POWER March 2014 - 25

pressure and SRV settings, as well as other
relevant ASME code-dictated work.
Wall-Mount Burner Conversion
Considerations
In a wall-mount arrangement, the burner or
burners are mounted within either the front
wall, side wall, or rear wall (Figure 1). Each
potential burner location must be evaluated
for a number of concerns:
■ What is the distance to the opposing
wall, thus what is the distance the
flame can occupy without impinging
on the opposite wall? This will help in
determining the number of burners and
burner design required to deliver the required
heat input while avoiding flame
impingement.
■ Are water wall tubes currently in the
way of where the burners should be
mounted? If so, new bent tube panels
would need to be installed to accommodate
the throats of the burners, thus
requiring engineering design of the
panels, shop fabrication, and field labor
to cut out the existing straight tubes
and weld in the new sections.
■ What is the front header clearance? If
the burners are to be mounted in the
front wall, then the front header height
becomes an important element. Depending
upon the header height from the
floor, the burners and windboxes may
have to be located between this header
and the operating floor. Low clearance
may also dictate multiple smaller burners,
extensive relocation costs for the
header, or modifications to the floor.
Most wall-mounted burner flames will
initially fire horizontally, then bend upward
based upon furnace draft. Once
burner location and the quantity of burners
are established, an analysis of the
flame geometry is required to ensure that
the " angled " heat can transfer effectively
within the radiant zone without flame
impingement. When utilizing this type of
conversion it is common to have multiple
burners that fire in unison to maintain an
even heat transfer.
Typically, a single FD fan is utilized to
produce combustion air regardless of the
number of burners used. This fan produces
the required static pressure and volume
of air into a common windbox that has
internal air distribution to regulate sufficient
and constant air to the burners. In
a multiple burner arrangement, the combination
of the combustion air, fuel train,
controls, and the burners' air/fuel mixing
design provides for simultaneous firing.
A successful implementation of the horizontal-mounted
burner arrangement is operating
at a manufacturing facility in Flint,
Mich. Under a design-build contract, Lipten
Co. converted three 45,000 lb/hr fielderected
coal-fired boilers to front wall-
fired, low-NOX
natural gas firing with new
FD fans, VFDs, fuel trains, controls, extensive
tube repairs, and tube modifications.
Because of the lack of a floor level
below the boilers, vertical firing was not
feasible. The project was designed so that
only a single burner was needed per boiler,
reducing controls complexity as compared
with a multiple burner boiler arrangement.
Use of a single burner was possible because
of the liberal furnace dimensions.
Vertical Burner Mounting
Considerations
A vertical-firing arrangement places a burnSpecializing
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POWER March 2014

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