SECTION 1 - Bryan Boilers
Contents
1. 2 1 5 LOW WATER CUT OFF S Most boilers are supplied with at least one float operated primary low water cut off and pump control or water feeder combination and electric probe type control designed to sense the level of the water in the boiler It operates to shut off the boiler if the water level drops below its sensing level The low water cut off controls must be operationally tested by manually lowering the boiler water level by opening the drain valve The boiler should cycle off when the water level drops below the control point of the low water cut off When the water level is restored the boiler should cycle back on Depress the manual reset button of devices which require manual reset in order to restore the boiler to operation Carefully read the enclosed literature on the low water cut off controls particularly installing operating and servicing 2 1 6 COMBINATION LOW WATER CUT OFF amp FEEDER The low water cut off feeder supplied with some boilers serves as a low water cut off see above and also causes make up water to be added to the boiler should the water level drop below its control point This type of control must be operationally tested to assure that the make up water is introduced as needed Carefully read the enclosed literature on the low water cut off controls particularly installing operating and servicing 2 1 7 OTHER CONTROLS 2 2 OPERATING CONTROLLER Additional controls as required for t2. of the valves being used to isolate the boiler to prevent leakage and resultant dilution of the lay up solution 3 9 8 ALTERNATE METHOD An alternate wet lay up method is to pipe clean continuous lowdown water from a properly treated boiler into any convenient bottom connection on the idle boiler allowing the water to flow through the boiler and out the top through any convenient top opening to the sewer This method will insure a continuous complete fill with warm properly treated water it also prevents in leakage of air by keeping the boiler slightly pressurized It may also provide enough heat to possibly produce adequate freeze protection 3 9 9 DRY LAY UP OF STEAM BOILERS LONG TERM The dry lay up method recommended requires that the boiler be drained dried as completely as is possible all opening and valves closed Nitrogen gas at 5 psig is introduced to the boiler to pressurize it and prevent air in leakage The success of the procedure depends on the thorough drying of the boiler metal surfaces after draining and the exclusion of air during the lay up l Drain the boiler before the steam pressure falls to zero Then pressurized with 5 psig nitrogen gas through a suitable top opening during draining The nitrogen pressure is to be maintained through draining and subsequent storage An alternate method is to completely dry a clean boiler by blowing hot dry air through he boiler and then purge the air from the
3. per day On humidification or process systems the lowdown schedule should be based on recommendation from a water treatment and maintenance program specifically designed for the boiler At the annual inspection all float type level controls should be disassembled cleaned and inspected thoroughly When re installed these controls must be given an operational test 3 8 WATER GAUGE GLASSES 3 8 1 INSTALLATION Check with the maintenance supervisor and engineering for the proper glass to be used Compare the box and the glass label or marking to assure that the gauge glass ratings or temperature and pressure are suitable for use on the boiler Use new gaskets when replacing glass The gaskets used should be the same type as those originally supplied with the boiler Make certain that the gauge glass valves are properly aligned All bolts and nuts must be free running and well lubricated preferably with graphite type lubricant Washers under nuts and bolt heads are desirable DO NOT tighten while equipment is in operation 3 8 2 MAINTENANCE Inspect the gauge glass regularly for any signs of clouding or scratching In new processes the gauge glass should be inspected daily until the need for replacement becomes apparent This will help establish the routine inspection cycle The gauge glass should be blown down daily so as to remove accumulated sediment from the valves 3 8 3 INSPECTION To examine for scratches shin
4. some cases the relay is built into the sequencer In case of power failure the function of this relay is to eliminate a sudden power load on the distribution system If a power failure occurs the recycle relay interrupts the control circuit power causing the magnetic contactors to drop out Power is shut off to the elements until the modulating motor has driven the sequencer back to its original starting position The relay is then activated and the sequencer will bring the steps back on one at a time until the system is again balanced There is also a limit supplied to be installed with the shunt trip on the main circuit breaker in order to completely shut down all power to the boiler Refer to your electric wiring diagram supplied 1 6 5 SAFETY RELIEF VALVES The safety relief valves are mounted on the top of the boiler These are a final safety device in case the operator and other safety devices fail Such a failure will cause the pressure to rise in the boiler to the set pressure of the relief valve The relief valve will discharge so that the boiler will not be able to generate pressure beyond the set pressure of the relief valve 1 6 6 LOW WATER CUT OFF The function of the low water cut off is to shut down the boiler if for any reason the water level should drop below the normal operating range 17 PROCEDURES TO BE FOLLOWED BEFORE PLACING BOILER IN OPERATION 1 7 1 HYDROSTATIC TEST OF BOILERS amp SYSTEM After com
