1、- 3535789 0209384 413 / ,R-27-s I TM 5-642 TECHNICAL MANUAL OPERATION AND MAINTENANCE SMALL HEATING SYSTEMS HEADQUARTERS, DEPARTMENT OF THE ARMY AUGUST 1990 3826 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-W 3515789 0209185 35T REPRODUCTION A UTH
2、ORIZATION/RESTRICTIONS This manual has been prepared by or for the Government and is public property and not subject to copyright. Reprints or republications of this manual should include a credit sub- stantially as foiiows: “Department of the Army Technical Manual, TM 5-642, Operation and Maintenan
3、ce, Small Heating Systems. ” TM 5-642 I 3925 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3535789 020938b 2b *TM 5-642 TECHNICAL MANUAL 1 HEADQUARTERS NO. 5-642 CHAPTER 1. CHAPTER 2. Section I. Section II. Section III. Section IV. CHAPTER 3. Secti
4、on I. Section II. Section III. Section IV. DEPARTMENT OF THE ARMY Washington, DC, 30 August 1990 OPERATION AND MAINTENANCE SMALL HEATING SYSTEMS Table of Contents Pamgmph INTRODUCTION Purpose and scope _._._._._._ References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abbreviations and
5、 terms Organization and responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6、 . , . . . . . . . . . . . . . . . . . . , . . . . . , . . . . . Systems overview. . Energy conservation . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUELS Coal Fuel O
7、ils General . * . . . . . . . . . . . . . . Classification of fuel oils . I . , . ,. ,. .* . ,.*. . * . , ,. . . Oil tanks . Natural Gas . . . . . . . . . . . . . Gas handling precautions . Liquefied Petroleum Gas General .I.,.1,.,.,.,.,. . . . . Characteristics ,., . # I. I I Specifications I . . .
8、 . . . . . . . ,. . , , , , . , , , . . . . . ,. . . . . . ,. . . . . . . . . . . . . . . , , . , . . . , . , . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,I . . , . . . . . . . . . . . . . . . I . LPG storage and handling 1.11.,.,.,. FUEL BURNING EQUIPMENT Coal Stokera
9、General . Single-retort underfeed stokers Operation II.I,.II.I . . . . . , . . . . . . . ,I.I. . I I Inspection and maintenance procedures Troubleshooting underfeed stokers 111I.,.,. Hand-Fired Coal Burners Ceneral . Furnace types Operation I,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,. . Oil Burners General . B
10、urner descriptions Ignition procedures . Oil burner operation Inspection and maintenance of oil burners 1,.1,.,.,.,., Fuel oil piping _. Gas Burners General . Burner types with descriptions . . . Operation procedures . Starting procedures Inspection and maintenance . . . . . . . . . . . . . . . . .
11、. . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a * This manual supercedes TM 5-642, Jun 46 and rescinds TM 5-644, Jul 46 and TM
12、 5-646, Jun 46. 1-1 1-2 1-3 1-4 1-5 1-6 2- 1 2-2 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-18 3-19 paao 1-1 1-1 1-1 1-1 1-1 1-2 2-1 2-1 2-1 2-2 2-3 2-3 2-4 2-4 2-4 2-4 2-4 3-1 3-1 3-1 3-2 3-2 3-2 3-2 3-4 3-6 3-5 3-9 3-10 3-10
13、3-13 3-16 3-16 3-16 3-18 3-19 i 3 826 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-TM 5-642 Section V Section VI, CHAPTER 4. Section I. Section II. Section III. Section IV. Section V. Section VI. Section VIL Section VIII. Section IX. ii 3827 35357
14、89 0209387 122 pnwmph Dual Fuel (Oil/Gas) Burners . . . . . , . Inspection and maintenance Energy Conservation Adjustments to excess air STEAM HEATING SYSTEMS . . . . . . General Two-pipe vapor system with return trap Two-pipe vapor system with condensate pump . Two-pipe vacuum system with vacuum pu
15、mp . Boiler Types Cast iron boilers . Steel boilers . . . Fire-tube boilers Initial operation and cleaning Special maintenance requirements . . Installation . . . . . . . Maintenance Installation . . . . . . ,. . . . . . Maintenance . Gravity one-pipe air vent system . . . . . . , , . . . . . . . .
16、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . .
17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . .
18、. . . . . . . . . . . . . , , . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , , . . .
19、. . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . Vacuum Pumps General . . . . . . , . . . . . , , . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . , , , . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . Initial
20、 operation and cleaning Typical operating difficulties . . Water Level Regulators and Controls General . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , , . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . .
21、. . . . . . , , . . . . . . . Initial operation and servicing . . . Operation and maintenance . . Typical operating difficulties Boiler Trimmings, Gauges, Pop Safety Valves General I. . . I. . . . . . . . , . . ,. . . , . . . * . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . .
