boilersmith ltd. p.o. box 70, 156 main st. … af2 af3 cf3... · fire protection apparatus and fire...

BOILERSMITH LTD. P.O. BOX 70, 156 MAIN ST. SOUTH SEAFORTH, ONTARIO CANADA

N0K 1W0

MANUAL OF

PARTS LIST

ASSEMBLY INSTRUCTIONS

INSTALLATION & SERVICE INSTRUCTIONS

OPERATING INSTRUCTIONS

AND

INDIVIDUAL COMPONENT MANUFACTURERS' INSTRUCTIONS

FOR

AF2 AND AF3 ALLSTAR SERIES

AND

CF3 COMPAK SERIES

PACKAGED FIREBOX BOILERS

GAS FIRED - OIL FIRED - GAS/OIL FIRED

These instructions have been reviewed by Underwriters' Laboratories of Canada (ULC) and found suitable for use in the installation of ULC labelled AF2, AF3 and CF3 boiler assemblies.

DEALER'S NAME : ___________________________________________________ ADDRESS : ___________________________________________________ : TELEPHONE NUMBER : ___________________________________________________ DATE OF INSTALLATION : ___________________________________________________

READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE

TABLE OF CONTENTS SECTION ONE : NAMEPLATE FACSIMILE, COMBUSTION TEST REPORT AND TRIM LIST SECTION TWO : ASSEMBLY INSTRUCTIONS SECTION THREE : INSTALLATION INSTRUCTIONS SECTION FOUR : OPERATING INSTRUCTIONS - GENERAL SECTION FIVE : OPERATING INSTRUCTIONS - STEAM BOILERS SECTION SIX : OPERATING INSTRUCTIONS - WATER BOILERS SECTION SEVEN : BURNER MANUAL SECTION EIGHT : MAINTENANCE AND REPAIR - GENERAL SECTION NINE : MAINTENANCE AND REPAIR - STEAM BOILERS SECTION TEN : MAINTENANCE AND REPAIR - WATER BOILERS SECTION ELEVEN : WATER TREATMENT SECTION TWELVE : WARRANTY/TERMS AND CONDITIONS OF SALE SECTION THIRTEEN : INDIVIDUAL COMPONENT MANUFACTURERS' INSTRUCTIONS SECTION FOURTEEN : DIMENSIONAL ARRANGEMENT AND/OR BULLETIN APPENDIX 'A' : COMBUSTION AND FRESH AIR VENTING REQUIREMENTS APPENDIX 'B' : STACKS AND BREECHING APPENDIX 'C' : LIGHT OIL PIPING INFORMATION APPENDIX 'D' : 12 WAYS TO AVOID BOILER TUBE CORROSION APPENDIX 'E' : SAFER MAINTENANCE OF STEEL HEATING BOILERS APPENDIX 'F' : TREATMENT & CONTROL OF FEED & BOILER FEED WATER APPENDIX 'G' : BLOW DOWN - STEAM BOILERS BIBLIOGRAPHY

Section Two Page 1

ASSEMBLY INSTRUCTIONS

Boilersmith AF2, AF3 or CF3 packaged firebox boilers come shipped fully assembled and pre-wired. However, certain shipping restrictions may require minimum assembly. The unit, under this circumstance, will be pre-trimmed and pre-wired as usual. Check the unit upon arrival: If the unit is damaged, make a claim to the carrier. A) Check specifications of electrical service to make sure that they correspond with the markings of the

electrical characteristics stamped on the unit nameplate. B) Check total ampere rating of the blower motor, control system, remote oil pump set motor and/or any

other circuits to make sure that the electrical service is adequate. C) Check the pressure of the distribution system (maximum 15 psig for steam boilers and maximum 30

psig for water boilers) with the operating pressure of the packaged boiler to make sure they correspond.

D) Investigate available natural gas pressure, if boiler is gas fired or gas/oil fired, and compare against the boiler nameplate.

E) Investigate for available fuel oil type (No. 1 or No. 2 oil) if boiler is oil fired or gas/oil fired. The successful operation of a Boilersmith AF2, AF3 or CF3 packaged firebox boiler is dependent upon proper installation. PLEASE READ these instructions carefully prior to starting installation.

Section Three Page 1

INSTALLATION INSTRUCTIONS

AF2, AF3 AND CF3 SERIES PACKAGED FIREBOX BOILERS The installer and owner are directed to the individual component manufacturers' instructions in Section Fourteen of this manual. The installer and owner are also directed to Section Seven: Burner Manual, as provided by the burner manufacturer.

THE INSTALLATION OF THE UNIT SHALL BE IN ACCORDANCE WITH THE CURRENT INSTALLATION CODE FOR GAS AND OIL BURNING APPLIANCES AND EQUIPMENT AND

APPLICABLE PROVINCIAL REGULATIONS FOR THE CLASS; WHICH SHOULD BE CAREFULLY FOLLOWED IN ALL CASES. AUTHORITIES HAVING JURISDICTION

SHOULD BE CONSULTED BEFORE INSTALLATIONS ARE MADE. A) PLACEMENT OF THE BOILER

1. These models must be installed on a non-combustible floor. Allow a minimum 18" clearance from the boiler sides and rear flue gas box and 24" from the burner (more if required for tube removal).

2. Refer to Section Fifteen: DIMENSIONAL ARRANGEMENT AND/OR BULLETIN for Rough Boiler Dimensions. Certified Dimensional Arrangement Drawings are available upon request from the manufacturer.

3. The boiler assembly is to be placed with the tubes level. Levelling of the boiler may be accomplished with the use of shims placed under the channel iron base. The shims shall be placed to equally distribute the weight of the boiler along its length.

B) PROTECTION OF THE UNIT DURING INSTALLATION

If the unit is exposed to the elements, dust, cement mortar, etc., the unit should be covered with a tarpaulin or protected in any manner that will prevent damage to the boiler controls and other components.

If there is a possibility of flooding of the boiler room, it is suggested that necessary steps be taken to install drains or sump pumps.

THE INSTALLER SHALL CLEARLY IDENTIFY ANY AND ALL EMERGENCY SHUT-OFF DEVICES, INCLUDING BUT NOT LIMITED TO ELECTRICAL SWITCHES AND MANUAL

GAS VALVES. C) LOCATION

Consideration must be given to proper location, when installing the boiler. Location should be as close to the stack or chimney as practicable, and as centralized to the piping system as possible. The boiler should be located in an area where leakage will not result in damage to the area adjacent to


the boiler or to the lower floors of the structure. When such locations cannot be avoided, a suitable drain pan should be installed under the boiler Such a pan should be at least two inches deep, have minimum length and width of at least two inches greater than the dimensions of the boiler and should be piped to an adequate drain. If a boiler is installed where down drafts may occur at freezing temperatures, precautions should be taken to prevent freezing during boiler shutdown.

NOTE: DAMAGE DUE TO FREEZING IS NOT COVERED BY THE WARRANTY.

D) CHIMNEY

The stack and breeching shall be installed in conformance with national, regional and local codes and standards and/or appropriate legislation. See appendix "B".

E) VENTILATION

1. The boiler room must have an adequate air supply to permit clean, safe combustion and to minimize soot formation. An unobstructed air opening should be provided.

FRESH AIR AND COMBUSTION AIR INLET VENTS SHALL BE INSTALLED IN

CONFORMANCE WITH NATIONAL, REGIONAL AND LOCAL CODES AND STANDARDS AND/OR APPROPRIATE LEGISLATION.

2. Exhaust fans are not recommended, as they compete for combustion air and may cause reverse

draft conditions in flues or chimneys. 3. Air Supply fans may be used to supply combustion air or cooling air for summertime operation

of the boiler plant.

THE BOILER ROOM AIR SUPPLY OPENINGS MUST BE KEPT CLEAR AT ALL TIMES.

Where air supply fans are used, the free area for air supply should be in addition to the minimum required free area for proper ventilation. See appendix "A".

F) CHEMICAL VAPOUR CORROSION

Boiler corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapours. Typical compounds which are potentially corrosive include spray can propellants, cleaning solvents, refrigerator and air conditioner refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes and process chemicals. These materials are corrosive at very low concentration levels with little or no odour to reveal their presence.

G) LIGHTING

The boiler room should be well lighted and it should have an emergency light source for use in case of power failure. If a flashlight is used for this purpose, it should be maintained in usable condition and it should be protected against removal from the boiler room.


H) WATER AND DRAIN CONNECTIONS

1. WATER CONNECTIONS: Proper and convenient water fill connections should be installed and provisions should be made to prevent boiler water from back feeding into the service water supply. Provisions should also be made in every boiler room for a convenient water supply which can be used to flush out the boiler and clean the boiler room floor.

2. DRAIN CONNECTIONS: Proper and convenient drain connections should be provided for

draining boilers. Unobstructed floor drains, properly located, will aid cleaning of the boiler room. Floor drains which are used infrequently should have water poured into them periodically to prevent the entrance of sewer gases and odours.

I) FIRE PROTECTION

Fire protection apparatus and fire prevention procedures for boiler room areas should conform to national, regional and local codes and standards and/or appropriate legislation.

J) PIPING - STEAM BOILERS

1. BOILER CONNECTIONS SUPPLIED: Refer to Section Fifteen: DIMENSIONAL ARRANGEMENT AND/OR BULLETIN for connections and their locations supplied as standard equipment on your AF2, AF3 or CF3 Series firebox boiler.

2. FEEDWATER:

All available condensate should be returned to the boiler feed system whenever possible to obtain peak operating efficiencies. Condensate lost by discharge to the sewer is wasteful of heat and fuel. Such waste increases the requirement for make-up water and adds to the problem of feedwater treatment. Water should be returned to the boiler at a minimum of 150oF. Refer to Section Eleven: Water Treatment.

a. Feedwater Piping

Piping should be Schedule 40 black steel pipe. Fittings should be minimum 150 psi black malleable. Water lines should be adequately supported to eliminate vibration and mechanical injury. Pipes running through walls should be encased in a sleeve.

b. Boiler Feed Pumps Where boiler feed pumps are used, AF2, AF3 and CF3 Series firebox boilers are supplied standard with a combination low-water cutoff and pump control and a baffled steam return connection at the rear of the boiler. The connection size is a guide only to feedwater piping size. Careful consideration must be given to proper feedwater piping size. This connection eliminates the requirement of a Hartford Loop. A feed shutoff valve should be installed on the feed water line, between the boiler and pump, close to the boiler followed by at least one feed check valve and/or solenoid valve. Solenoid valves are generally used when more than one boiler is being fed by one pump.


Solenoid valves require a bypass back to the boiler feed tank. Contact a competent pump technician or engineer for proper sizing, pump selection and system design. A throttling valve with pressure gauge and gauge cock is recommended when certain pump types are utilized. Consult the pump manufacturer and/or pump supplier. NOTE: It is good practice to install a separate water line which bypasses the feed water pumps for fast filling of the boiler initially. Using boiler feed pumps to return water in conjunction with a pump control device on the boiler is considered the preferred method for boiler water level control. Other methods, as described later in this section, can under certain operating conditions, lead to flooding of the boiler.

c. Water Feeders

Numerous boiler installations use a combination feeder cut-off device such as a McDonnell & Miller 51-2 for controlling water level in a steam boiler. AF2, AF3 and CF3 Series firebox boilers are available with this device as optional. Under certain operating conditions, such as a cold start when condensate has not yet had time to return to the boiler or feedwater tank, the water feeder may flood the boiler. It is not uncommon to install a water feeder as well as a pump controller to provide the system with an extra degree of safety protection. In the event the boiler feed pump is rendered inoperative and it is absolutely essential that the boiler be kept in operation, the mechanical boiler water feeder will maintain a water level which will allow the boiler to function, until the condition can be corrected.

3. BLOWDOWN:

The purpose of boiler blowdown is to regulate the amount of total solids, dissolved and suspended, contained in the boiler water. Added feedwater carries dissolved solids that are left behind in the boiler as it is evaporated. Chemicals also add to the solids concentration. Since evaporation is continuous, the accumulation is also continuous. Blowing off to waste a part of the concentrated water and replacing it with feedwater is the only way the total solids concentration can be held in check. AF2, AF3 and CF3 firebox boilers are supplied with a surface blowoff and bottom blowdown/drain connection.

a. Intermittent Blowdown

The bottom blowdown connection is used for this purpose. Blowdown piping must conform to the ASME Boiler Code. The Code requires the use of Schedule 40 black pipe for low pressure boilers. Valves and fittings must be rated at 125 PSI minimum. It is recommended that 250 lb. iron fittings be used. No valves should be placed in the line between the boiler blowdown valves and the blowoff tank. All elbows should be of the long radius type. Blowdown valves can be a conventional gate valve or a specifically designed 'Y' pattern valve. Conventional globe valves cannot be used. Where more than one boiler connects to a blowdown header, the connection should be


made through 45 degree lateral fittings. Check the local jurisdictional requirements regarding the discharge of boiler blowdown into the sewer. Some municipalities prohibit blowdown into the sewers. A blowoff tank between the blowdown line and the sewer allows the blowdown to cool and lose pressure before entering the sewer. (See Boilersmith Limited Bulletin No. 119-84 on blowdown tanks) The size of the header may be the size of the largestboiler blowdown since only one boiler will be blown down at atime. The header should slope toward the blowdown tank toprevent the deposit of sludge in the line. Because the line between the blowdown valve and the tank expands rapidly on blowing off the boiler, the piping should be arranged to afford sufficient flexibility and anchored to prevent undue stress on the boiler and tank connections.