5. AINTENANCE AND SERVICING 21 LIMIT CIRCUIT CUT OUT TEST 2 1 1 PROTECTIVE DEVICES All operating and limit controls and low water cutoffs must be tested for proper operation 2 1 2 STEAM PRESSURE OPERATING CONTROL The steam pressure in the boiler is regulated by the Boiler Operator This is a pressure control which senses the steam pressure and turns the boiler on and off accordingly This control must be operationally tested Adjust the pressure setting on the control to a pressure less than the boiler pressure as shown on the boiler pressure gauge The control should turn the boiler off Restore the control setting to normal The boiler should cycle on 2 1 3 HIGH LIMIT CONTROL At least two additional temperature controllers are provided as high limit controls They are set at a pressure above the operator to act as a back up should the operator fail The high limit control must be operationally tested With the boiler operating decrease the pressure setting of the limit control below the current pressure of the boiler The boiler should cycle off Restore the high limit control setting to normal pushing the reset button if it is a manual reset type The boiler should now cycle on 2 1 4 COIL LIMIT CONTROL On indirect water heating boilers an additional temperature limit control is installed to limit the temperature leaving the heat exchanger It must be tested in the same manner as the boiler High Limit control
6. E sowers Installation Operation Service Manual Tor Electric Steam Boilers BRYAN BOILERS P O BOX 27 PERU INDIANA 46970 Telephone 765 473 6651 Fax 765 473 3074 E Mail bryanboilers iquest net Internet www bryanboilers com SECTION 1 INSTALLATION INSTRUCTIONS Date 10 1 97 FOR Revision New ELECTRIC STEAM BOILERS Form 2055 1 Please read the entire instruction manual before attempting installation Insurance Local and or State regulatory codes may contain additional or more stringent requirements than those contained in this manual Installation must conform to these codes2 and any other authority having jurisdiction Appropriate sections of NEC should be consulted and followed 11 BOILER FOUNDATION Before uncrating the boiler location should be prepared The boiler should set upon a good level concrete floor If the boiler is not level or the floor in good condition a concrete foundation should be built utilizing dimensions larger than the outside dimensions of the boiler base The front of the boiler should not be any closer and the minimum clearances established than 36 from any obstruction for servicing the accordingly Provisions must also be made for electrical panels The element end of the boiler service accessibility and clearance for piping should not have any obstruction for the same and electrical connections length as the boiler supplied for removal and servicing of elements The ba
7. R SYSTEM TO PUMP CONDENSATE INTO THE BOILER FEED SYSTEM TANK NOTE FOR SOME OLD SYSTEMS THERE IS A RELUCTANCE TO CLEAN THE PIPING BECAUSE OF THE POSSIBILITY OF LEAKS OCCURRING IN BADLY CORRODED LINES SHOULD THE CUSTOMER REFUSE CLEANING IT IS NECESSARY TO INSTALL FILTRATION EQUIPMENT INSTALL EITHER A FIBROUS FILTER OR A CENTRIFUGAL FILTER IN THE BOILER RETURN PIPING THIS WILL COLLECT AND REMOVE SEDIMENT FROM THE SYSTEM A BOOSTER PUMP MAY HAVE TO BE INSTALLED AS WELL TO OVERCOME THE ADDITIONAL PRESSURE DROP INTRODUCED IN THE LINE BY THE FILTER WHEN FILLING THE SYSTEM PROVIDE CHEMICAL TREATMENT AS OUTLINED IN SECTION 3 5 3 0 BOILER WATER TREATMENT 3 5 1 PURPOSE OF WATER TREATMENT Water treatment is required for satisfactory operation of the boiler It must be devised to prevent depositing of scale and corrosion from acids oxygen and other such harmful elements that may be in the water supply A qualified water treatment chemist should be consulted and the water systematically treated 3 5 2 OBJECTIVES The basic objectives of water treatment are Prevent the accumulation of scale and deposits in the boiler Remove dissolved gases from the water Protect the boiler against corrosion Maintain the highest possible boiler efficiency Decrease the amount of boiler down time from cleaning 3 5 3 CONTINUOUS MONITORING REQUIRED Water treatment should be checked and maintained whenever the boiler is