22、. . . . . . . . . . , . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gauge glass breakage . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . * . . , . . . Blowdown pipes Dampers . Traps General . I ,.I.*. . . . . . . . . . . . .
23、 . . . . . . . . . . . . . . . . . . . 3-20 3-21 3-22 3-23 4- 1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-10 4-11 4-12 4-13 4-14 4-15 4-16 4-17 4-18 4-19 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-27 4-28 4-29 4-30 4-31 4-32 4-33 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41 4-42 4-43 4-44 4-45 4-46 Page 3-21 3-21 3-21
24、 3-21 4-1 4-1 4-1 4-4 4-5 4-6 4-8 4-11 4-11 4-13 4-14 4-14 4-15 4-15 4-15 4-18 4-18 4-18 4-18 4-18 4-19 4-20 4-20 4-21 4-22 4-23 4-24 4-25 4-26 4-26 4-28 4-28 4-29 4-29 4-29 4-33 4-33 4-33 4-33 4-33 4-33 4-34 4-34 4-34 4-34 4-36 Provided by IHSNot for ResaleNo reproduction or networking permitted wi
25、thout license from IHS-,-,-3515789 0209188 Ob9 TM 5-642 Section XI. Section XII. Section XIII. Section XIV. Section XV. Section XVI. Section XVII. Section XVIII. Air Vents General Installation and operation . . . . General . Initial operation and cleaning . Typical operating difficulties . Steam Uni
26、t Heaters General . Installation . Maintenance . Steam Heating Coils General . Installation . Initial operation and cleaning Maintenance . Typical operating difficulties . . Steam Humidifiers General . Installation of duct type humidifiers . Installation of unit humidifiers . Pressure Reducing Valve
27、s Types . Installation and initial operation . Operation and maintenance . Typical operating difficulties . General Procedures for Operation and Maintenance General . Water level . . Combustion equipment and controls . Boiler structure Housekeeping . . Typical Steam Heating Operating Difficulties Wa
28、ter line fluctuation . . Low water level . Loss of pressure . Pounding in the system . Heating unit malfunction . Failure of space to heat Pump venting steam . Pump venting water . Steel boiler failure . Cast iron boiler failure . Boiler room smoke . . Summer Lay-up Procedures General Draining syste
29、m . Boiler cleaning and lay up . . Typical operating difficulties . . . . . . . . . . Gas burners . Pumps . Valves and strainers Traps Controls and electrical connections . Stack and breeching . . 4-47 4-48 4-49 4-50 4-51 4-52 4-53 4-54 4-55 4-56 4-57 4-58 4-59 4-60 4-61 4-62 4-63 4-64 4-65 4-66 4-6
30、7 4-68 4-69 4-70 4-71 4-7 2 4-73 4-74 4-75 4-76 4-77 4-78 4-79 4-80 4-81 4-82 4-83 4-84 4-85 4-86 4-87 4-88 4-89 4-90 4-91 4-92 4-93 4-94 4-95 4-96 4-97 4-98 Page 4-38 4-38 4-38 4-39 4-39 4-39 4-39 4-39 4-39 4-42 4-43 4-43 4-43 4-43 4-44 4-44 4-44 4-44 4-44 4-45 4-45 4-46 4-47 4-48 4-48 4-48 4-48 4-
31、48 4-49 4-49 4-49 4-49 4-49 4-50 4-50 4-50 4-50 4-50 4-51 4-51 4-51 4-52 4-52 4-52 4-53 4-54 4-54 4-54 4-54 4-54 4-55 4-55 . 111 3828 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-m 3515789 0209189 TT5 m TM 5-642 Section XIX . CHAFTER 5 . Section I
32、 . Section II . Section III . Section IV . Section V . CHAPTER 6 . Section I . Section II . Section III . Section IV . Pamgraph Energy Conservation Isolate off-line boilers . Maintenance of pipe and boiler insulation Steam trap leak detection . HOT WATER HEATING SYSTEMS Gravity Systems General . Equ
33、ipment Startup Water level . Inspection and maintenance . Forced Circulation Systems General . Equipment Piping systems . Inspection and maintenance Hot Water Fan-Coil Units General . Fan coil capacity control . Electrical requirements . Maintenance Heat Exchangers General . Installation . Operation
34、 . Maintenance Energy Conservation Hot water temperature reduction . Night setback WARM AIR SYSTEMS Description of Systems Warm air furnaces . Gravity warm-air heating systems Forced warm-air heating systems Ratings of warm air furnaces . Coal Fired Warm Air Furnaces Steel furnaces Cast iron furnace
35、s Ratings and shea Motor damper Chimney . Oil-Fired Warm Air Furnaces General description Oil furnaces . il-conversion furnace . Gas-Fired Warm Air Furnaces General . Construction Furnace rating Central furnaces . Vertical furnaces (hi-boy type) . Horizontal furnaces Gas conversion furnaces Fully co