The blowoff tank must be equipped with an unobstructed and direct vent to the atmosphere. It must be twice the blowdown header pipe size and it should terminate 8 to 10 feet above the nearest window or normally accessible area. Standard black pipe is suitable. The discharge line should be installed with no valves and should pitch toward the sewer or drain. It must be twice the size of the blowdown header. A syphon breaker should be installed equal in size to the blowdown header in the tank discharge line at its highest point to prevent the tank form draining completely.

b. Continuous Blowdown

Refer to Section Fifteen: DIMENSIONAL ARRANGEMENT AND/OR BULLETIN for location and size of the surface drawoff connection. Continuous blowdown allows dissolved and suspended solids to be removed continuously near the water surface. Schedule 80 pipe and 250 lb. fittings should be used. A micrometer type flow control valve is occasionally used to give a more precise control. Automatic surface blowdown is also available. Briefly, in this situation, blowdown occurs as a function of feed water volume. A separate control monitors the volume of feedwater and then opens a solenoid valve for a predetermined time. Consult your chemical consultant for information on automatic blowdown versus continuous blowdown information.

4. SAFETY VALVE DISCHARGE PIPING:

AF2, AF3 and CF3 Series firebox boilers have been supplied with ASME safety valves. Safety valves must be connected to the boiler independent of any other steam connection without any unnecessary pipe or fittings between the valve(s) and the boiler. Any such intervening pipe or fittings cannot be longer than the face-to-face dimension of the


corresponding tee fitting of the same diameter. All safety valves must be connected in the upright position. No other valve may be placed between the boiler and safety valve. Safety valve outlets must be located or piped so that the discharge is carried clear of any normal access area. When a discharge pipe is used, the cross-sectional area of the pipe must be at least equal to the area of the safety valve outlet. Where two or more valves discharge into a common pipe, the cross-sectional area of the pipe must be at least equal to the combined cross-sectional area of the valves. No other valve may be placed between the safety valve and the atmosphere. The discharge pipe may be Schedule 40 steel with 125# iron fittings or Schedule 40 butt weld steel fittings.

5. STEAM SUPPLY PIPING:

All steam piping must be suitably anchored to prevent undue strains on equipment and boiler connections. Flexibility in the form of pipe bends or changes in the direction the piping should be given early consideration during system design. Adequately support all piping and equipment to prevent excessive vibration. All steam lines should be insulated to conserve energy. Steam lines passing through a wall or floor should pass through a sleeve of sufficient diameter to allow free movement. The requirements of the latest revision of the ASME Boiler Code for low pressure boilers should be followed. A steam stop valve is not a requirement on the boiler lead. However, on multiple boilers it is good practice to install a stop valve on each boiler. When a valve is installed on the boiler lead, a stop valve must also be located in the return line at each boiler. Both the valves must be of the outside-screw-and-yoke, rising stem design. A Hartford Loop is not required on AF2, AF3 and CF3 Series firebox boilers. It is advisable to run the vertical riser from the boiler outlet nozzle to the horizontal run of the boiler lead the full size of the outlet. The remainder of the boiler lead and steam lines should be sized according to actual steam flow. NOTE: Obtain competent assistance for the design of the steam system. To ensure drainage, mains and branches should have a pitch of 1 inch in 20 feet. Where condensate flows against the steam flow, the pitch should be 1 inch in 10 feet. Provision must be made to accommodate the thermal expansion of the piping.

K) PIPING - WATER BOILERS

NOTE: Consult a competent hydraulic system technologist or design engineer for proper system design and pump and piping selection.

Listed below are some suggested piping practices for closed systems.

1. BOILER CONNECTIONS: Refer to Section Fifteen: DIMENSIONAL ARRANGEMENT

AND/OR BULLETIN for connections and their locations supplied as standard equipment on


your AF2, AF3 and CF3 Series firebox boiler.

2. BOILER ROOM PIPING PRACTICE a. Closed System Design

Open systems are piping circuits, pumped or gravity circulated, that are open to the atmosphere at some point.

Closed systems are designed and installed as hermetically sealed systems and offer several advantages. i. little, if any make-up water is ever required. ii. with little make-up water, there can be little accumulation of oxygen and other

corrosive agents. System life is extended. iii. closed systems can be pressurized, allowing elevated water temperatures and

greater temperature drops. Piping and operating costs can be reduced. iv. closed systems with positive air control offer improved control, faster temperature

response and quieter system operation.

NOTE: Closed systems require that all components must be pressure tight and leak proof. Special considerations should be given to pump seals, manual air vents and tight installation.

b. Circulating Pumps

Pumps should discharge into the piping system with the compression (expansion) tank located at the pump suction. The wrong pump location will decrease system static pressure by an amount equal to the operating pump head. System circulation and mechanical pump problems may occur. The properly located pump increases system static pressure during operation and eliminates potential trouble.

c. Pump Selection

Pumps should be selected to approximate curve mid point, using flat curved pumps to better allow for high and low peak heads. System distribution pumps should be selected for system needs. The large multi-circuited hydronic system needs a pump selection that will help overcome circuit distribution problems.

NOTE: Mechanical Seals are required for all closed system circulating pumps.

d. Piping Size at Pump Suction and Discharge

Pipe size at the pump suction and discharge should conform to distribution main size; not to suction and discharge pump opening size.

e. Multiple Pump Check Valves Check valves (conventional, triple duty or flow control) should be installed at each pump discharge when more than one pump is used in the boiler room. Trouble will develop when check valves are not installed because of reversed flow through non-operating pumps. When these pumps are started, they must overcome a heavy flow inertial load and will overload.

f. Pump Piping Support


Piping for pumps should be supported. The pump should not serve as a piping anchor.

g. Manual Air Vents Manual air vents should be used where initial venting of high points is necessary to fill the system with water. Automatic air vents, if allowed to operate automatically after the system is placed in operation, are a potential source of system leakage.

h. Piping

Schedule 40 black pipe and minimum 125 lb. fittings and valves are suitable for use in a 30 psig water designed system. Proper installation techniques with adequate allowance for pipe expansion and contraction are necessary to ensure your system remains closed or sealed.

i. Compression Tank and Air Control

Water expands when heated and contracts when cooled. Since water is incompressible, a lack of expansion space on heating means that any volume increase will cause an immediate and definite pressure increase. The most practical and economical method to accommodate this volume is to use an air cushion compression tank. The compression tank, also establishes a base for determining pressures throughout the piping system as a result of pump operation.

i. Tank Selection

Consult a competent technician or engineer for proper tank selection for installation. Tanks should be selected with as few openings as possible, and any connections above the water line should not be used. ASME code tanks, only, should be used.

ii. Air Control

Should the boiler not be made available or usable as a point of air separation, another low velocity area must be provided in the system as the air separating point. Standard in line air separators are available from various manufacturers. Air cushion tanks may also be used to trap air from the system. A 3/4" pipe size is the smallest diameter pipe that should be used for this purpose to allow simultaneous exchange of air and water. Special compression tank fittings are also available to prevent gravity circulation of hot water between the compression tank and the system thus resulting in lower compression tank temperature and size.

j. Water Fill Requirements

The most commonly used device is a small pressure reducing valve and operates when the system pressure falls below the valve setting. On a properly designed system, where efficient air control is used, the pressure reducing valve operates to keep the system full of water despite small leaks.


CAUTION: LEAKS CAN CAUSE DAMAGE.

REPAIR LEAKS IMMEDIATELY.

Low water feeders are sometimes required (check local jurisdictional requirements). However, they only fill when the water level reaches the point where installed. Water feeders are sometimes used in conjunction with a pressure reducing valve.

A water meter installed in the water feed line might be used to indicate excessive water fill and the possible presence of a system leak.

Fill connections should be made directly into the expansion tank, as this is the point of no pressure change in the system. Also, any free air entering the system on filling can enter directly into the expansion tank.

k. Boiler Piping

i. Boiler Return(s) System return piping should be sized to meet system requirements. On AF3 and CF3 Series firebox boilers supplied with two return connections, it is recommended that both returns be used with the return flow split as equal as possible. It is good piping practice to install return valves.

ii. Boiler Supply

System supply piping should be run full size, to match the boiler connection, to the main distribution header. A full size shut-off valve should be installed.

iii. Piping - Relief Valve

AF2, AF3 and CF3 Series firebox boilers have been supplied with ASME relief valves. Relief valves must be connected to the boiler independent of any other water connection without any unnecessary pipe or fittings between the valve(s) and the boiler. Any such intervening pipe for fittings cannot be longer than the fact-to-face dimension of the corresponding tee fitting of the same diameter. All relief valves must be connected in the upright position. No other valve may be placed between the boiler and relief valve. Relief valve outlets must be located or piped that the discharge is carried clear of any normal access area. When a discharge pipe is used, the cross-sectional area of the pipe must be at least equal to the area of the relief valve outlet. Where two or more valves discharge into a common pipe, the cross-sectional area of the pipe must be at least equal to the combined cross-sectional area of the valves. No other valve may be placed between the relief valve and the atmosphere. The discharge pipe may be Schedule 40 steel with 125# iron fittings or Schedule 40 butt weld steel fittings.

L) GAS LINE PIPING

Piping shall be in accordance current installation codes for gas burning appliances and equipment. Authorities having jurisdiction should be consulted before installations are made.


THE INSTALLER SHALL CLEARLY IDENTIFY ANY AND ALL EMERGENCY SHUT-OFF DEVICES, INCLUDING BUT NOT LIMITED TO ELECTRICAL SWITCHES AND MANUAL

GAS VALVES. M) OIL LINE PIPING

See Appendix "C"

Section Four Page 1

OPERATING INSTRUCTIONS - GENERAL

The owner is directed to Section One: (Trim List) and the manufacturers' specification sheets included in Section Fourteen of this manual.

READ AND SAVE THESE INSTRUCTIONS FOR REFERENCE. A) This manual covers the AF2, AF3 and CF3 Series packaged firebox boilers for either 15 PSIG steam

or 30 PSIG water design. Burners will be either natural gas, No. 1 or 2 oil or natural gas/No. 1 or 2 oil.

B) Burner starting procedures are described in Section Seven: Burner Manual. DO NOT RELIGHT PILOT OR START BURNER WITH THE COMBUSTION CHAMBER FULL

OF GAS OR OIL VAPOURS, OR WITH A VERY HOT COMBUSTION CHAMBER. DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE.

CONSULT A COMPETENT BURNER SERVICEMAN/TECHNICIAN TO START THE BURNER.

C) When shutting down the burner/boiler, cut power to the burner at its shutoff switch. Only after the

heat exchanger has cooled right down, can the power be shut off to the boiler feed pumps in the case of steam boilers or the circulators in the case of water boilers.

ALWAYS KEEP THE FUEL MAIN SUPPLY VALVE SHUT OFF IF THE BURNER IS SHUT

DOWN FOR AN EXTENDED PERIOD OF TIME. D) INSPECTION OF NEW BOILERS

1. Inspection for Acceptance: Before any new boiler is accepted for operation, a final inspection should be completed and all items of exception corrected. In addition to determining that all equipment called for is supplied and installed in accordance with the plans and specifications, all controls should be tested by a competent person familiar with the control system.

2. Inspection for Operating Integrity: A boiler put into operation for the first time should be

inspected by an authorized boiler inspector as required by law. If such an inspection is not required or not available, then the boiler should be inspected by a reputable insurance company inspector. It is also recommended that a subsequent inspections be made by an authorized inspector at intervals required by law or as recommended by the boiler insurance company.

E) SAFETY

Safety is very important to boiler operation and it should be foremost in the minds of the persons responsible for operation and maintenance of heating systems. Only properly qualified, trained persons should operate or maintain this equipment. Adequate supervision should be provided.

Section Four Page 2

THE INSTALLER SHALL CLEARLY IDENTIFY THE EMERGENCY SHUT-OFF DEVICE. F) BOILER ROOM CLEANLINESS

Usually, a neat boiler room indicates a well run plant. Materials and equipment not necessary to the operation of maintenance of the heating system should not be stored in the boiler room.

G) POSTING OF CERTIFICATES AND/OR LICENSES

Some states and municipalities require licensing or certificates of personnel who operate or maintain heating equipment. Also, some authorities require the posting of inspection certificates in the boiler room. The supervisor in charge should ensure that such requirements are being met.

H) RECORD KEEPING LOGS, ETC.

1. MANUAL, DRAWINGS, DIAGRAMS, INSTRUCTION BOOKS ETC: A copy of this manual should be kept in the boiler room or other suitable location at all times along with all drawings, wiring diagrams, dimensional arrangements, descriptive literature and spare parts lists.

Other material should be assembled and enclosed in a suitable binder. When changes or additions are made, the data and drawings should be revised accordingly.

2. LOG BOOK AND MAINTENANCE SCHEDULE: A permanent log book and maintenance

schedule should be provided in each boiler room to record maintenance work, inspections, test results and other pertinent data.

Section Five Page 1

OPERATION INSTRUCTIONS - STEAM A) STANDARD EQUIPMENT

1. Basic Boiler - AF2, AF3 and CF3 Series Firebox Boiler 2. ASME Safety Valve(s) - set at 15 PSIG 3. MM 157 LWCO & Pump Control c/w 1" NPT Blowdown Valve 4. Safgard Manual Reset Aux. LWCO 5. Manual Reset High Limit Pressuretrol 6. Operating Pressuretrol 7. High fire or Modulating Pressuretrol (on sizes 30 BHP and over) 8. Pressure gauge 9. Gauge Cock 10. Control line valve 11. 3 Trycocks 12. Waterglass set 13. Burner

For non-standard items supplied please consult Section One, (TRIM LIST). Specific information on non-standard equipment supplied is included in Section Fourteen of this manual.

Refer also to Section Fourteen of this manual for manufacturers information on standard items listed above. Consult Section Seven: Burner Manual for information on the burner supplied with this unit.

B) STARTING A NEW BOILER AND HEATING SYSTEM

NOTE: SPECIALISTS IN BOILER FEED CHEMICALS SHOULD BE CONSULTED TO GUARANTEE THAT YOUR BOILER RECEIVES THE BEST POSSIBLE TREATMENT.