8. UCTION FOR LAY UP Many boilers have been ruined with system contaminants such as pipe dope cutting oil metal shavings or chips and other debris which are left in the piping If these contaminants are not removed they will end up in the boiler 3 3 1 SYSTEM CLEANING PROCEDURE For steam systems the boiler will need to be connected to the header utilizing steam to purge the piping and thus push the debris out of the system However at this time all condensate must be wasted until it runs clear and water analysis of the condensate indicates that it is free of contaminants Steam trap strainers must be periodically opened and cleaned of any debris which accumulates During this system clean out the boiler make up water must be properly softened and treated At the conclusion of the system clean out the condensate must be reconnected For old or existing steam systems the installation process may have jarred debris loose Following the boil out of the new boiler the condensate should be wasted until it is within proper guidelines Check all steam trap strainers to assure their cleanliness Refer to the succeeding section on replacement boiler installations 3 4 REPLACEMENT BOILER INSTALLATIONS PROTECTION AGAINST CORROSION amp SEDIMENT 3 4 1 BOILER MUST CONTROL FEED WATER The water feed to the boiler must be controlled by the boiler mounted water level control It is unacceptable to use gravity return or to let the w
9. aces completely dry or excluding air from the boiler Air exclusion is accomplished either by keeping the boiler completely full of water short term lay up or filling the boiler with nitrogen gas long term lay up The nitrogen gas prevents air infiltration and does not react with the metal In addition to the corrosion damage that occurs the metal particles that are released will form an insulating scale on the boiler when it is returned to service These corrosion products will accumulate on critical heat transfer areas of the boiler increasing the potential for localized corrosion and over heating 3 9 2 PRE OPERATIONAL CLEANING AND LAY UP Proper lay up techniques must be used on an idle boiler even if it has never been in operation Before pre operational lay up the boiler must be chemically cleaned as outlined in Section 3 2 and 3 3 of this manual This is required as noted in this section to remove preservatives oil and grease from the inner boiler Follow the short term or long term lay up procedure as appropriate 3 9 3 TAKING BOILERS OFF LINE In operation boiler water contains suspended solids which are held in suspension due to water circulation and the action of treatment chemicals Unless care is exercised when draining the boiler these suspended solids settle on the tube surfaces and will air dry to an adherent deposit sometimes requiring chemical cleaning to remove In addition these deposits may be misle
10. ading regarding the effectiveness of the chemical treatment program 3 9 4 PRE SHUTDOWN PRECAUTIONS For a period of three to seven days proper to shutdown manual lowdown frequency should be increased During this period the lower conductivity limit should be below 3500 micro ohms per centimeter The feed of internal treatment must be increased to maintain a specific residual concentration Continuous lowdown when used should be kept to a minimum so the reduction of solids is achieved by the increased manual lowdown 3 9 5 WASHDOWN As the boiler cannot be washed immediately the heat in the boiler may cause baking of residual sludge The boiler should not be drained until cooled enough to prevent this However never leave the boiler filled with water for any extended period of time without taking measures to prevent corrosion 3 9 6 LAY UP CONSIDERATIONS There are two basic methods of steam boiler lay up Wet lay up and Dry lay up The choice of which method should be used depends on The possibility that the boiler may need to be placed in operation on short notice Disposal of lay up solutions Freezing potential Wet Lay up is recommended for relatively short outages such as seasonal lay up This method has the advantage of allowing the boiler to be brought on line with short notice But it can pose problems if there is any likelihood of freezing Dry lay up is recommended for longer periods of boiler sh
11. al fill should be at room temperature and must be softened as noted he After filling turn the boiler on at a low temperature at a frequency as necessary to hold the boiler solution at boiling point temperature DO NOT PRODUCE STEAM PRESSURE Boil the water supervised at all times for at least five hours 8 After the five hour boil out begin to add a small amount of fresh softened water so as to create a slight overflow of the overflow pipe This will carry out impurities which have accumulated at the water surface Continue to apply heat and overflow until the water emitted from the overflow pipe clears Then shut off the boiler 9 Let the boiler cool to 120 F or less Drain the boiler Use caution that the 10 Remove the inspection cleanout openings in the boiler and wash the waterside surfaces thoroughly using a high pressure water stream 11 Inspect the boiler s internal waterside surfaces thoroughly after the procedure If the surfaces are not clean repeat the boil out water is discharged with safety 12 After boil out close all openings Install relief valves gauge glasses and other components as necessary Completely fill the boiler with fresh softened ambient temperature water Operate the boiler until water temperature of at least 180 F is reached 13 The boiler is now ready to operate IMPORTANT IF BOILER IS NOT TO BE OPERATED WITHIN 24 HOURS A LAY UP PROCEDURE IS REQUIRED REFER TO INSTR
