Benchmark with Edge [I]: Operation-Maintenance Manual
SECTION 8
– MAINTENANCE
OMM-0145_A99
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138
of
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Rear Refractory Replacement Instructions
15. The combustion chamber can now be viewed and inspected with a full view of the Burner
assembly and rear tubesheet. A borescope can be used to inspect the front tubesheet as
well as under the expansion joints.
16. Following inspection, reinstall the components in the reverse order in which they were
removed.
IMPORTANT!
If the rear refractory (P/N
83027
) was damaged during removal, it should be replaced with a
new part. If rear refractory replacement is required, a 2-hour burn-in period at a 30% fire rate
must be performed to drive off organic binders. These organic binders are not hazardous
materials; however, they may emit an odor similar to burning wood.
17. Tighten the bolts on the rear plate using an alternating pattern to ensure a uniform seal.
Torque bolts to approximately 20 ft-lbs.
18. To avoid exhaust leaks, ensure that a uniform seal is established when reconnecting the flue
system to the boiler.
Figure 8-10: Partial Rear View
– Rear Plate and Refractory Removed
WARNING!
The heat exchanger insulation utilizes ceramic fiber material. Wear a fitted NIOSH-approved
particulate respirator (3m n95 or equiv.) When servicing the heat exchanger and burner
assemblies. At high temperatures, ceramic fibers can be converted to crystalline silica fibers
which have been identified as carcinogenic when inhaled.
8.10.2
Front Refractory Replacement
As previously mentioned, it is much easier to remove the rear refractory to inspect the combustion
chamber of the unit.
However, if the front refractory must be replaced, order the AERCO Front Refractory
Replacement kit, P/N
27103
, which includes full instructions in Technical Instruction Document
TID-0117. In addition, AERCO provides a Front Refractory Replacement Tool Kit, P/N
27105
,
which includes tools and safety equipment useful in replacing the front refractory.
METAL TABS
(4 EACH)
REFRACTORY
REFLECTOR