1. Cleaning and filling a new boiler:

a. An inspection should be made to insure that no foreign objects such as tools, equipment, rags, etc. are left in the boiler.

b. Make certain that the firing equipment is working properly to the extent that this is possible without actually lighting a fire in the empty boiler before filling the boiler. Raw water must be boiled (or heated at least to 180o F) promptly after filling the boiler to drive off dissolved gases which might otherwise corrode the boiler.

c. Fill the boiler to the proper water line and operate the boiler with steam in the entire system for a few days to bring oil and dirt back to the boiler. If the condensate is to be wasted to the sewer this is not necessary, in which case the boiler will be operated until the condensate runs clear.

d. Oils and greases which accumulate in a new boiler can usually be washed out by boiling as described below: i. Fill the boiler to the normal water line. ii. Remove one of the plugs from the top of the boiler. If all connections are in use, a

safety valve may be removed, in which case the valve must be handled with extreme care to avoid damage.

iii. Run a temporary line to a drain. iv. A boilout compound may be made by using caustic soda and trisodium phosphate

in the proportions of one pound of each chemical per fifty (50) U.S. gallons of

Section Five Page 2

water.

CAUTION: CARE MUST BE USED WHEN HANDLING THESE CHEMICALS. CAUSTIC SODA IS HARMFUL TO SKIN, CLOTHING AND EYES. THE DRY CHEMICAL OR THE CONCENTRATED SOLUTION SHOULD NOT BE PERMITTED TO COME IN CONTACT

WITH SKIN OR CLOTHING.

v. Replace the plug, or the safety valve. vi. Review the operating instructions that follow and Section Seven: Burner Manual

for boiler and burner start-up procedures. Then, start the firing equipment and check operating, limit and safety controls.

vii. Turn off the firing equipment. viii. The boiler should be drained in a manner and to a location that hot water can be

discharged safely. ix. Wash the boiler thoroughly, using high pressure water. The handhole located

above the burner end flue gas box (opposite end on AF2 series) or on top of the shell (on certain, 'water only' AF3 models) should be removed to facilitate cleaning of the waterside of the boiler. Larger CF3 models are also equipped with a manhole on the top of the shell. Other handhole plates and/or the brass cleanout/inspection openings should also be removed to insure a thorough cleaning and flush out of the boiler.

x. Replace all plugs, handhole and manhole plates in the boiler. It may be necessary to replace the rubber gaskets used on the manhole and handhole cover plates. Then, fill the boiler to the normal water line.

xi. Remove temporary piping if second boilout is not required. xii. Water treatment compound should now be added as needed. Section Eleven: Water

Treatment should be reviewed. xiii. Boil the water or heat it to 180oF immediately to aid in removal of dissolved gases. xiv. The boiler is now ready to be put into service or on standby.

2. Second Boilout

The above boilout procedures may not remove all the oil and grease, and another boilout may become necessary. Proceed as follows: a. The boiler should be prepared for cleaning by running a temporary pipe line from the

surface blowoff connection (Section Fifteen: DIMENSIONAL ARRANGEMENT AND/OR BULLETIN) to an open drain or some other location where hot water may be discharged safely. Do not install a valve or any other obstruction in this line.

b. Fill the boiler until water reaches the top of the water gauge glass. c. Add caustic soda and trisodium phosphate in the proportions of one (1) pound of each

chemical per fifty (50) U.S. gallons of boiler water.

CAUTION: CARE MUST BE USED WHEN HANDLING THESE CHEMICALS. CAUSTIC SODA IS HARMFUL TO SKIN, CLOTHING AND EYES. THE DRY CHEMICAL OR THE CONCENTRATED SOLUTION SHOULD NOT BE PERMITTED TO COME IN CONTACT

WITH SKIN OR CLOTHING.

d. Mix the chemicals with water and pour into the boiler.

Section Five Page 3

e. The firing equipment should be started and operated sufficiently to boil the water without producing steam pressure.

f. Boil for about five (5) hours. g. Open the boiler feed pipe, as mentioned in (a) above, sufficiently to allow a steady trickle

of water to flow. h. The slow boiling should be continued for several hours or until the water coming from

the surface blowoff piping is running clear. i. Stop the firing equipment. j. Drain the boiler in a manner and to location that hot water may be discharged safely. k. Remove all covers and plugs from all inspection and cleanout openings and flush the

boiler thoroughly using a high pressure water hose. l. Refill the boiler to the Normal Water Line. If water in the water gauge glass does not

appear to be clear, repeat steps (b) to (l). m. Remove the temporary piping. n. Water treatment compound should now be added as needed. Section Eleven: Water

Treatment should be reviewed. NOTE: Specialist in boiler feed chemicals should be consulted to guarantee that you boiler receives

the best possible treatment.

o. Close the boiler. p. Boil the water or heat it to 180oF immediately to aid in removal of dissolved gases q. The boiler is now ready to be put into service or on standby.

C) STARTING A BOILER AFTER LAYUP

(Single boiler installation) 1. Refer to Section Seven: Burner Manual and the operating instructions that follow for burner

and boiler start-up procedures. 2. Set control switch in the 'OFF' Position. (Located on panel attached to burner). 3. Check to make sure that fresh air to the boiler room is unobstructed. 4. Check fuel availability. 5. Check the water level in gauge glass. Make sure the gauge glass valves are open. 6. Use the trycocks, if provided, to double-check the water level. 7. Vent the combustion chamber to remove unburned gases. 8. Clean the rear peepsite glass. 9. Set the main steam shutoff valve to open position. 10. Open the cold water supply valve to the water feeder, if provided. Open the suction and

discharge valves on vacuum or condensate pumps and set electrical switches for desired operation. Vent boiler to remove air when necessary.

11. Check the operating pressure of the boiler. See Section Five (G) 2. Steaming Pressure below and the manufacturers' specification sheets in Section Fourteen of this manual for proper settings and how to adjust the pressuretrols.

12. Check the manual reset, if provided, on the low water fuel cutoff and high limit pressuretrol to determine if they are properly set. Refer to SECTION ONE: TRIM LIST.

13. Set the manual fuel oil supply or manual gas valve in the open position. 14. Place the circuit breaker or fused disconnect switch on the 'ON' position

Section Five Page 4

15. Follow the Burner Manufacturer's guidelines included in the Burner Manual in Section Seven and the Flame Safeguard Control manufacturer's guidelines in Section Fourteen for proper start-up procedures for the burner. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH.

16. Place the boiler control starting switch in the 'ON' or 'START' position. (Do not stand in front of furnace access doors, breeching or flue cleaning doors. This is a precautionary measure should a combustion explosion occur).

17. Bring pressure and temperature up slowly. Stand by the boiler until it reaches the established cut-out point (see Section Five, (G) 2. Steam Pressure below and the manufacturers' specification sheets in Section Fourteen of the manual for proper settings and how to adjust pressuretrols).

18. Walk around the boiler frequently during the pressure buildup period to ensure that all associated equipment and piping is functioning properly.

19. Immediately after the burner shuts off, inspect the watercolumn and open each trycock individually to determine the true water level.

20. If a log book is used, enter: a. Date and time of startup. b. Any irregularities observed and corrective measures taken. c. Time when controls shut off burner at established pressure, tests preformed, etc. d. Operators signature.

21. Check safety valve for simmering or weeping. Perform a try lever test. See Section Five, (H)1.(a) Try Lever Test.

D) ABNORMAL CONDITIONS DURING STARTING

If any abnormal conditions occur during light-off or pressure buildup, immediately open the emergency switch. (Do not attempt to restart until difficulties have been identified and corrected.

E) CONDENSATION

Condensation (sweating) may occur in a gas fired boiler following a cold start. It may be severe enough that it appears that the boiler is leaking. This condensation should stop after the boiler is hot.

F) PLACING A BOILER ON LINE WITH ADDITIONAL BOILERS

1. Start the boiler using procedure (C) above but the supply shutoff valve and return stop valve should be closed.

2. If a drain valve is supplied between the supply stop valve and steam supply outlet, open it. 3. When the pressure within the boiler is approximately the same as the pressure in the steam

main, open the supply stop valve very slightly. If no unusual disturbances, such as noise, vibration, etc. occur, continue to open the supply stop valve slowly, until it is fully open. Open the valve in the return line.

CAUTION: WHEN THE STOP VALVE AT THE BOILER OUTLET IS CLOSED, THE STOP

VALVE IN THE RETURN LINE OF THAT BOILER SHOULD ALSO BE CLOSED. G) OPERATION

Section Five Page 5

1. Water Level a. For specific information on water level control devices and low-water cutoffs supplied

with your boiler, refer to Section One: TRIM LIST at the front of this manual and the manufacturers' specification sheets located in Section Fourteen of this manual.

b. Check the water level of all steaming boilers immediately, whenever going on duty. c. The water gauge should be checked regularly. Frequency will be determined by trial and

error. This check should be made when there is steam pressure on the boiler. i. Close the lower gauge glass valve, then open the drain cock which is on the bottom

of the valve, and blow the glass clear. ii. Close the drain cock and open the lower gauge glass valve. Water should return

immediately to the gauge glass. iii. If water is sluggish, leave the lower gauge glass open and close the upper gauge

glass valve. Then open the drain cock and allow water to flow until it runs clear. iv. Close the drain valve and repeat (a) - (c) above. v. If leaks appear around the water gauge glass or fittings, correct the leaks

immediately. A steam leak may result in a false water level indication and may also damage the fittings.

d. If water disappears from the water gauge glass, blow down water gauge glass to see if the water appears. If it does not appear, then shut the burner off immediately.

DO NOT turn on the water feed line DO NOT open the safety valve. Let the boiler cool until the crown sheet is at hand touch temperature. Then add water to one (1) inch in the gauge glass. DO NOT put the boiler back into service until the condition that caused the low water condition is identified and corrected.

2. Steaming Pressure

a. For specific information on safety valves, operating pressuretrol (control), high pressure

pressuretrol (control) and high fire or modulating pressuretrol (control) refer to Section One: TRIM LIST at the front of the manual and the manufacturers' specification sheets in SECTION FOURTEEN of this manual.

b. Replace safety valve(s) with ASME rated valves only set at 15 psig steam maximum. c. The maximum recommended operating pressure in accordance with An American

National Standard ANSI/NB-23 and the ASME Boiler and Pressure Vessel Code, Section VI (current edition) is 10 PSIG.

Should this be somewhat restrictive in some applications, the boiler operating pressure may be adjusted to 15 psi minus the blowdown pressure of the safety valve. To determine this maximum operating pressure increase the steam pressure in the boiler until the safety valve pops, then slowly reduce the pressure until the safety valve closes and seats properly without simmering. This will ensure that the closing pressure is above the operating pressure.

These maximum pressure restrictions are intended to minimize weeping or simmering of safety valves. Weeping or simmering may cause the valve to freeze closed and thereafter the valve could fail to open at the set pressure later on. This could result in a pressure in the boiler that could exceed the rupture pressure of the vessel. Therefore, it is important

Section Five Page 6

that the pressure is sufficiently large to prevent the safety valve from weeping or simmering.

CAUTION: DO NOT block the discharge side of safety valves by means of other types of valves, plugs etc.

DO NOT attempt to alter or tamper with the safety valves as supplied with your boiler.

ONLY use authorized repair organizations to repair safety valves.

3. Blowdown

Where low-pressure steam boilers are used solely for heating and where practically all of the condensate is returned to the boiler, blowdown only as often as concentration of solids require.

Boilers used for process steam requiring high make-up should be blown down as required to maintain desired chemical concentration levels and to remove precipitated sediments.

Boilers which are supplied with slow-opening blowoff valves and quick opening blowoff valves should have the quick opening valves opened first, followed by a gradual opening and closing of the slow opening valve. When the slow-opening valve has been shut tight, then close the quick opening valve.

All AF2, AF3 and CF3 Series firebox boilers are supplied with ball valves on the low-water cutoffs for blowdown purposes of these devices. All steam boilers include a surface drawoff connection, for continuous or manual surface blowdown if desired, and a blowdown/drain connection in the rear head at the bottom.

Refer to Section Eleven: Water Treatment for general information on boiler feed water treatment.

CAUTION: DO NOT OPEN THE SLOW-OPENING BLOWDOWN VALVE FIRST AND PUMP THE LEVER ACTION QUICK OPENING BLOWDOWN VALVE OPEN AND CLOSED AS WATER HAMMER IS APT TO BREAK THE VALVE BODIES OR PIPE FITTINGS.

4. Appearance of Rust

If rust appears in the water gauge glass, this is an indication of corrosion and corrective action must be taken. Check the boiler water for proper chemical concentrations. Also, make sure the boiler is not requiring considerable quantities of make-up water.

Refer to Section Eleven: Water Treatment for general information on boiler feed water treatment.

5. Waterline Fluctuation

Section Five Page 7

Wide fluctuation of the waterline may indicate that the boiler is foaming or priming. One cause is too high a water level in the boiler. A very high rate of steaming may also cause this fluctuation. Foaming may also be caused by dirt or oil in the boiler water. Sometimes, foaming may be cured by blowing the boiler down, draining two (2) or three (3) inches of water and then refilling. This procedure may have to be done several times.

If the problem persists, the boiler may have to be taken out of service, drained and washed out thoroughly as described in Section Five (B) 1 above, Cleaning and Filling a New Boiler, then refill and put back into service.

6. Abnormal Water Losses

When water loss becomes abnormal, as indicated by the requirement of large amounts of makeup water, the situation should be investigated immediately to determine the cause.

Proper repair and/or replacement should commence immediately rather than increase the amount of chemical used.

Excessive, untreated, makeup water may cause scaling. It is also considered corrosive due to its high oxygen content. Cracked furnace plates or tube ligament cracks may result.

If the operator cannot determine the cause of water loss, a competent contractor should be consulted.

7. Make-up Water

All standard AF2, AF3 and CF3 Series firebox boilers are supplied with a combination low water cutoff and pump control. Refer to Section One: TRIM LIST at the front of the manual for a list of items supplied on your boiler. Refer to the manufacturers' specification sheets in Section Fourteen of this manual.

When make-up is required and neither the boiler or the condensate tank is equipped with an automatic water feeder, manually feed water to the boiler.