12. and operation of the boiler 3 2 1 BOIL OUT PROCEDURE heat transfer rate and reduce operating The internal surfaces of a newly installed boiler efficiency The operator must be familiar with will have oil grease or other protective the procedure outlined in the boiler operating coatings used in manufacturing Such coatings instruction manuals must be removed since these coatings lower the BOILING OUT UNDER PRESSURE IS NOT RECOMMENDED IF BOILING OUT UNDER PRESSURE IS REQUIRED COMPETENT ASSISTANCE MUST BE PROVIDED CAUTION THE BOIL OUT PROCEDURE OUTLINED MUST BE PERFORMED BY OR UNDER THE DIRECT SUPERVISION OF A QUALIFIED TECHNICIAN THE CHEMICALS USED PRESENT A HAZARD OF BURNS AND PHYSICAL INJURY IF MISHANDLED ALWAYS USE SUITABLE FACE MASK GOGGLES PROTECTIVE GLOVES AND GARMENTS WHEN HANDLING CAUSTIC CHEMICALS DO NOT PERMIT THE CHEMICAL TO COME INTO CONTACT WITH SKIN OR CLOTHING ALWAYS FOLLOW THE SAFETY PRECAUTIONS ON THE CONTAINER S LABEL ADD CHEMICALS SLOWLY AND IN SMALL AMOUNTS TO PREVENT EXCESSIVE HEAT AND AGITATION DO NOT ADD WATER TO ACID DO NOT ADD WATER TO DRY CHEMICAL THIS WILL CAUSE SPLATTERING AND OR EXPLOSION AND SEVERE RISK OF PERSONAL INJURY In combination with system contamination bacteria may cause objectionable odors sometimes resembling natural gas It is important to keep these fumes from air Your water consultant or water treatment company will be able to recommend a cleaning or boil out procedure I
13. ater feed be controlled by a condensate receiver condensate pump system The water feed to the boiler must be controlled 2 By a feed pump control which is mounted on the boiler This control is to activate the feed pump on a boiler feed system It will be necessary to supply such a system if not already installed By an automatic water feeder mounted on the boiler This is used only on systems requiring 100 make up such as humidification steam process etc NOTE IT IS NOT RECOMMENDED TO PROVIDE THE MAKE UP FOR A CLOSED STEAM HEATING SYSTEM TO THE BOILER BY MEANS OF A WATER FEEDER IT IS PREFERRED THAT SYSTEM MAKE UP BE CONNECTED TO THE CONDENSATE RETURN TANK OF A BOILER FEED SYSTEM 3 4 2 CLEAN OR REPLACE ALL SYSTEM PIPING AND HEATING UNITS Arrange for chemical and mechanical cleaning of the entire system A chemical treatment company should be consulted for the proper means of this chemical cleaning Replace any piping considered to be deteriorated beyond safe or cleanable condition Flush the system clean being certain to isolate the boiler DO NOT FLUSH THE SYSTEM THROUGH THE BOILER CAUTION FAILURE TO PROPERLY CLEAN THE SYSTEM OR TO INSTALL MECHANICAL SEDIMENT REMOVAL EQUIPMENT CAN RESULT IN PIPE BLOCKAGE AND SEVERE CORROSION PLUS DAMAGE TO PUMPS CONTROLS AND AIR REMOVAL DEVICES A BOILER FEED SYSTEM MAY BE USED IN CONJUNCTION WITH AN EXISTING CONDENSATE RECEIVER SYSTEM BY ALLOWING THE RECEIVE
14. boiler and pressurize with 5 psig nitrogen Be aware that all metal surfaces which are not completely dry are vulnerable to corrosion particularly if oxygen is present 2 If a boiler has been down for repairs and is to be laid up it should be operated to pressurize with steam and then drained and pressurized with nitrogen as in Step 1 3 All connections must be blanked or tightly closed 3 9 10 RETURNING IDLE BOILER TO SERVICE After Wet Lay Up To start an idle boiler after wet lay up use the and the water level are returned to following procedure proper operating conditions the boiler 1 the boiler was pressurized with can be started in the normal manner nitrogen disconnect the nitrogen supply source and vent the boiler 2 Using the After Dry Lay Up lowdown valve drain the boiler To start an idle boiler after dry lay up use the partially and make up with feedwater so following procedure as to dilute the chemical residuals to 1 Disconnect the nitrogen supply source operating concentration levels and vent the boiler in a safe manner 3 After the boiler water concentrations external to the building and away from air intakes Then thoroughly purge the CAUTION THE USE OF NITROGEN FOR boiler of nitrogen with dry air BLANKETING IS RECOMMENDED IN BOTH THE 2 The boiler was to have been cleaned WET AND DRY LAY UP PROCEDURES EVEN before the lay up procedure So it is THOUGH NITROGEN IN DILUTE QUANTITIES IN necessary on