36、ndensing furnaces Fully condensing furnace maintanance . Pulse Combustion furnaces . Pulse combustion furnace maintenance . Automatic vent dampers . Smokepipe 4-99 4-100 4-101 5- 1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6
37、-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 page 4-55 4-56 4-56 5-1 5-1 5-2 5-2 5-2 5-2 5-3 5-4 5-5 5-6 5-7 5-7 5-8 5-8 5-8 5-9 5-9 5-9 5-10 6-1 6-1 6-2 6-4 6-4 6-6 6-5 6-6 6-7 6-7 6-8 6-8 6-8 6-12 6-15 6-15 6-15 6-15 6-16 6-17 6-18 6-19 6-20 6-20 6-21 iV 3 829 Pro
38、vided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-3515789 0209370 717 H TM 5-642 Section V . Section Vi . Section VI1 . Section VI11 . CHAFTER 7 . Section I . Section II . APPENDIX A . APPENDIX B . APPENDIX C . BIBLIOGRAPHY . GLOSSARY . INDEX . +re No . 2
39、.1 . 2.2 . 2.3 . 3.1 . 3.2 . 3.3 . 3.4 . 3.5 . 3.6 . 3.7 . 3.8 . 3-9 . 3.10 . 3.11 . 3.12 . 3-13 . Gas-Fired Unit Heaters General . Description . Operation . Installation . Infrared Heaters Gas-fired infrared heaters . Electric infrared heaters . Oil-fired infrared heaters Precautions Maintenance Op
40、erating and Maintenance Procedures General . Blower and motor maintenance . Air filter maintenance . Humidifiem Blower and limit controls . Troubleshooting Energy Conservation Space temperature setback . Maintenance of duct insulation . AUTOMATIC CONTROLS General Types of controls and control system
41、s Thermostats . Primary controls . Limit controls and safeties . Operation and Maintenance General . Thermostats . Hand fired coal primary controls Coal stoker primary controls Oil burner primary controls . Gas burner primary controls Limit controls Safety pilot and pilotstat . Auxiliary controls .
42、6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-37 6-38 6-39 6-40 6-4 1 6-42 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-9 7-10 7-11 7-12 7-13 7-a RELATED PUBLICATIONS TROUBLESHO(YTING UNDERFEED STOKERS . TROUBLESHOOTING STEAM PRESSURE PUMPING SYSTEMS poge 6-22 6-22 6-22 6-23 6-24 6-25 6-26 6-26 6-27 6-2
43、7 6-27 6-29 6-29 6-33 6-33 6-34 6-35 7-1 7-1 7-1 7-1 7-1 7-2 7-3 7-4 7-4 7-5 7-8 7-10 7-10 A-1 B-1 c-1 . Bibliography-1 G10ry-l . 1-1 . List of Figures Tifle Inside or elevated outside oil tank installation . Buried oil tank installation . Typical LPG installation . Single retort screw feed stoker .
44、 Grates for updraft furnaces Downdraft furnace Preseure atomizing gun type oil burner . Air atomizing gun type burner Operating principles of low pressure gun type burner Horizontal rotary oil burner . Settings of ignition points and nozzle for oil burners Typical fuel oil piping Automatic oil shut-
45、off valve Individual low pressure gas burner . Assembly of low pressure gas/oil burner . Typical installation of low pressure gas burner 2-2 2-3 2-6 3-1 3-3 3-4 3-6 3-7 3-8 3-9 3-12 3-14 3-15 3-16 3-16 3-17 V 3 830 Provided by IHSNot for ResaleNo reproduction or networking permitted without license
46、from IHS-,-,-H 3535789 0209393 653 TM 5-642 List of Figures-Continued and wet, which is intermingled with moisture, mist or spray. Saturated steam is commonly used for space heating and process heat. (2) Superheated steam. When steam has a temperature higher than its corresponding satura- tion press
47、ure, it is called superheated steam. The difference between the temperature of superheated steam and its saturation temperature is called the superheat. Usually, superheated steam is generat- ed in central heating plants when necessary to avoid condensation in the steam lines of the plant and the di
48、stribution system, or to drive steam tur- bines. Normally in such instances, not more than 50F superheat is imparted to the steam. (3) Total heat content. A certain amount of heat is needed to change water into steam. The specific amount depends on the initial condition of the water and the desired
49、pressure and tempera- ture of the steam. The amount of heat required to convert water at 32F into steam at a specific pres- sure and temperature is called the total heat con- tent (or enthalpy) of the steam at that particular pressure and temperature. As pressure rises from atmospheric conditions up to a