Use every practical means for excluding oxygen from the boiler water. Since make-up water is one source of oxygen, hold it to a minimum. Returning as hot a water that is possible is one method of reducing oxygen content in water.

If a boiler feed pump is used for returning condensate or adding feedwater, be certain that the air vent at the receiver is working properly.

In systems where large quantities of feedwater are required, deaerating equipment is recommended to remove dissolved gasses, thereby reducing oxygen corrosion.

8. Low-Water Cutoff

All standard AF2, AF3 and CF3 Series firebox boilers are equipped with two (2) low-water cutoffs. Refer to Section One: TRIM LIST at the front of this manual for the specific items

Section Five Page 8

supplied on your boiler and to Section Fourteen at the back of this manual. See Section Three, (J) 3. Blowdown and Section Eleven, (G) Blowdown.

Check the operation of the low-water cutoff(s), pump control and water feeder depending on what may have been supplied on your boiler at regular intervals.

a. Pump Control Operation (if supplied and/or used)

i. Where necessary, provide adequately supported temporary piping from blowdown valve supplied on each float type low-water cutoff or water feeder.

ii. With the burner off, open the low-water cutoff blowdown valve and observe when the boiler feed pump(s) activate. This level, as observed in the water gauge glass, should be approximately 3/4" above the primary low-water cutoff point as indicated by the mark on the casting. The pump should shut off at approximately 1 1/2" above the LWCO point as observed in the water gauge glass.

iii. Repeat (ii) above with the burner on and the boiler steaming under actual operating conditions. This will also confirm the ability of the boiler feed pumps to supply enough water under operating conditions.

iv. If, in (ii) and (iii) above, the pump fails to start or is unable to supply enough water to the boiler to restore the normal waterline, shut power off to the boiler immediately.

Take corrective action to restore pump operation before proceeding with this test or returning the boiler back on line.

b. Primary Low-Water Cutoff & Auxiliary Low-Water Cutoff Test

i. Close all valves in the feedwater lines and shut power off to the boiler feed pumps so the boiler does not receive any replacement water.

ii. With burner on and the boiler steaming at the proper water level, carefully observe the waterline to determine where the cutoff switch stops the burner.

On AF2, AF3 and CF3 Series firebox boilers using a float type primary low-water cutoff, the cutout point is approximately two (2) inches above the cutout point for the auxiliary low-water cutoff or approximately two and one-half (2 1/2) inches above the top of the tubes.

McDonnell & Miller float type low-water cutoffs have a mark on the casting indicating the cutoff point. Refer to Section Fourteen at the back of this manual.

iii. If the primary low-water cutoff fails to shut off the burner, disconnect power to the boiler immediately. Take corrective repair action immediately before proceeding with this test or returning the boiler back on line.

iv. Shut power off to the boiler controls and low-water cutoffs and install test leads on the contacts of the primary low-water cutoff. Restore power to the controls and low-water cutoffs.

v. With the burner again on and the boiler steaming properly with all feedwater valves to the boiler closed and power disconnected still to the boiler feed pumps, continue to observe the water level in the water gauge glass.

The auxiliary low-water cutoff should cut out at approximately one-half (1/2) inch

Section Five Page 9

above the tubes. If the auxiliary low-water cutoff fails to shut off the burner, disconnect power to the boiler immediately. Take corrective repair action before returning the boiler back on line.

vi. Disconnect power to the controls and low-water cutoffs. Remove the test leads installed in (iv) above. Return the boiler back on line.

H) TESTS EXERCISE EXTREME CAUTION AND CARE WHEN PERFORMING THE TESTS AS OUTLINED IN SUBSECTION (H). FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY.

1. Safety Valve Tests

As precautionary measures, all personnel concerned with conducting a pop or capacity test should be briefed on the location of all emergency shutdown controls in the event of an emergency, and there should be at least two people present. Care should be taken to protect those present from escaping steam.

EXERCISE EXTREME CAUTION AND CARE WHEN PERFORMING THE TESTS AS OUTLINED IN SUBSECTION (H). FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY.

CAUTION: Check local jurisdiction requirements as to placement of discharge piping for safety valves.

a. Try Lever Test

Every 30 days that the boiler is in operation or after any period of inactivity a try lever test should be performed as follows: With the boiler under a minimum of 5 psi pressure, lift the try lever on the safety valve to the open position and allow steam to be discharged for 5 to 10 seconds. Release the try lever and allow the spring to snap the disk to the closed position. If the valve simmers, operate the try lever two or three times to allow the disk to seat properly. If the valve continues to simmer it must be replaced or repaired by an authorized representative of the manufacturer. Inspect the valve for evidence of scale or encrustation within the body. Do not disassemble valve or attempt to adjust the spring setting. It is advisable to have a chain attached to the try lever of the valve to facilitate this test and allow it to be conducted in a safe manner from the floor. The date of this test should be entered into the boiler log book if one is used.

b. Pop Test

A pop test of a safety valve is conducted to determine that the valve will open under boiler pressure at operating temperatures, within the allowable tolerances. It should be conducted annually, preferably at the beginning of heating season if the boiler is used only for space heating purposes. Hydrostatic testing (using water) is not to be considered as an acceptable test to check safety valve opening pressure. A recommended procedure is as follows:

Section Five Page 10

i. Provide adequately supported temporary piping from the valve discharge to a safe location outside the boiler room. In some installations temporary ventilation may dispose of the steam vapour satisfactorily. Review preparation for test with personnel involved. All such tests should have at least two people present.

ii. Install a temporary calibrated test pressure gauge to check accuracy of boiler gauge. iii. Isolate the boiler, if possible, by shutting the stop valves in the steam supply and

condensate return piping. iv. Temporarily place test leads across the appropriate terminals on the operating

control to demonstrate the ability of the high-limit pressure control to function properly. After this has been checked, also place another set of test leads across the high-limit pressure control terminals to permit continuous operation of the burner.


v. The safety valve should pop open at an acceptable pressure, i.e., 15 psig plus or

minus 2 psig. A simmering action will ordinarily be noticed shortly before the valve pops to the open position.

vi. If the valve does not open in the 13 to 17 psig range, it should be replaced or repaired. It is not necessarily a dangerous situation if the valve opens below 13 psig, but it could indicate a weakening of the spring, improper setting of the spring, etc. If the valve does not open at 17 psig, shut off the burner and dissipate the steam to the system by slowly opening the supply valve. When the pressure has dropped sufficiently, open the valve using the try lever test method. If this releases the disk from the seat, continue with the pop test procedure as previously described. If the valve still does not open at or below 17 psig, it must be replaced with an new valve, returned to the manufacturer for repair, or field repaired by the valve manufacturer.

vii. If the valve pops open at an acceptable pressure, immediately remove the test leads from the high-limit pressure control. The burner main flame should cut off when the test leads are removed.

viii. The safety valve will stay open until the pressure drops sufficiently in the boiler to allow it to close, usually 2 to 4 psig below the opening pressure.

ix. Relieve the higher pressure steam to the rest of the system by slowly opening the steam supply valve. After the boiler and supply piping pressures have become equalized, open the return valve.

x. Remove the test leads from the operating control and check to make certain that it functions properly. This is best done by allowing it to cycle the burner on and off at least once.

xi. Enter the necessary test date into the boiler log book if one is used.

c. Capacity Test i. Capacity tests should be performed on safety valves on all new boiler installations

and also when a safety valve is repaired or replaced. They should also be made on existing boiler installations when any modification is made which affects the steam generating capacity of the boiler such as changing the size of the burner, the rate of fuel flow, or the grade or type of fuel not previously fired.


ii. All such test should be made with at least two people present.


iii. Provide adequately supported temporary, piping from the safety valve discharge to

a safe location outside the boiler room. In some installations, temporary ventilation may dispose of the steam vapour satisfactorily. Review preparation for test with personnel involved.

iv. A calibrated test gauge shall be temporarily installed to check accuracy of the boiler pressure gauge during all phases of these tests.

v. Isolate the boiler, if possible, by shutting the stop valve in the supply and return piping for the boiler. The water feeder or boiler feed pump should be able to operate if it is necessary to do so during the test. It may be necessary to manually feed 1 or 2 in. of water to the boiler to prevent the low-water fuel cutoff from shutting down the burner.

vi. Set burner to operate at its maximum capacity, making sure that combustion is complete with proper overfire draft.

vii. When the operating control has shut off the burner, place test leads across its terminals to switch control to the high-pressure cutout.

viii. When this has demonstrated its ability to shut off the burner, place another set of test leads across its terminals. Reset it if it has this feature, and allow the burner to continue running without control.

ix. The safety valve should pop open at the set pressure (15 psig) plus or minus 2 psig or within the range of 13 to 17 psig. If it opens below 13 psig or does not open at 17 psig, it should be replaced or repaired by the authorized representative of the safety valve manufacturer.

x. If the safety valve opens within this range, continue running the burner. If the pressure continues to rise, allow it to reach a maximum and hold it for a minimum of 30 sec. The maximum reached should not exceed 20 psig.

xi. If the pressure continues to rise above 20 psig, the burner should be stopped by removing the test leads from the high-pressure cutout. If the boiler room is filled with steam, the disconnect switch at the door may be used. The safety valve should be replaced by one which demonstrates its ability to maintain a pressure of not more than 20 psig in the boiler.

xii. If the safety valve does maintain a maximum pressure of 20 psig or below, the burner should stopped by removing the test leads from the high-pressure cutout. Observe the pressure at which the safety valves closes.


xiii. Remove the test leads from the operating control and let the burner cycle once to

determine that it is functioning properly. xiv. Enter all pertinent data in boiler room log, if one is used: date, time, personnel

present, opening pressure, maximum pressure, closing pressure, and any other


pertinent data or information.

2. High Limit Steam Pressuretrol (Control) Test

For information on adjusting pressuretrols, see Section One: TRIM LIST and consult the manufacturers' specification sheets in Section Fourteen of this manual.

This test is conducted to ensure that the high limit pressuretrol (control) is functioning properly. It should be conducted annually and preferably at the beginning of the heating season in the case of heating boilers.

Disconnect power to the boiler controls and place a test lead across the contacts of the operating steam pressuretrol (control). Check setting of the high-limit control. It should be higher than the operating control, but lower than 15 psig. (For how to adjust the pressuretrols, refer to the manufacturers' specification sheets in Section Fourteen of this manual).

Restore power to the controls and fire the boiler. Allow the boiler to fire until the steam pressure reaches the setting of the high-limit pressuretrol. The high-limit pressuretrol should operate at this point, shutting off the firing equipment. If the test is okay, then disconnect the power to the controls and remove the test leads previously installed. Reset the high-limit pressuretrol, if manual reset type is supplied, and fire boiler. Observe the boiler for proper operation.

I) REMOVAL OF BOILER FROM SERVICE

1. Procedure:

When a steaming boiler is to be taken out of service at the end of the heating season or for repairs proceed as follows: a. While maintaining boiler water temperature (180-200oF), drain off boiler water, from

rear drain at bottom, until it runs clear. b. Refill to top of water gauge glass, and add sufficient water treatment compound to bring

the treatment up to strength. c. When all the dissolved gases are released (approximately one (1) hour), shut down the

firing equipment by disconnecting the main switch.

For general information on boiler water treatment refer to Section Eleven: Water Treatment.

2. Cleaning

AF3 and CF3 Series packaged firebox boilers have supplied, as standard equipment on the burner end flue gas box, (opposite end on AF2) a single hinged flue cleaning door. Larger CF3 models have double doors. These doors give access to all boiler tubes. A small access cover plate is provided on the flue-outlet flue gas box for soot/scale removal.

AF2 boilers are supplied with a peepsite to view combustion at the rear while AF3 and CF3 boilers can be supplied with a rear bolt-on access door to the furnace complete with a peepsite


to view combustion.

When the boiler is cool, clean the tubes thoroughly and scrape the surfaces down to clean metal with the flue brush supplied, by removing or opening the flue cleaning door.

It is also important to clean the furnace section, if there are signs of soot accumulation. Access may be gained by removing burner mounting plate on boilers not supplied with a rear bolt-on access door. The furnace will be accessed through the rear bolt-on access door when supplied. Clean the fireside heating surface thoroughly, and scrape the furnace down to clean metal.

Clean the flue gas boxes and other areas where soot or scale may accumulate. Soot is not corrosive when it is perfectly dry, but can be very corrosive when it is damp. For this reason, it is necessary to remove all soot from a boiler at the end of the operating season, or any extended nonfiring period.

3. Protection Against Corrosion

The fireside heating surfaces may be swabbed with mineral oil to protect against corrosion. In damp boiler rooms, place a tray of calcium chloride or unslaked lime in the furnace and replace the chemical when it becomes damp.

4. Water Level

Drain the boiler back to the normal waterline before putting the boiler back into service. (Approximately 4 inches above the tubes). A marking label to indicate low-water level is provided on the boiler.

5. Periodic Checks

The boiler should be occasionally checked during the idle period to make certain that it is not corroded. This is a good time to repaint the exposed metal parts of the boiler and to inspect and service the firing equipment and combustion chamber.

Section Six Page 1

OPERATION INSTRUCTIONS - WATER A) STANDARD EQUIPMENT

1. Basic Boiler - AF2, AF3 and CF3 Series Firebox Boiler 2. ASME Relief Valve(s) - set at 30 PSIG 3. Safgard Manual Reset Low-Water Cutoff 4. High Limit Temperature Control 5. Operating Temperature Control 6. High fire Temperature Control (on sizes 30 BHP and over) 7. Water Temperature Indicator and Water Pressure Indicator 8. Burner

For non-standard items supplied please consult Section One: TRIM LIST. Specific information on non-standard equipment supplied is included in Section Fourteen of this manual.

Refer also to Section Fourteen of this manual for manufacturers information on standard items listed above. Consult Section Seven: Burner Manual for information on the burner supplied with this unit.

B) STARTING A NEW BOILER AND HEATING SYSTEM

NOTE: Specialists in boiler feed chemicals should be consulted to guarantee that your boiler receives the best possible treatment.