15. ck of the boiler as long as panels are not supplied in the rear can be mounted next to an obstruction Local INSTALLATION AND CLEARANCES codes must be applied to specific installations NOTE ADHERE TO ALL APPLICABLE LOCAL CODES AND NEC REGARDING BOILER 13 UNCRATING THE BOILER Uncrate the boiler near its permanent location Remove the bolts attaching the boiler to the Leave it on the bottom crating until ready to crate at the underside of the bottom crating place permanently Leave the plastic shroud on Lift or slide the boiler off of the bottom crating the boiler until all piping work is complete into position Be careful not to tip the boiler up cutting holes in the plastic for access to on one corner or side which could cause connections damage to the jacket 14 BOILER CONNECTIONS 1 4 1 GENERAL Do not run any pipes along the element access and power panel side of the boiler Maintain clearances as shown on the dimensional drawing for servicing and as referenced in NEC All piping should be designed and installed to avoid any loadings on the boiler connections or piping 1 4 2 FLOW CONNECTIONS A steam shut off valve must be installed between each boiler and the steam main This valve must be of the outside screw and yoke design to allow indication from a distance whether the valve is open or closed 1 4 3 FEEDWATER CONNECTION Install a check valve and a globe valve between the feed pump and the boiler It is also re
16. commended to install a globe valve between the feed pump and the receiver tank This valve can then be adjusted to bypass excess pump capacity to better control the boiler feed rate 1 4 4 SAFETY RELIEF VALVE S A connection is provided in the top of the boiler for the relief valve The relief valve discharge piping must be the same size as the relief valve discharge opening Avoid over tightening as this can distort valve seats All piping from relief valve must be independently supported with no weight carried by the valve 1 45 BLOWDOWN CONNECTION Blowdown valve s must be full size of the connection on the boiler Steam boilers 15 psig and below require at least one blowdown valve Higher pressure boilers require two blowdown valves with one or both valves being slow opening type Each water column and float type low water cut off must be equipped with a blowdown valve 1 5 ELECTRICAL CONNECTION IMPORTANT All electrical connections must conform to the NEC and to all other applicable State and Local Codes The heating elements supplied with Bryan electric boilers are of the resistance type with an incoloy sheath and a watt density not exceeding 75 watts square inch These elements are typically delta wired unless otherwise specified Power supply voltage must be as shown on the wiring diagram enclosed CAUTION A fused main disconnect switch must be supplied per NEC requirements Wiring to the main power terminals in th
17. e a bright concentrated light at about a 45 angle Anything which glistens brightly should be inspected closely Any scratches which glistens and will catch a fingernail or crescent shaped or star shaped mark is cause for replacement This is because scratches corrosion chips and surface damage weaken the glass If inner surface appears cloudy or roughened and will not respond to cleaning procedures this is evidence of chemical attack If severe this is cause for replacement 3 8 4 REPLACEMENT OF GLASS Any glass that has been removed from its mounting in process boilers regardless of the reason for removal should be discarded and replaced with a new glass and gaskets Used glasses may contain hidden damage and represent a safety hazard Be sure that the replacement glass is suitable for service conditions Protective shields to keep cold air water or falling objects from glass must be replaced 3 9 IDLE BOILER CARE AND LAY UP 3 9 1 GENERAL Corrosion damage to boiler is often the result of improper lay up during non operating periods Substantial damage can occur in only a few days in proper precautions are not taken This damage is irreversible and will reduce boiler reliability increase maintenance costs and eventually shorten the life of the boiler Idle boilers are vulnerable to attack when air contacts untreated wet metal surfaces To prevent corrosion the boiler metal must be protected by either keeping the surf
18. e power panel by the contractor must have current carrying capacity equal to at least 125 of the amperage rating of the boiler The lugs supplied are at the top of the power panel and suggested entrance can be recognized on the dimensional EQUIPMENT GROUNDING The boiler must be grounded in accordance with the NEC ANSI NFPA 70 1981 ALL CONTROL PANELS AND CONTROLS ARE SUBJECT TO SOME INTERNAL HEAT ADEQUATE BOILER ROOM VENTILATION MUST BE PROVIDED 16 BOILER ACCESSORY EQUIPMENT 1 6 1 ELEMENTS The immersion type electric resistance heating elements are mounted in a standard 150 flange 300 flange if required These elements are held into this flange with brass fittings Each element hairpin is rated at 5 KW or 10 KW at the rated volts The incoloy sheath is a nickel chrome and iron alloy which provides good resistance to oxidation and has good strength characteristics at elevated temperatures By virtue of its very high nickel content the material does not have a tendency to become embrittled after prolonged exposure to temperatures Corrosion resistance of the incoloy is attributed to the chrome and nickel content of the alloy This type of material was chosen as a sheath material because of its resistance to corrosion oxidizing conditions and attacks from impurities in the various water conditions Each element is easily replaced by using ordinary hand tools This eliminates the necessity of having a complete element b
