9.3.3 HORIZONTAL CONCENTRIC FLUE FITTING DETAILS LBF151 –401..............................................................................................................................24
9.3.4 VERTICAL CONCENTRIC FLUE FITTING DETAILS LBF151 –401 ...................................................................................................................................25
9.4 TWIN PIPE FLUE SYTEM ..............................................................................................................................................................................................................26
9.4.1 HORIZONTAL TWIN PIPE FLUE FITTING DETAILS LBF81/121 ........................................................................................................................................26
9.4.2 VERTICAL TWIN PIPE FLUE FITTING DETAILS LBF81/121 ..............................................................................................................................................27
9.4.3 HORIZONTAL TWIN PIPE FLUE FITTING DETAILS LBF151 –401 ...................................................................................................................................28
9.4.4 VERTICAL TWIN PIPE FLUE FITTING DETAILS LBF151 –401 .........................................................................................................................................29
9.5 MAXIMUM FLUE LENGTH - CONCENTRIC.................................................................................................................................................................................30
9.6 MAXIMUM FLUE LENGTH –TWIN-PIPE......................................................................................................................................................................................30
9.6.1 AIR RESTRICTION PLATE ....................................................................................................................................................................................................30
9.7 FLUE DISCHARGE.........................................................................................................................................................................................................................31
9.8 FLUE HOOD POSITION.................................................................................................................................................................................................................31
9.9 FLUE TERMINAL GUARDING .......................................................................................................................................................................................................31
10.0 AIR SUPPLY...........................................................................................................................................................................................................................................31
10.1 COMBUSTION VENTILATION.......................................................................................................................................................................................................31
10.2 COOLING VENTILATION...............................................................................................................................................................................................................31
11.0 WATER CONNECTIONS .......................................................................................................................................................................................................................32
11.1 GENERAL .......................................................................................................................................................................................................................................32
11.1.1 SYSTEM DE-STRATIFICATION.....................................................................................................................................................................................32
11.2 OPEN VENTED SYSTEM ARRANGEMENT.................................................................................................................................................................................32
11.3 UNVENTED SYSTEM ARRANGEMENT .......................................................................................................................................................................................32
11.3.1 EXPANSION VESSEL SIZING .......................................................................................................................................................................................35
12.0 ELECTRICAL SUPPLY ..........................................................................................................................................................................................................................35
12.1 ELECTRICAL CONNECTION ........................................................................................................................................................................................................35
12.2 EXTERNAL CONTROLS ................................................................................................................................................................................................................36
12.3 ARC WELDING PRECAUTIONS ...................................................................................................................................................................................................36
12.4 ANCILLARY EQUIPMENT..............................................................................................................................................................................................................36
12.5 WIRING DIAGRAMS.......................................................................................................................................................................................................................37
13.0 COMMISSIONING AND TESTING ........................................................................................................................................................................................................39
13.1 ELECTRICAL INSTALLATION.......................................................................................................................................................................................................39
13.2 GAS INSTALLATION......................................................................................................................................................................................................................39
13.3 WATER CONNECTIONS ...............................................................................................................................................................................................................39
13.4 COMMISSIONING THE EQUIPMENT ...........................................................................................................................................................................................39
13.4.1 GENERAL CHECKS PRIOR TO LIGHTING ..................................................................................................................................................................39
13.4.2 EQUIPMENT CHECKS PRIOR TO LIGHTING ..............................................................................................................................................................39
13.4.3 CONTROL PANEL ..........................................................................................................................................................................................................40
13.4.4 PROCEDURE FOR INITIAL LIGHTING .........................................................................................................................................................................40
13.4.5 GAS PRESSURE ADJUSTMENT...................................................................................................................................................................................41
13.5 TEMPERATURE ADJUSTMENT PROCEDURE...........................................................................................................................................................................42
14.0 LPG FUEL...............................................................................................................................................................................................................................................42
14.1 RELATED DOCUMENTS ...............................................................................................................................................................................................................42
14.2 GAS PRESSURE GOVERNOR .....................................................................................................................................................................................................42
14.3 CONVERSION TO LPG..................................................................................................................................................................................................................43
14.3.1 LBF81 –121 ....................................................................................................................................................................................................................43
14.3.2 LBF151 –401 ..................................................................................................................................................................................................................44
14.4 LPG COMMISSIONING AND TESTING ........................................................................................................................................................................................44
15.0 MAINTENANCE......................................................................................................................................................................................................................................45
15.1 GENERAL .......................................................................................................................................................................................................................................45
15.2 MAINTENANCE SCHEDULE .........................................................................................................................................................................................................45
15.3 DRAINING WATER HEATER SYSTEM ........................................................................................................................................................................................45
15.4 REMOVING SCALE AND SEDIMENT ...........................................................................................................................................................................................46
15.5 SACRIFICIAL MAGNESIUM ANODES ..........................................................................................................................................................................................46
15.5.1 ANODE REMOVAL LBF81/121 ......................................................................................................................................................................................46
15.5.2 ANODE REMOVAL LBF151/171 ....................................................................................................................................................................................47
15.5.3 ANODE REMOVAL LBF221 –401 .................................................................................................................................................................................47
15.6 REFILLING THE WATER HEATER ...............................................................................................................................................................................................48
15.7 BURNER REMOVAL AND CLEANING..........................................................................................................................................................................................48
15.7.1 LBF81 & LBF121 .............................................................................................................................................................................................................48
15.7.2 LBF151 –LBF401............................................................................................................................................................................................................48
15.8 OTHER CHECKS............................................................................................................................................................................................................................49
15.8.1 RELIEF VALVE................................................................................................................................................................................................................49
15.9 FLUE SYSTEM ...............................................................................................................................................................................................................................49
15.9.1 CORREX ELECTRICAL ANODE PROTECTION SYSTEM...........................................................................................................................................49
16.0 USER INSTRUCTIONS..........................................................................................................................................................................................................................49
17.0 WARRANTY ...........................................................................................................................................................................................................................................49