1. Cleaning and filling a new boiler:

a. An inspection should be made to insure that no foreign objects such as tools, equipment, rags, etc. are left in the boiler.

b. Make certain that the firing equipment is working properly to the extent that this is possible without actually lighting a fire in the empty boiler before filling the boiler. Raw water must be boiled (or heated at least to 180o F) promptly after filling the boiler to drive off dissolved gases which might otherwise corrode the boiler.

c. Fill the boiler and the entire system (other then the expansion tank) full of water. To insure that the system is full, water should come out of all air vents when opened.

d. Oils and greases which accumulate in a new boiler can usually be washed out by boiling as described below: i. Add caustic soda or trisodium phosphate to the boiler water at the rate of one (1)

pound of either chemical per 50 U.S. gallons of total water in the system.

CAUTION: CARE MUST BE USED WHEN HANDLING THESE CHEMICALS. CAUSTIC SODA IS HARMFUL TO SKIN, CLOTHING AND EYES. THE DRY CHEMICAL OR THE CONCENTRATED SOLUTION SHOULD NOT BE PERMITTED TO COME IN CONTACT WITH SKIN OR CLOTHING. ii. Fill the entire system with water. iii. Review the operating instructions that follow and Section Seven: Burner Manual

for boiler and burner start-up procedures. Then, start the firing equipment and check operating, limit and safety controls.

iv. Circulate the water through the entire system. v. Vent the system, including the radiators.

Section Six Page 2

vi. Allow the boiler water to reach operating temperature if possible. vii. Continue to circulate the water for a few hours. viii. Stop the firing equipment. ix. The boiler should be drained in a manner and to a location that hot water can be

discharged safely. x. Wash the boiler thoroughly, using high pressure water. All handhole and manhole

plates and/or the brass cleanout/inspection openings should be removed to insure a thorough cleaning and flush out of the boiler.

xi. Replace all plugs and handhole/manhole plates in the boiler. It may be necessary to replace the rubber gaskets used on the handhole and manhole plates.

xii. Refill the system with fresh water. xiii. Water treatment compound should now be added as needed. Section Eleven:

Water Treatment should be reviewed. xiv. Bring the water temperature to at least 180oF immediately to aid in removal of

dissolved gases. xv. The boiler is now ready to be put into service or on standby.

C) STARTING A BOILER AFTER LAYUP

(Single boiler installation)

1. Refer to Section Seven: Burner Manual and the operating instructions that follow for burner and boiler start-up procedures.

2. Set control switch in the 'OFF' Position. (Located on panel attached to burner). 3. Check to make sure that fresh air to the boiler room is unobstructed. 4. Check fuel availability. 5. Fill boiler and system, venting air at the highest point in the system. 6. Check the pressure gauge for proper fill pressure and the expansion tank to assure that the

system is properly filled. 7. Vent the combustion chamber to remove unburned gases. 8. Clean the rear peepsite glass. 9. Check for proper operation of the water pressure regulator and turn circulator pumps on. 10. Check the aquastats for proper setting. Refer to Section Fourteen for the manufacturers'

specification sheet at the back of this manual. 11. Check the manual reset button on the low-water cutoff and high limit aquastat, if supplied. 12. Set the manual fuel oil supply or manual gas valve in the open position. 13. Place the circuit breaker or fused disconnect switch on the 'ON' position. 14. Follow the Burner Manufacturer's guidelines included in the Burner Manual in Section

Seven and the Flame Safeguard Control manufacturer's guidelines in Section Fourteen for proper start-up procedures for the burner. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH.

15. Place the boiler control starting switch in the 'ON' or 'START' position. (Do not stand in front of furnace access doors, breeching or flue cleaning doors. This is a precautionary measure should a combustion explosion occur).

16. Do not leave the boiler until it reaches the established cutout point to make sure the controls are working properly.

17. During the temperature and pressure buildup period, walk around the boiler frequently to observe that all associated equipment and piping is functioning properly. Visually check the burner for proper combustion.

Section Six Page 3

18. Inspect water pressure and open the highest vent, immediately after burner shuts off, to determine that the system is completely full of water.

19. If a log book is used, enter: a. Date and time of startup. b. Any irregularities observed and corrective measures taken. c. Time when controls shut off burner at established temperature, tests preformed, etc. d. Operators signature.

20. Check relief valve for evidence of leaking. Perform a try lever test. See Section Six, (H)1. Try Lever Test.

D) ABNORMAL CONDITIONS DURING STARTING

If any abnormal conditions occur during light-off or pressure buildup, immediately open the emergency switch. (Do not attempt to restart until difficulties have been identified and corrected.

E) CONDENSATION

Condensation (sweating) may occur in a gas fired boiler following a cold start. It may be severe enough that it appears that the boiler is leaking. This condensation should stop after the boiler is hot.

F) PLACING A BOILER ON LINE WITH ADDITIONAL BOILERS

1. Start the boiler using procedure (C) above but the supply shutoff valve(s) and return stop valve(s) should be closed.

2. When the pressure within the boiler is the same as the other operating boiler(s), then partially open the supply shutoff valve(s). If no unusual disturbances, such as noise, vibration, etc. occur, continue to open the supply shutoff valve(s) very slowly until it is fully open. Then open the valve in the return line.

CAUTION: WHEN THE SHUTOFF VALVE(S) AT THE BOILER OUTLET IS CLOSED, THE SHUTOFF VALVE(S) IN THE RETURN LINE OF THAT BOILER SHOULD ALSO BE CLOSED.

G) OPERATION

1. Temperature and Pressure: Whenever going on duty, check the temperature and pressure in all the hot water boilers.

2. Combination Altitude and Pressure Gauge:

Refer to Section One: TRIM LIST at the front of the manual for specific trim supplied with your boiler.

If a combination altitude and pressure gauge is supplied, the stationary and movable hands of the gauge should be together when the boiler is cold. The fixed or stationary hand represents the initial fill pressure or it can represent the minimum pressure under which the boiler system can operate and still maintain a positive pressure at the highest point in the system. When the boiler is hot, the movable hand should be above the stationary or fixed hand.

3. Operating Temperature Controls and Pressure Relief Valves

a. For specific information on relief valve(s), operating controls (aquastats), high

Section Six Page 4

temperature control (aquastat) and high fire or modulating control (aquastat) refer to Section One: TRIM LIST at the front of this manual and Section Fourteen of this manual.

b. Replace relief valve(s) with ASME rated valves only, set at 30 psig water maximum. c. The maximum operating temperature should not exceed 250oF, and should be as low as

possible to heat the space adequately under design conditions. d. The maximum recommended operating pressure in accordance with An American

National Standard ANSI/NB-23 and the ASME Boiler and Pressure Vessel Code Section IV, current editions is 20 psig.

A common unsafe condition is the failure of the relief valve(s) to open at the set pressure. Usually a buildup of corrosive deposits between the disk and the seat of the relief valve is the cause. The corrosive deposits are usually caused by a weeping or simmering relief valve. It is for this reason the pressure differential between the boiler operating pressure and the relief valve set pressure should be as high as possible.

i. DO NOT block the discharge side of relief valves by means of other types of

valves, plugs etc. ii. DO NOT attempt to alter or tamper with the relief valves as supplied with

your boiler. iii. ONLY use authorized repair organizations to repair relief valves.

4. Blowdown

The purpose of blowdown is to keep the amount of dissolved solids and sludge to a minimum. Hot water boilers usually make up a closed system where very little make up water, if any, is required. Therefore, blowdown on a hot water boiler is not recommended. If a float type low-water cutoff device is supplied, periodic blowdown should be performed to clear sediment and corrosive deposits and ensure maximum reliability of this control. If rust appears, when the low-water cutoff is blowndown, this is an indication of corrosion and corrective action must be taken immediately. Check the boiler water for proper chemical concentration. Refer to Section Eleven: Water Treatment for general information on boiler water treatment.

5. Abnormal Water Losses

Hot water systems are generally considered closed systems. It is not normal to have any water losses. If there is evidence of make-up water being required, take corrective action immediately. Excessive, untreated make-up water may cause scaling. It is also considered corrosive due to its high oxygen content. Cracked or broken stays, cracked furnace plates or tube ligament cracks may result. If the operator cannot determine the cause of water loss, then a competent contractor should be consulted.

H) TESTS


Section Six Page 5

1. Relief Valve Tests As precautionary measures, all personnel concerned with conducting a pop or capacity test should be briefed on the location of all emergency shutdown controls in the event of an emergency, and there should be at least two people present. Care should be taken to protect those present from escaping steam.

CAUTION: Check local jurisdictional requirements as to placement of discharge piping for relief valves.

a. Try Lever Test

Every 30 days that the boiler is in operation or after any period of inactivity a try lever test should be performed as follows: i. Lift the try lever to the open position and hold it open for at least (5) seconds or

until clear water is discharged. ii. Release the lever and allow the spring to snap the disk to the closed position. If the

valve leaks, operate the try lever two or three times to clear the seat of any object that is preventing proper seating. As relief valves are normally piped to the floor or near a floor drain, it may take some time to determine if the valve closed completely.

iii. If the relief valve continues to leak, it shall be replaced with a new valve, returned to the manufacturer for repair, or field repaired by the valve manufacturer.

b. Pop (Pressure Relief) Test

i. A pop (pressure relief) test should be performed annually, preferably at the beginning of the heating season if the boiler is shut off during the summer months.

ii. Establish necessary general trial conditions at your location. Review preparation for test with personnel involved. See that relief valve discharge piping is secure. There should be at least two people present.

iii. If possible, a calibrated test gauge and thermometer should be temporarily installed to check the accuracy of the boiler pressure gauge and thermometer during the test.


iv. Isolate the boiler from the rest of the heating system by closing the supply and

return valves if provided. v. If an automatic water feeder is provided, the water inlet valve should be closed. vi. Shut valve to expansion tank. Drain water from tank to make sure that an air

cushion is provided. Open valve to tank. Prepressurized expansion tanks do not require draining. In all cases the expansion tank should not be isolated from the boiler during the pop test.

vii. Drain water from the boiler through the relief valve to reduce boiler pressure to not more than 50% of the relief valve set pressure.

viii. Place test leads across the appropriate terminals of the operating control to demonstrate the ability of the high temperature control to function properly. After this has been checked, place test leads across the high temperature control terminals to permit continuous operation of the burner.

Section Six Page 6

ix. Make sure that all personnel are clear of the relief valve discharge. x. Observe that the pressure and temperature of the boiler water are rising. If an

adequate air cushion is provided, the water temperature may rise to 274oF in a system with a relief valve set to open at 30 psig.

xi. The relief valve should open within an acceptable range below or above the set point. This is plus or minus 3 psig for valves set to open up to and including 60 psig.

xii. The valve should open and discharge a mixture of water and vapour. xiii. If the valve does not open between the allowable pressure tolerances described in

(k), it must be replaced with a new valve, returned to the manufacturer for repair, or field repaired by the valve manufacturer.

xiv. If the valve does open satisfactorily, remove the test leads from the high-limit control. The valve will remain open and discharge water and steam until the closing pressure is reached. This may be 10 to 50% below the set pressure of the valve. There are no blowdown requirements for relief valves.

xv. After the relief valve has closed, the remainder of the stored energy may be dissipated by slowly and carefully opening the boiler supply valve. The return valve may be opened after the pressures between the boiler and the supply systems have equalized.

xvi. Allow the high-limit control to cycle the burner at least once to determine that it is functioning properly.

xvii. Remove the test leads from the operating control and allow it to cycle the burner on and off at least once to determine that it is functioning properly.


c. Capacity Test

DO NOT PERFORM THIS TEST IF WATER FEEDER IS OF INSUFFICIENT CAPACITY.

i. Capacity tests should be performed on relief valves on all new boiler installations

or on existing boilers when any modification that changes the output of the boiler. They should also be made when the relief valve is repaired or replaced. Hydrostatic (water pressure) testing is not to be considered as an acceptable means of determining the capacity of a relief valve. As with steam safety valves, the capacity of a relief valve is measured in pounds of steam per hour or Btu/hr.

ii. Establish necessary general trial conditions at particular location, review preparation for test with personnel involved. If temporary piping is run from the relief valve discharge, it must be properly secured in place to prevent a whipping action during the test. All such tests should be made with at least two people present.

iii. It is recommended that a calibrated test gauge and thermometer be temporarily installed to check accuracy of the boiler pressure gauge and thermometer. It should be determined that all controls, gauges, etc., are designed to withstand the temperatures that will be experienced during this test.

Section Six Page 7

iv. Isolate the boiler from the supply and return piping by shutting these respective valves. The valve in the line to the expansion tank should also be shut. The water feeder should be able to operate if it is necessary to do so during the test.

v. Set burner to operate at its maximum capacity, making sure that combustion is complete with proper overfire draft, cutting back on fuel supply if necessary to accomplish this. It would be advantageous to be able to meter the fuel flow to calculate the output of the boiler. On gas burners this can be done by shutting off all other gas appliances in the building and using the gas company's meter.

vi. Temporarily place test leads across the appropriate terminals on the operating control. This will transfer operation to the high-limit control which should shut off the burner at its high setting and requires a manual reset for continued operation on some units. After it has satisfactorily demonstrated its function, place test leads across its terminals to permit continuous operation of the burner.

vii. The relief valve should open within the acceptable pressure range: the set pressure of the valve plus or minus 3 psig for valves set up to and including 60 psig. The valve should open at this point and discharge a mixture of water and vapour. All personnel should keep clear of the end of the discharge pipe.


viii. If the relief valve does not open (2.4 in3/min.) within its opening tolerances, or if

the relief valve pressure exceeds that which is allowable, immediately shut down the burner and make the boiler inoperative until a new valve is installed and passes the tests prescribed herein. For valves set at pressures up to and including 60 psig, the pressure should not rise more than 6 psig above the set pressure.

ix. If the valve opens within its opening tolerances, keep the burner running until the maximum pressure is reached unless the pressure exceeds those specified in (h) above. If the maximum pressure is within acceptable limits, hold it there for 30 seconds to check for further rise. If there is no further pressure rise, shut down burner by pulling test leads from the high temperature cutout.

x. The relief valve will continue to discharge until the blowdown pressure is reached. This may be 20 to 50% below the valve's set pressure. This will vary because of differences in seat and disk design.

xi. After the valve has closed, the residual steam in the boiler may be dissipated through the relief valve by using the try lever or by slowly opening the stop valve in the supply line. After the supply valve has been opened, the return valve and the valve in the piping to the expansion tank must be opened.

xii. Allow the high-limit control to operate and shut down the burner at least one time to check its function. After this has been done, remove the test leads from the operating control and check to make certain it is functioning properly.

xiii. Enter all pertinent data in boiler room log, if one is used: date, time, personnel present, opening pressure, maximum pressure, closing pressure, and any other pertinent data or information.