19. ew construction to not be limited to the following assist in curing of building components or to 1 Knowledge of boiler operation provide temporary heat for the construction 2 Possession and understanding of boiler crew or for other purposes during the time the operating instruction manual building is under construction If precautions Assurance that the boiler is fed with are not taken during this time to protect the only treated water at all times and that boiler a great deal of damage can occur before chemical treatment and blowdown the ultimate owner takes over the building procedures are always followed 4 Notification to the manufacturer or It is the mutual responsibility of the installing contractor and the boiler owner to consider the effect of temporary usage on the boiler with start up by a factory warranty The following should be observed so representative as to assure the longevity of the boiler 5 Adherence to all of the start up procedures noted in the boiler manual Considerations of warranty should the boiler be used for temporary heat without adherence to the recommended start up and operating procedures outlined in the instruction manuals 3 2 CLEANING THE BOILER AND SYSTEM NEW SYSTEMS manufacturer s agent to provide start up services if the boiler was purchased 3 1 2 OPERATOR SKILLS RESPONSIBILITIES 6 During the temporary use period a single individual must be assigned responsibility for the care
20. he particular installation may also be provided Refer to the literature on these devices included in the boiler manual All such devices must be operationally tested to assure reliable operation of the boiler and system 2 1 8 BOILER FEED SYSTEM The boiler feed pump must be operationally tested to assure that it can provide boiler feedwater at the pressure and in the amount needed for safe and reliable boiler operation 2 1 9 CHEMICAL FEED SYSTEM amp SOFTENER Check the performance of the boiler water softener and chemical treatment system Chemically test the feedwater to be certain it complies with the recommendations of the chemical treatment consultant As previously discussed electric boilers are broken down into branch circuits Each circuit is controlled by a step control if two steps or less then controlled by their own pressure control Step control operates by having a signal sent from the operating control that typically sends a modulation signal depending on the pressure setting at the pressure operating control The pressure operating controller will send a signal to the step control to cycle on more steps until the desired pressure is reached Once the pressure control is satisfied steps will begin to cycle off therefore turning off elements and reducing the heat output Each step control is supplied with a dead band area When the desired pressure is reached the step control will stay constant until a large
21. hirty minutes at low temperature to circulate and mix the chemicals 2 After filling the boiler must be closed or blanked tightly The power supply to the boiler must be cut off Vent all air from the top of the boiler to allow complete fill with the required solution Nitrogen gas at 5 psig may be introduced through a suitable opening to prevent air in leakage during the lay up period An alternative to the nitrogen gas see safety precautions under dry lay up is to install a 55 gallon drum or auxiliary vessel This is to be fitted with a cover and filled with properly treated water This vessel or drum should be connected to an available opening in the top of the vessel Its purpose is to create a hydrostatic head and to allow a ready visual check of water level loss or in leakage during the lay up period 3 During lay up test the boiler weekly to assure the proper levels of sulfite and alkalinity To do this take a sample of the boiler water from the surface lowdown line or other high point The test results should be Sodium Sulfite 200 ppm minimum Phenolphthalein Alkalinity as CaCO3 400 ppm minimum If the tests indicate chemical concentration has decreased chemical may be introduced to the boiler by putting it in the drum Then lower the boiler water level to introduce it into the boiler Operate the boiler at low temperature to circulate the water and mix the chemical Repeat Step 2 Pay attention to the maintenance
22. ly to fill the boiler with NON TOXIC IT WILL NOT SUPPORT LIFE properly treated water Then proceed PRECAUTIONS MUST BE TAKEN BEFORE with start up ENTERING EQUIPMENT FILLED WITH NITROGEN FOR INSPECTION OR ANY OTHER PURPOSES THESE PRECAUTIONS SHALL BE AS FOLLOWS NOTE OPERATING BOILERS MUST BE REMOVED FROM SERVICE TO MINIMIZE ADHERENCE OF BOILER WATER SUSPENDED SOLIDS ON BOILER METAL SURFACES REFER TO PREVIOUS INSTRUCTIONS FOR BOILER WASHDOWN DISCONNECTION OF NITROGEN SUPPLY LINE COMPLETE PURGING AND VENTING OF THE EQUIPMENT WITH FRESH AIR TESTING OXYGEN LEVELS INSIDE BEFORE ANY ATTEMPT TO ENTER ALL CONFINED ENTRY GUIDELINES APPLICABLE TO SITE MUST BE FOLLOWED APPROPRIATE CAUTION SIGNS SHALL BE POSTED AROUND THE EQUIPMENT TO ALERT PERSONAL THAT NITROGEN BLANKETING IS IN USE A BOILER LAID UP DRY MUST BE TAGGED WITH INFORMATION THAT THE UNIT IS NOT TO BE OPERATED UNTIL THE BOILER IS PROPERLY REFILLED