2. High Limit Aquastat (Control) Test

For information on adjusting aquastats, see Section One: TRIM LIST and consult the

Section Six Page 8

manufacturers' specification sheets in Section Fourteen of this manual.

This test is conducted to ensure that the high limit aquastat (control) is functioning properly. It should be conducted annually and preferably at the beginning of the heating season in the case of heating boilers. Disconnect power to the boiler controls and place a test lead across the contacts of the operating aquastat (control). Check setting of the high-limit control. It should be higher than the operating control, but lower than 250oF. (For how to adjust the aquastats, refer to the manufacturers' specification sheets in Section Fourteen of this manual). Restore power to the controls and fire the boiler. Allow the boiler to fire until the water temperature reaches the setting of the high-limit aquastat. The high-limit aquastat should operate at this point, shutting off the firing equipment.


If the test is okay, then disconnect the power to the controls and remove the test leads previously installed. Reset the high-limit aquastat, if manual reset type is supplied, and fire boiler. Observe the boiler for proper operation.

3. Low-Water Cutoff

All standard AF2, AF3 and CF3 Series firebox boilers are equipped with one float type low-water cutoff. Refer to Section One: TRIM LIST at the front of this manual for the specific items supplied on your boiler and to the manufacturers' specification sheets in Section Fourteen of this manual.

See (G) 4, Blowdown above and Section Eleven, (G) Blowdown.

I) REMOVAL OF BOILER FROM SERVICE

1. Procedure: When a hot water boiler is to be taken out of service at the end of the heating season or for repairs proceed as follows:

a. While the boiler is still hot (180-200oF), drain water from rear drain at bottom, until it

runs clear. b. Refill to normal fill pressure. If water treatment is used in the system, sufficient

treatment compound should be added to condition the added water.

For general information on boiler water treatment refer to Section Eleven: Water Treatment.

2. Cleaning

Section Six Page 9

AF3 Allstar and CF3 Compak Series packaged firebox boilers have supplied, as standard equipment on the burner end flue gas box, (opposite end on AF2) a single hinged flue cleaning door. Larger CF3 Series boilers have double doors on the front flue gas box. These doors give access to all boiler tubes. A small access cover plate is provided on the flue-outlet flue gas box for soot/scale removal.

AF2 boilers are supplied with a peepsite to view combustion at the rear while AF3 and CF3 boilers can be supplied with a rear bolt-on access door to the furnace complete with a peepsite to view combustion.


It is also important to clean the furnace section, if there are signs of soot accumulation. Access may be gained by removing the burner mounting plate on boilers not supplied with a rear bolt-on access door. The furnace will be accessed through the rear bolt-on access door when supplied. Clean the fireside heating surface thoroughly, and scrape the furnace down to clean metal.

Clean the flue gas box and other areas where soot or scale may accumulate. Soot is not corrosive when it is perfectly dry, but can be very corrosive when it is damp. For this reason, it is necessary to remove all soot from a boiler at the end of the operating season, or any extended nonfiring period.

3. Protection Against Corrosion


4. Periodic Checks


Section Seven Page 1

BURNER MANUAL

DO NOT RELIGHT PILOT OR START BURNER WITH THE COMBUSTION CHAMBER

FULL OF GAS OR OIL VAPOURS, OR WITH A VERY HOT COMBUSTION CHAMBER.

THE INSTALLER SHALL CLEARLY IDENTIFY ANY AND ALL EMERGENCY SHUT-OFF DEVICES, INCLUDING BUT

NOT LIMITED TO ELECTRICAL SWITCHES AND MANUAL GAS VALVES.

DO NOT START THE BURNER UNLESS ALL CLEANOUT DOORS ARE SECURED IN PLACE.

CONSULT A COMPETENT BURNER SERVICEMAN/TECHNICIAN TO

START THE BURNER.

Section Eight Page 1

MAINTENANCE, REPAIR AND INSPECTION - GENERAL

TESTS AND INSPECTIONS OF HOT WATER HEATING AND SUPPLY BOILERS A) INSPECTION DURING CONSTRUCTION:

AF2 and AF3 Allstar and CF3 Compak Series firebox boilers are designed and constructed to the ASME Low Pressure Boiler Code Section IV and the local jurisdictional requirements.

B) INITIAL INSPECTION AT PLACE OF INSTALLATION:

As opposed to inspection during manufacture which pertains primarily to conforming to Code construction requirements, this inspection will be concerned with whether boiler supports, piping arrangements, safety relief valves, other valves, water columns, gauge cocks, altitude gauges, thermometers, controls, and other apparatus on the boiler meet Code and/or other jurisdictional requirements. The inspector usually represents the same jurisdiction which will be making subsequent periodic inspections.

C) PERIODIC INSPECTION OF EXISTING BOILERS:

The main purposes for reinspection include protection against loss or damage to the pressure vessel because of corrosion, pitting, etc., protection against unsafe operating conditions possibly caused by changes in piping or controls or lack of testing of safety devices. It is important that inspections be thorough and complete, and so that important elements may all be checked, the following recommended directions and instructions for such inspections are given.

1. All boilers should be prepared for inspection, whenever necessary, by the owner or user when

notified by the inspector. The owner or user should prepare the boiler for an internal inspection and should prepare for and apply the hydrostatic test whenever necessary on the date specified in the presence of a duly qualified inspector.

2. Before inspection, every part of boiler that is accessible should be open and properly prepared for examination, internally and externally. In cooling down a boiler for inspection or repairs, the water should not be withdrawn until the setting is sufficiently cooled to avoid damage to the boiler and, when possible, it should be allowed to cool down naturally.

3. Preparation: Prepare your boiler for internal inspection in the following manner:

a. Water should be drained and boiler washed thoroughly.

b. All manhole, cleanout/flushout plugs, handhole plates and water column connections should be removed and the furnace and combustion chambers thoroughly cooled and cleaned.

c. Any leakage of hot water or steam into the boiler should be cut off by disconnecting the

pipe or valve at the most convenient point.

d. It is not necessary to remove insulation material, masonry, or fixed parts of the boiler


unless defects or deterioration are suspected. Where there is moisture or vapour showing through the covering, the covering should be removed at once and a complete investigation made. Every effort should be made to discover the true condition, even if it means drilling holes or cutting away parts.

e. Get as close to the parts of the boiler as is possible in order to obtain the best possible

vision of the surface and to use a good artificial light if natural light is not adequate.

f. Whenever it becomes necessary to test boiler apparatus, controls, etc., these test should be made by a plant operator in the presence of the inspector, unless otherwise ordered.

g. Scale, Oil, etc. Examine all surfaces of the exposed metal on the waterside to observe any

action caused by treatment, scale solvents, oil, or other substances which may have entered the boiler. Any evidence of oil should be noted carefully as a small amount is dangerous and immediate steps should be taken to prevent the entrance of any more oil into the boiler. Oil or scale on plates over the fire of any boiler is particularly bad, often causing sufficient weakening to bag or rupture.

h. Corrosion, Grooving: Corrosion along or immediately adjacent to a seam is more serious

than a similar amount of corrosion in the solid plate away from the seams. Grooving and cracks along longitudinal seams are especially significant, as they are likely to occur when the material is highly stressed. Severe corrosion is likely to occur at points where the circulation of water is poor; such places should be examined very carefully. For the purpose of estimating the effect of corrosion or other defects upon the strength of a shell, comparison should be made with the efficiency of the longitudinal joint of the same boiler, the strength of which is usually less than that of solid sheet.

i. Stays: All stays, whether diagonal or through, should be examined for cracks or severe

corrosion. Stays are to be immediately replaced if these conditions are evident.

j. Handholes and Other Openings: The handholes as well as nozzles and other connections (flanged or screwed) into the boiler, should be examined internally as well as externally to see that they are not cracked or deformed. Wherever possible, observation should be made from the inside of the boiler as to the thoroughness with which its pipe connections are made to the boiler. All openings to external attachments, such as connections to a low-water cutoff and openings to safety relief valves, should be examined to see if they are free from obstructions.

k. Fire Surfaces - Bulging, Blistering, Leaks: Particular attention should be given to the

plate or tube surface exposed to fire. Observe whether any part of the boiler has become deformed during operation by bulging or blistering. If bulges or blisters are of such size as would seriously weaken the plate or tube, and especially when water is leaking from such a defect, the boiler should be discontinued from service until the defective part or parts have received proper repairs. Careful observation should be made to detect leakage from any part of the boiler structure, particularly in the vicinity of seams and tube ends. Firetubes sometimes blister but rarely collapse; the inspector should examine the tubes for such defects; if they are found to have sufficient amount of distortion to warrant it, they should be replaced.


l. Testing Staybolts: Test staybolts by tapping one end of each bolt with a hammer. When

practical, a hammer or other heavy tool should be held at the opposite end to make the test more effective.

m. Tube Defects: Tubes in horizontal firetube boilers deteriorate more rapidly at the ends

toward the fire and they should be carefully tapped with a light hammer on their outer surface to ascertain if there has been a serious reduction in thickness. They should be reached, as far as possible, either through the handholes or inspected at the ends.

The surface of tubes should be carefully examined to detect bulges or cracks or any evidence of defective beads. Where there is a strong draft, the tubes may become thinned by erosion produced by the impingement of particals of fuel. A leak from a tube frequently causes serious corrosive action on a number of tubes in its immediate vicinity.

n. Ligaments Between Tube Holes: The ligaments between tube holes in the heads of all

firetube boilers should be examined. If leakage is noted, broken ligaments are probably the reason.

o. Pipe Connections and Fittings: All piping should be examined for leaks; if any are found,

it should be determined whether they are the result of excess strains due to expansion or contraction or other causes. The general arrangement of the piping in regard to the provision for expansion and drainage, as well as adequate support at the proper points, should be carefully noted.

The arrangement of connections between individual boilers and the supply and return headers should be especially noted to see that any change of positions of the boiler due to settling or other causes has not placed an undue strain on the piping. It should be ascertained whether all pipe connections to the boiler possess the proper strength in their fastenings, whether tapped into or welded to the boiler shell. It should be determined whether there is proper provision for the expansion and contraction of such piping and that there is no undue vibration tending to damage the parts subjected to it. This includes all water pipes. Special attention should be given to the blowoff pipes with their connections and fittings because the expansion and contraction due to rapid changes in temperature and water-hammer action bring a great strain upon the entire blowoff system. The freedom of the blowoff and drain connection on each boiler should be tested, whenever possible, by opening the valve for a few seconds, at which time it can be determined whether there is excessive vibration.

p. Low-Water Cutoff: All automatically fired hot water heating or steam supply boilers are

equipped with an automatic low-water fuel cutoff so located as to automatically cut off the fuel supply when the surface of the water falls below the lowest safe water line. Such a fuel control device is attached directly to the boiler shell. Equalizing connections are provided for attaching a primary LWCO & Pump control on steam boilers.

A ball valve is supplied at the lowest point in the water equalizing pipe connections, by which the float type LWCO and the equalizing pipe can be flushed and the LWCO tested.


q. Localization of Heat: Localization of heat brought about by improper or defective burner operation, creating a blowpipe effect upon the boiler, should be cause for shutdown of the boiler until the condition is corrected.

r. Safety/Relief Valves: As the safety relief valve is the most important safety device on the

boiler, it should be inspected with the upmost care.

There should be no accumulation of rust, scale or other foreign substances in the body of the valve which will interfere with its free operation. The valve should not leak under operating conditions. The opening pressure and freedom of operation of the valve should be tested preferably by raising the water pressure to the point of opening (Pop Test), see Section 6(H)2. If this cannot be done, the valve should be tested by opening with try lever in accordance with the procedure in Section 5(H)1. or 6(H)1. Where the valve has a discharge pipe, it should determine at the time the valve is operating whether or not the drain opening in the discharge pipe is free and in accordance with the Code requirement.

If necessary, in order to determine the freedom of discharge from a safety relief valve, the discharge connection should be removed. Under no circumstances shall a stop valve be permitted between a boiler and its safety relief valve.

s. Combination Temperature and Pressure Gauges: A test gauge or spare control connection

is provided on the boiler so that the gauge on the boiler can be tested under operating conditions. The gauge should not be exposed to excessively high ambient temperatures.

t. Imperfect Repairs: When repairs have been made, especially tube replacements, it should

be observed whether the work has been done safely and properly. Excessive rolling of tubes, where they are accessible, is a common fault of inexperienced workmen. When it is difficult to reach the tube end and observe the extent of rolling, however, they are frequently underrolled. This inevitably results in separation of the parts.

u. Hydrostatic Tests: When there is question or doubt about the extent of a defect found in a

boiler, the inspector, in order to more fully decide upon its seriousness, should cause the application of hydrostatic pressure under the Code provisions.

A hydrostatic pressure test shall not exceed 1.5 times the maximum allowable working pressure. Consult with the inspector as to how long the boiler should remain under this pressure. During the test, the safety relief valve should be removed from the boiler, as should all controls and trim unable to withstand the test pressure without damage. It is suggested that the minimum temperature of the water be 70oF and the maximum 120oF.

v. Suggestions: The inspector, whether he is the employee of a state, province, municipality,

or insurance company, should be well informed of the natural and neglected causes of defects and deterioration of boilers. He should be extremely conscientious and careful in his observations, taking sufficient time to make the examinations thorough in every way taking no one's statement as final as to conditions not observed by him, and, in the event of inability to make a thorough inspection, he should note it in his report and not accept the statement of others.


The inspector should make a general observation of the boiler room and apparatus, as well as of the attendants, as a guide in forming an opinion of the general care of the equipment. He should question responsible employees as to the history of old boilers, their peculiarities and behaviour, ascertain what, if any, repairs have been made and their character, and he should investigate and determine whether they were made properly and safely.

Section Nine Page 1

MAINTENANCE, REPAIR AND INSPECTION - STEAM BOILERS A) CLEANING - FIRESIDE SURFACES

AF3 Allstar and CF3 Compak Series packaged firebox boilers have supplied, as standard equipment on the burner end flue gas box, (opposite end on AF2) a single hinged flue cleaning door (double doors on large CF3's). These doors give access to all boiler tubes. A small access cover plate is provided on the flue-outlet flue gas box for soot/scale removal.

All AF2 boilers and smaller AF3 and CF3 boilers are supplied with a peepsite to view combustion at the rear while larger AF3 and CF3 boilers are supplied with a rear bolt-on access door to the furnace complete with a peepsite to view combustion.


It is also important to clean the furnace section, if there are signs of soot accumulation. Access may be gained by removing the burner mounting plate on boilers not supplied with a rear bolt-on access door. The furnace can be accessed through the rear bolt-on access door when supplied. Clean the fireside heating surface thoroughly, and scrape the surfaces down to clean metal.

Clean the flue gas boxes and other areas where soot or scale may accumulate. Soot is not corrosive when it is perfectly dry, but can be very corrosive when it is damp. For this reason, it is necessary to remove all soot from a boiler at the end of the operating season, or any extended non-firing period.

B) PROTECTION AGAINST CORROSION


C) PERIODIC CHECKS


Clean the boiler tubes and other fireside heating surfaces whenever required. The frequency of cleaning can best be determined by trial. Clean the flue gas boxes at the same time.

See Section Five: Operating Instructions - Steam Boilers (I) for information on "Removal of Boiler From Service"

D) DRAINING

Do not drain a clean, properly maintained steam heating boiler unless there is a possibility of freezing or the boiler has accumulated a considerable amount of sludge or dirt on the waterside, or unless draining is necessary to make repairs.

Very little sludge should accumulate in a boiler where little makeup water is added and where an

Section Nine Page 2

appropriate water treatment is maintained at the proper strength.

AF2, AF3 Allstar and CF3 Compak Series firebox boilers are manufactured with numerous flushout/cleanout and inspection openings.

See Section Fifteen: Dimensional Arrangement and/or Bulletin for quantity, type and placement of cleanout, flushout and inspection openings.

E) PROTECTION AGAINST FREEZING

Antifreeze solutions, when used in heating systems, should be tested annually as recommended by the manufacturer of the antifreeze being used. Antifreeze solutions should not be circulated through the boiler proper. It should be heated in an indirect heat exchanger.

NOTE: DO NOT ADD ANTIFREEZE INTO A STEAM BOILER

F) FIRESIDE CORROSION

Some fuels contain substances which may cause fireside corrosion. Sulphur, vanadium and sodium are some materials which may contribute to this problem.

1. Sulphur: Trouble from this source depends on the amount of sulphur in the fuel and on the care

used in cleaning the fireside heating surfaces. Preventing this trouble depends also on keeping the boiler heating surfaces dry when it is out of service. See Section Five: (I) 2 - Cleaning and Section Eight, for information on cleaning your boiler.

2. Vanadium and Sodium Compounds: Deposits of these compounds may also cause fireside corrosion, particularly when the boilers are in service.

The person responsible for boiler maintenance should ensure that the fireside surfaces of the boilers in his care are thoroughly cleaned at the end of the firing season. If signs of fireside corrosion appear, a reputable consultant should be contacted.

G) SAFETY VALVES

Safety valves should be tested for proper operation in accordance with Section Five: Operating Instructions - Steam (H) 1.

AF2 and AF3 Allstar and CF3 Compak Series packaged firebox boilers are supplied only with ASME rated safety valves.

Replace only with ASME rated safety valves of the total required capacity.

H) BURNER MAINTENANCE

Consult Burner Manual in Section Seven and Flame Safeguard Control Bulletin in Section Fourteen.

1. Oil Burners: Oil burners require periodic maintenance to keep the nozzles and other parts clean. Check and clean oil line strainers, filters, air intake screens, blowers and air passages. Check oil nozzles, ignition equipment and linkages and adjust linkages as required. Lubricate in accordance with the burner manufacturers' instructions.

Section Nine Page 3

2. Gas Burners: Check and clean air intake screens, blowers and air passages. Linkages and other moving parts should be checked for proper adjustment. On combination oil and gas burners, the gas outlets may become caked with carbon residues from unburned fuel oil after prolonged periods of oil firing and require cleaning. Lubricate in accordance with the burner manufacturers' instructions. Also check pilot burners and ignition assemblies for proper adjustment and performance.

For more specific operating and maintenance information, refer to Section Seven: Burner Manual.

I) LOW-WATER CUTOFF AND PUMP CONTROL, AUXILIARY LOW-WATER CUTOFF

AND WATER FEEDER MAINTENANCE

Low-water cutoffs and Water Feeders should be dismantled annually, by qualified personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts.

Inspect the connecting lines to the boiler for accumulation of mud, scale, etc. and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and functioning properly. Special attention should be given to solder joints on bellows and floats, where used. Check float for evidence of collapse or water logging. Check mercury contacts, where used, for mercury separation or discolorations.

DO NOT attempt to repair defective parts in the field. Replace only with original manufacturers' repair parts which are readily available. After re-assembly of the devices, test in accordance with Section Five: Operating Instructions - Steam (H) 7 Low-Water Cutoff.

To determine what equipment was supplied, refer to Section One: TRIM LIST at the front of this manual.

For more information on the operation and maintenance of equipment supplied, refer to Section Fourteen for the manufacturers' specification sheets.

J) OPERATING, HIGH-LIMIT, HIGH FIRE/MODULATING PRESSURE CONTROL

MAINTENANCE

Maintenance of these devices is usually limited to visual inspection for evidence of wear, corrosion, etc. If the control is a mercury bulb type, check for mercury separation and discoloration of the bulb. If the control is defective, replace it.

DO NOT attempt to repair pressuretrols.

For information on what was supplied, refer to Section One: TRIM LIST at the front of the manual.

For more information on the operation and maintenance of pressuretrols, refer to Section Fourteen for the manufacturers' specification sheets.

K) REFRACTORY MAINTENANCE

AF2, AF3 and CF3 Series firebox boilers contain refractory on the burner combustion plate, floor and

Section Nine Page 4

rear furnace access door (when supplied).

Inspect and replace or repair all loose refractory. L) FLUE GAS BOX INSULATION

Burner end flue gas boxes of the AF3 and CF3 and both smokeboxes on AF2 Series firebox boilers are lined with a high temperature board insulation.

Inspect during periodic fireside cleaning and replace if damaged or worn. A hot spot on the flue gas box is also an indication of worn or damaged insulation.

GASKETING MAINTENANCE

Check and replace all worn or leaking gasketing in flue cleaning doors, burner mounting plate, rear door, flue gas boxes, handhole plates, etc.

M) WATERSIDE MAINTENANCE

Refer to Section Five: Operating Instructions - Steam (G) 3 and Section Eleven (G) for blowdown procedures. If the water does not run clear, the boiler should be cleaned.

AF2, AF3 and CF3 Series firebox boilers are manufactured with numerous flushout/cleanout and inspection openings.

After the boiler is allowed to cool; vent and drain the boiler and remove all handhole and manhole covers and brass inspection/flushout connections. Refer to section Fifteen: Dimensional Arrangement and/or Bulletin.

NOTE: Where brass plugs are used for inspection/flushout/cleanout openings, damage to the plugs will be minimized by using 4 or 8 point sockets. Plug size : Socket size (Double Square) 2" NPT 1 5/16" 2 1/2" NPT 1 1/2"

Wash the inside of the boiler with a high pressure water stream. Loosen any solidified sludge, scale, etc. with a hand scrapper. Start at the top of the boiler and work down. Flush thoroughly after cleaning. Where scale buildup is difficult to remove, it may be necessary to clean the boiler chemically. Consult a qualified water treatment specialist for this procedure.

Use a flashlight in preference to an extension light for internal inspection purposes. If an extension light is to be used, be sure the cord is rugged, in good condition and that is properly grounded. It should be equipped with a vapour tight globe, substantial guard and non-conducting holder and handle.

N) LEAKING TUBES

If a tube leak develops due to corrosion, then it is likely that other tubes are corroded also. A capable and experienced inspector should examine the boiler prior to the replacing of one or a few tubes. If all the tubes will need replacement soon, then it will be more economical to replace them all at one time.

Section Nine Page 5

O) USE OF SEALANT

The use of sealant is not recommended. P) MAINTENANCE SCHEDULE

Suggested frequencies for various routines and tests are listed below. 1. Daily (Boilers In Service): Observe operating pressures, water level and general conditions.

Determine the cause of unusual noises or conditions and correct. Where low-pressure steam boilers are used solely for heating and where practically all of the condensate is returned to the boiler, blowdown only as often as concentration of solids require. Boilers used for process steam requiring high make-up should be blown down as required to maintain desired chemical concentration levels and to remove precipitated sediments.

2. Weekly (Boilers In Service): a. Test low-water fuel cutoff, pump control and/or water feeder. See Section 3(I)2(c),

Section 5(H)7 and Section 11(G). b. Blowdown boiler if considerable make up is used. c. Test water column or water gauge glass Section 5(G)1. d. Observe condition of flame (for oil observe daily). See Section Seven: Burner Manual

for information on the burner supplied. e. Check fuel oil supply. f. Observe operation of condensate return or vacuum pump. g. Monthly (Boilers In Service) h. Safety Valve - Try Lever Test Section 5(H)1(a). i. Test flame detection devices See Section Seven: Burner Manual. j. Test Limit Controls Section 5(H)2 k. Test Operating Controls. l. Bottom Blowdown where required. Section 3(I)2(c)., Section 5(H)7., and Section 11(G) m. Check boiler room floor drains for proper functioning. n. Inspect fuel supply systems in boiler room area. o. Check conditions of fireside heating surfaces.\

3. Annually a. Internal and external inspection after thorough cleaning Section 5(I), Section 8(C). b. Routine burner maintenance Section Seven: Burner Manual. c. Routine Maintenance of condensate or vacuum return equipment. d. Routine Maintenance of combustion control equipment See Section Seven: Burner

Manual. e. Combustion and draft tests. f. Safety Valve Pop Test Section 5(H)1.b g. Slow drain test of Low-Water Cutoff Section 5(H)7. h. Inspect gas piping for proper support and tightness. i. Inspect boiler room ventilation louvres and intake.

Q) REPAIR

FAILURE TO EXERCISE EXTREME CAUTION AND CARE WHEN REPAIRING

Section Nine Page 6

BOILERS MAY RESULT IN PERSONAL INJURY.

1. DO NOT PERMIT REPAIRS TO A BOILER WHILE IT IS IN SERVICE, OR UNDER PRESSURE, EXCEPT WITH THE APPROVAL AND UNDER THE SUPERVISION OF AN AUTHORIZED INSPECTOR OR RESPONSIBLE ENGINEER.

2. Notify the authorized boiler and pressure vessel inspector when repair work is required. Follow the inspector's recommendations.

3. All repair work should be done by experienced boiler makers. All welding should be done by experienced qualified welders in accordance with ASME Boiler and Pressure Vessel Code Section IX.

4. Safety of the personnel working at your boiler is of utmost importance. Pull the main burner switch and lock it out and tag it, close and lock valves, etc., and always have on man standing by outside when a man is working inside a boiler.

Section Ten Page 1

MAINTENANCE, REPAIR AND INSPECTION - WATER BOILERS

A) CLEANING - FIRESIDE SURFACES

AF3 Allstar and CF3 Compak Series packaged firebox boilers have supplied, as standard equipment on the burner end flue gas box, (opposite end on AF2) a single hinged flue cleaning door (double doors on large CF3's). These doors give access to all boiler tubes. A small access cover plate is provided on the flue-outlet flue gas box for soot/scale removal.

All AF2 boilers and smaller AF3 and CF3 boilers are supplied with a peepsite to view combustion at the rear while larger AF3 and CF3 boilers are supplied with a rear bolt-on access door to the furnace complete with a peepsite to view combustion.


It is also important to clean the furnace section, if there are signs of soot accumulation. Access may be gained by removing the burner mounting plate on boilers not supplied with a rear bolt-on access door. The furnace can be accessed through the rear bolt-on access door when supplied. Clean the fireside heating surface thoroughly, and scrape the surfaces down to clean metal.

Clean the flue gas boxes and other areas where soot or scale may accumulate. Soot is not corrosive when it is perfectly dry, but can be very corrosive when it is damp. For this reason, it is necessary to remove all soot from a boiler at the end of the operating season, or any extended non-firing period.

B) PROTECTION AGAINST CORROSION


C) PERIODIC CHECKS


Clean the boiler tubes and other fireside heating surfaces whenever required. The frequency of cleaning can best be determined by trial. Clean the flue gas boxes at the same time.

See Section Six: Operating Instructions - Water (I)1. for information on "Removal of Boiler From Service"

D) DRAINING

Do not drain a clean, properly maintained hot water heating boiler unless there is a possibility of freezing or the boiler has accumulated a considerable amount of sludge or dirt on the waterside, or

Section Ten Page 2

unless draining is necessary to make repairs.

Very little sludge should accumulate in a boiler where little makeup water is added and where the appropriate water treatment is maintained at the proper strength.

AF2 and AF3 Allstar Series and CF3 Compak Series firebox boilers are manufactured with numerous flushout/cleanout and inspection openings.