23. n the event that such service is unavailable or as yet not selected the following may be used l The boil out of the boiler and system is neither difficult nor expensive The chemicals needed for cleaning are readily available Trisodium phosphate and sodium hydroxide lye are the most commonly used chemicals Use only one type of solution in the system The amount of chemical required will vary according to conditions but an amount of one pound of chemical per fifty gallons of water is suggested 2 Before introducing the solution into the boiler an overflow pipe should be attached to the top of the boiler and routed to a safe point of discharge 3 Remove all safety valves to ensure that none of the solution will come into contact with the valve seats Use care in removing and reinstalling valves 4 All valves in the piping to and from the system must be closed to prevent the chemical solution from getting into the intakes which would distribute them throughout the building On steam humidification systems this is especially critical Consult your local water treatment chemist for further information system 5 Gauge glasses must be protected from contact with the boil out chemicals 6 Fill the boiler with clean softened water until the water level reaches the upper header Then add the cleaning solution into the upper header Add more clean water until the boiler is completely filled The water used for this initi
24. operating The boiler operator should be sure that the boiler is not operating for long periods without proper water treatment Water treatment may vary from season to season or over a period of time Therefore the water treatment procedure should be checked not less than four times a year and possibly more frequently as the local water conditions may indicate All water introduced into the boiler should be softened and should include an oxygen removal system This is required to remove dissolved oxygen from the water Dissolved oxygen can cause severe corrosion in a heating system 3 6 SUGGESTED MAINTENANCE SCHEDULE w 6 1 DAILY Make visual inspection of gauges monitors and indicators and record readings in boiler log Make visual check of instrument and equipment settings against factory recommended specifications Check operation of float type low water cutoffs to ensure control is functioning The lower piping connections of float type level controls should have a suitable blowdown valve piped into a proper discharge station This valve should be opened periodically to allow any sludge accumulated in the control to be flushed out Consult manufacturer s instructions w D N WEEKLY Confirm boiler area is free of combustible materials and has no obstructions check all limit controls as specified in manufacturer s manual Check float low water cutoff as described above Make sure all fu
25. pleting the boiler installation the boiler connections fittings attachments and adjacent piping must be inspected for leaks by filling the unit with water The pressure should be gradually increased to a pressure just below the setting of boiler safety relief valve s Remove the boiler access panels see dimensional drawing in this manual Inspect all openings and fittings for any leaks Although the boiler is hydrostatically tested at the factory minor leaks in fittings and attachments can develop from shipping vibrations or from installation procedures It is often necessary to re tighten such fittings after installation and after the boiler has been in operation for some time Replace panels before starting boiler Section 2 START UP AND OPERATION ELECTRIC STEAM BOILERS Date 10 1 97 Revision New Form 2055 2 WARNING IMPROPER SERVICING AND START UP OF THIS EQUIPMENT MAY CREATE A POTENTIAL HAZARD TO EQUIPMENT AND TO OPERATORS OR PERSONS IN THE BUILDING SERVICING AND START UP MUST BE DONE ONLY BY FULLY TRAINED AND QUALIFIED PERSONNEL CAUTION BEFORE DISCONNECTING OR OPENING ANY BOILER ITEMS OR ACCESSORIES BEFORE CLEANING OR REPLACING PARTS OF ANY KIND TAKE THE FOLLOWING PRECAUTIONS 1 TURN OFF AND LOCKOUT ALL ELECTRICAL DISCONNECTS TO THE BOILER AND ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BOILER 2 ALL COVER PLATES ENCLOSURES AND GUARDS MUST BE IN PLACE AT ALL TIMES EXCEPT DURING M
26. r degree of drop is recognized This will keep the step controller from oscillating between steps during operation The operating control pressure needs to be set and maintained by the operator for the desired output 2 3 OPERATING INSTRUCTIONS 2 3 1 FAMILIARIZATION WITH MANUAL S The user of the boiler must familiarize himself with this manual to be sure he is prepared to operate and maintain the boiler properly The operating instructions should be kept in a safe place and available to all who may be working or operating the boiler READ THE MANUAL BEFORE CAUTION CHECK ALL ELECTRICAL TERMINALS AND CONNECTIONS FOR TIGHTNESS BEFORE START UP ATTEMPTING A START UP 24 MAINTENANCE SCHEDULE 2 4 1 POSTING SCHEDULE Post a maintenance schedule in accordance with the recommendations in this manual A copy of a typical schedule is included in this manual SECTION 3 CARE AND MAINTENANCE Date 10 1 97 FOR Revision New ELECTRIC STEAM BOILERS Form 2055 2 CAUTION X THE BOILER AREA SHOULD BE KEPT FREE OF COMBUSTIBLE MATERIALS GASOLINE AND OTHER FLAMMABLE LIQUIDS THE FOLLOWING PROCEDURES MUST BE CONDUCTED AS OUTLINED TO ASSURE SAFE OPERATION OF THE BOILER ALL COVER PLATES ENCLOSURES AND GUARDS MUST BE IN PLACE AT ALL TIMES EXCEPT DURING MAINTENANCE AND SERVICING 3 1 REQUIRED PRECAUTIONS DURING TEMPORARY USE 3 1 1 GENERAL This person s responsibility must include but A boiler is often utilized in n
27. ses are in operating order f 3 5 4 DRAINING AND REFILLING THE BOILER amp SYSTEM If the system is drained and then refilled chemical treatment is essential to treat the raw water Use only clean softened water MONTHLY Make visual inspection of all wiring and components Check float low water cutoff as described above 2 For those units equipped with a power burner check low draft fan air pressure and damper position interlocks as specified in burner manual Check branch circuit operation and electrical power panels and check for continuity between elements by using a continuity meter ANNUALLY Check operating control high limit and other electrical components for proper operating procedures as specified in manufacturers instructions The elements in the boiler should be removed at least yearly for proper visual inspection If elements need to be replaced they should be replaced or the element bundle sent to the factory for service at this time The boiler pressure vessel and piping should be checked annually 3 7 FLOAT ACTUATED WATER LEVEL CONTROLS Inspect float type water level controls for proper operation Visually inspect sight glasses for evidence of scale forming residues Refer to section 3 8 for gauge glass maintenance On closed steam heating systems the float low water cutoff should be blown down by means of opening a lowdown valve on the lower connection of the cutoff once
28. undle as spare parts and also eliminates the necessity of returning the element bundle to the manufacturer for repair although this service is available 1 6 2 BOILER COMPONENTS GENERAL The boiler equipment list in this manual lists the components supplied with this boiler A description of the major components follows however detailed information can be found in each manufacturers literature data 1 6 3 POWER PANEL WIRING These circuits are broken down into branch circuits of no more than 50 amps per circuit A distribution lug in the BE Series and a copper bus bar in the BH Series is used to branch the power to individual fuses and contactors in each branch circuit Each leg in each circuit is individually fused with fast acting fuses to interrupt power if required The contactors are then wired using high temperature wire to each element circuit and bundle located in the element flange discussed earlier 1 6 4 CONTROL CIRCUIT WIRING The control circuit voltage is 120 V single phase and fed from a step down transformer if provided The transformer s primary side is connected to two fuses located in the power panel One side of the secondary is grounded and the other side feeds the control circuit through the control circuit fuse All of the safety controls are wired in series so that any one of the safety controls will shut down the boiler if the limit is reached Also located in the control circuit is a recycle relay in
29. ut down or storage But it is practical only if boiler can be drained hot 120 F to 170 F or if external drying can be provided 3 9 7 WET LAY UP OF STEAM BOILERS SHORT TERM In the wet lay up procedure the boiler is to be filled with chemically treated water and sealed to prevent air in leakage Nitrogen gas under slight pressure can also be used to displace air and protect the boiler surfaces from corrosion The following steps should be taken for wet lay up of a boiler la Procedure for Operational Boiler At least thirty minutes before the boiler comes off line add the following chemicals Sodium Sulfite 0 5 lbs Per 100 gallons water Polymeric Sludge Dispersant 0 1 Ibs Per 100 gallons water amp Caustic Soda 0 3 Ibs Per 100 gallons water 1b Procedure for Idle Boiler If the boiler has never been on line or has been out of service for cleaning select the highest quality water available to fill the boiler Steam condensate softened water filtered fresh water and boiler feedwater are generally acceptable for lay up Raw city water is not recommended and should not be used Prepare the chemical solution described in 1a in a separate tank Adhere to the safety precautions described in Section 3 2 of this manual Add the concentrated lay up solution to the boiler during the time it is being filled After the boiler is filled and the lay up solution has been added the boiler is to be operated for t
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