See Section Fifteen: Dimensional Arrangement and/or Bulletin for quantity, type and placement of cleanout, flushout and inspection openings.

PROTECTION AGAINST FREEZING

Only use ethylene glycol based antifreezes with an added inhibitor in hot water heating systems. Antifreeze concentrations should not be less than 33% nor greater than 66%. (100% antifreeze has a freezing point of about -96oF, while a concentration of 68% has a freezing point of about -92oF and a 50% solution has a freezing point of about -34oF). Such factors as heating system design and condition, hours of operation, solution and metal temperatures, aeration and rate of contamination affect the service life of the antifreeze. Therefore, the antifreeze solution should be tested annually and as often as recommended by the manufacturers' of the antifreeze. Because high metal temperatures accelerate depletion of antifreeze solutions, maximum service life may be increased by maintaining metal temperatures in contact with the solution under 350oF. The fluid temperature should not exceed 250oF.

Antifreeze solutions expand more than water. Therefore, allowance must be made for this expansion. (i.e. a 50% by volume solution expands 4.8% by volume with a temperature increase from 32oF to 180oF, while water expands 3% in the same temperature range). Allowance must also be made for reduced heat transfer within the heating system when antifreeze solutions are used.

E) FIRESIDE CORROSION

Some fuels contain substances which may cause fireside corrosion. Sulphur, vanadium and sodium are some materials which may contribute to this problem.

1. Sulphur: Trouble from this source depends on the amount of sulphur in the fuel and on the care

used in cleaning the fireside heating surfaces. Preventing this trouble depends also on keeping the boiler heating surfaces dry when it is out of service. See Section Six: (I)2. - Cleaning.

2. Vanadium and Sodium Compounds: Deposits of these compounds may also cause fireside corrosion, particularly when the boilers are in service.

The person responsible for boiler maintenance should ensure that the fireside surfaces of the boilers in his care are thoroughly cleaned at the end of the firing season. If signs of fireside corrosion appear, a reputable consultant should be contacted.

F) RELIEF VALVES

Relief valves should be tested for proper operation in accordance with Section Six: Operating Instructions Water (H) 2.

Section Ten Page 3

AF2, AF3 and CF3 Series packaged firebox boilers are supplied only with ASME rated safety valves.

Replace only with ASME rated safety valves of the total required capacity.

G) BURNER MAINTENANCE

Follow the Burner Manufacturer's guidelines included in the Burner Manual in Section Seven and the Flame Safeguard Control manufacturer's guidelines in Section Fourteen for proper start-up procedures for the burner. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH.

1. Oil Burners: Oil burners require periodic maintenance to keep the nozzles and other parts

clean. Check and clean oil line strainers, filters, air intake screens, blowers and air passages. Check oil nozzles, ignition equipment and linkages and adjust linkages as required. Lubricate in accordance with the burner manufacturers' instructions.

2. Gas Burners: Check and clean air intake screens, blowers and air passages. Linkages and other moving parts should be checked for proper adjustment. On combination oil and gas burners, the gas outlets may become caked with carbon residues from unburned fuel oil after prolonged periods of oil firing and require cleaning. Lubricate in accordance with the burner manufacturers' instructions. Also check pilot burners and ignition assemblies for proper adjustment and performance.

For more specific operating and maintenance information, refer to Section Seven: Burner Manual.

H) LOW-WATER FUEL CUTOFF

Low-water cutoffs and Water Feeders should be dismantled annually, by qualified personnel, to the extent necessary to insure freedom from obstructions and proper functioning of the working parts.

Inspect the connecting lines to the boiler for accumulation of mud, scale, etc. and clean as required. Examine all visible wiring for brittle or worn insulation and make sure electrical contacts are clean and functioning properly. Special attention should be given to solder joints on bellows and floats, where used. Check float for evidence of collapse or water logging. Check mercury contacts, where used, for mercury separation or discolorations.

DO NOT attempt to repair defective parts in the field. Replace only with original manufacturers' repair parts which are readily available.

To determine what equipment was supplied, refer to Section One: TRIM LIST at the front of this manual.

For more information on the operation and maintenance of equipment supplied, refer to Section Fourteen for the manufacturers' specification sheets.

I) OPERATING, HIGH-LIMIT, HIGH FIRE/MODULATING AQUASTAT MAINTENANCE

Section Ten Page 4

Maintenance of these devices is usually limited to visual inspection for evidence of wear, corrosion, etc. If the control is a mercury bulb type, check for mercury separation and discoloration of the bulb. If the control is defective, replace it.

DO NOT attempt to repair aquastats.

For information on what was supplied, refer to Section One: TRIM LIST at the front of the manual. For more information on the operation and maintenance of temperatuare controls , refer to Section Fourteen for the manufacturers' specification sheets.

J) REFRACTORY MAINTENANCE

AF2, AF3 and CF3 Series firebox boilers contain refractory on the burner combustion plate, floor and rear furnace access door. Inspect and replace or repair all loose refractory.

K) FLUE GAS BOX INSULATION

Burner end flue gas boxes on the AF3 and CF3 and both smokeboxes on AF2 Series firebox boilers are lined with a high temperature board insulation.

Inspect during periodic fireside cleaning and replace if damaged or worn. A hot spot on the flue gas box is also an indication of worn or damaged insulation.

L) GASKETING MAINTENANCE

Check and replace all worn or leaking gasketing in flue cleaning doors, burner mounting plate, rear door, flue gas boxes, handhole plates, etc.

M) WATERSIDE MAINTENANCE

If the condition of the water in the boiler indicates there is considerable foreign matter in it, the boiler should be allowed to cool, then drained and thoroughly flushed out.

AF2, AF3 and CF3 Series firebox boilers are manufactured with numerous flushout/cleanout and inspection openings.

After the boiler is allowed to cool; vent and drain the boiler and remove all handhole and manhole covers and brass inspection/flushout connections. Refer to section Fifteen: Dimensional Arrangement and/or Bulletin.

NOTE: Where brass plugs are used for inspection/flushout/cleanout openings, damage to the plugs will be minimized by using 4 or 8 point sockets. Plug size : Socket size (Double Square) 2" NPT : 1 5/16" 2 1/2" NPT : 1 1/2"

Wash the inside of the boiler with a high pressure water stream. Loosen any solidified sludge, scale, etc. with a hand scrapper. Start at the top of the boiler and work down. Flush thoroughly after

Section Ten Page 5

cleaning. Where scale buildup is difficult to remove, it may be necessary to clean the boiler chemically. Consult a qualified water treatment specialist for this procedure.

Use a flashlight in preference to extension lights for internal inspection purposes. If an extension light is to be used, be sure the cord is rugged, in good condition and that is properly grounded. It should be equipped with a vapour tight globe, substantial guard and non-conducting holder and handle.

N) LEAKING TUBES

If a tube leak develops due to corrosion, then it is likely that other tubes are corroded also. A capable and experienced inspector should examine the boiler prior to the replacing of one or a few tubes. If all the tubes will need replacement soon, then it will be more economical to replace them now when all the work will be done at one time.

O) USE OF SEALANT

The use of sealant is not recommended. P) MAINTENANCE SCHEDULE

Suggested frequencies for various routines and tests are listed below.

1. Daily (Boilers In Service): Observe operating pressure and temperature and general conditions. Determine the cause of unusual noises or conditions and correct.

2. Weekly (Boilers In Service): a. Observe condition of flame (for oil observe daily). Refer to Section Seven: Burner

Manual for information on the burner supplied. b. Check fuel supply (oil). c. Observe operation of circulating pumps.

3. Monthly (Boilers In Service) a. Relief Valve - Try Lever Test Section 6(H)1. b. Test flame detection devices See Section Seven: Burner Manual. c. Test high limit aquastat (control). Section 6(H)4. d. Test operating aquastat (controls). e. Test modulating or high fire aquastat (control). f. Check boiler room floor drains for proper functioning. g. Test low-water fuel cutoff. h. Check conditions of fireside heating surfaces.

4. Annually a. Internal and external inspection after thorough cleaning. b. Routine burner maintenance Section Seven: Burner Manual. c. Routine maintenance of circulating pump(s) and expansion tank equipment. d. Routine Maintenance of combustion control equipment See Section Seven: Burner

Manual. e. Combustion and draft tests. f. Relief valve pop test - Section 6(H)2. g. Slow drain test of low-water cutoff - Section 6(H)5.

Section Ten Page 6

h. Inspect gas piping for proper support and tightness. i. Inspect boiler room ventilation louvres and intake.

Q) REPAIR

FAILURE TO EXERCISE EXTREME CAUTION AND CARE WHEN REPAIRING BOILERS MAY RESULT IN PERSONAL INJURY.

1. DO NOT PERMIT REPAIRS TO A BOILER WHILE IT IS IN SERVICE, OR UNDER

PRESSURE, EXCEPT WITH THE APPROVAL AND UNDER THE SUPERVISION OF AN AUTHORIZED INSPECTOR OR RESPONSIBLE ENGINEER.

2. Notify the authorized boiler and pressure vessel inspector when repair work is required. Follow the inspector's recommendations.

3. All repair work should be done by experienced boiler makers. All welding should be done by experienced qualified welders in accordance with ASME Boiler & Pressure Vessel Code Section IX.

4. Safety of the personnel working on your boiler is of utmost importance. Pull the main burner switch and lock it out and tag it, close and lock valves, etc., and always have a man standing by outside when a man is working inside a boiler.

Section Eleven Page 1

WATER TREATMENT A) CONSIDERATION

The following factors should be considered before deciding whether or not to treat the water. 1. The water itself; ie hard, soft, corrosive or scale forming. 2. The initial treatment ie softeners, preheaters, deaerators. 3. The amount of make-up water and blowdown required. 4. The use of the steam or water, ie for heating only or process. 5. The amount of supervision and control testing required.

B) WATER TREATMENT SPECIALISTS

Every boiler plant should be considered on an individual basis. Test kits for day-to-day analysis of your boiler water are available from water treatment specialists.

Do not hesitate to ask for the chemical formulation of the boiler compound supplied.

Make sure the chemicals used do not violate any local jurisdictional requirements with the respect to disposal of blowdowns, draining of boilers, etc.

NOTE: A COMPETENT WATER TREATMENT SPECIALIST SHOULD BE CONSULTED REGARDING YOUR WATER TREATMENT REQUIREMENTS.

C) BOILER WATER TROUBLES

1. Corrosion:

Raw water contains impurities including dissolved gases such as oxygen and carbon dioxide. Soft water is acidic and corrosive. General overall corrosion or localized pitting or cracking in stressed metal can occur. High temperatures accelerate these reactions. If uncorrected, serious pitting can result with possible rupture of boiler tubes.

Rusty water in the gauge glass is a sure sign of corrosion, either in the boiler or in the system.

2. Scale Deposits:

All raw water contains dissolved salts, with hard water containing mainly calcium and magnesium compounds. These solids come out of solution to form hard scaly deposits on hot boiler metal. Scale forms an insulating barrier on boiler tubes and boiler metal surfaces, resulting in heat losses and lower efficiency and possibly overheating and failure to the areas of deposit.

3. Metal (Caustic) Embrittlement:

Under certain conditions of high caustic alkalinity where metal is under stress, cracks can develop in


the metal below the waterline and under welds.

4. Foaming, Priming and Carryover:

These conditions, referring to steam boilers only, refer to the formation of froth and suds on the water surface. Under severe conditions, water is carried over with the steam, resulting in possible scale formation in steam piping and valves and loss in efficiency.

D) CHEMICALS USED

1. Phosphates: a. Trisodium Phosphate (TSP) - Na3PO4 b. Sodium Acid Phosphate - NaH2PO4 c. Sodium Tripolyphosphate - Na5P3O10

Sodium phosphates serve to precipitate hard water salts as insoluble lime and magnesia phosphates. Polyphosphates sequester rather than precipitate.

2. Caustic Soda

a. Sodium hydroxide - NaOH:

Caustic Soda is used to insure proper pH and complete precipitation of magnesium salts. The pH should be in the range of 8.5 to 10.

3. Chromates and Sulphites:

a. Sodium Chromate - Na2Cro4 b. Sodium Sulphite - Na2SO3

Sodium chromate and sodium sulphite are used to control corrosion. Sodium sulphite is an oxygen scavenger.

4. Borates:

a. Sodium Borate - Na2B4o7:

Borates are occasionally used as a buffering agent.

5. Nitrates and Nitrites: a. Sodium Nitrate NaNO3 b. Sodium Nitrite -NaNO2:

Nitrates serve to prevent metal embrittlement. Nitrites are oxygen scavengers, but under certain conditions where dissimilar metals are immersed in the boiler water, particularly copper or brass and soft solder, severe localized corrosion may occur unless suitable inhibiting agents are present. Nitrites are generally confined to hot water systems.

6. Organic Agents:

Organic agents act as protective colloids and tend to keep precipitated hard water salts in


suspension as a sludge. This prevents the formation of dense adherent scale on boiler heat transfer surfaces.

E) BOILER TREATMENT COMPOUNDS

Boiler treatment compounds are for the most part, mixtures of the above chemicals. Solutions of the chemicals are much easier to handle when feeding than solids.

Two widely used basic types are: 1. Those based on chromates 2. Those based on alkaline scale combinations plus sodium sulphite.

F) TREATMENT

External or Internal A water softener is a means of externally treating hard water. However, corrosion is aggravated due to increased carbon dioxide, and foaming is apt to occur.

Deaerators to remove oxygen and carbon dioxide from boiler water are also considered a form of external treatment.

In general, however, the problem is internal treatment.

G) BLOWDOWN

The purpose of blowdown is to keep the concentration of dissolved solids and sludge in the boiler under control. Solids remain behind as water is turned into steam and unless condensate return is 100%, then the solids tend to build up.

As a general rule of thumb, a concentration level of 1000 ppm can be considered a safe maximum. A hard water containing 200 ppm in the feed water would tolerate 5 concentrates in the boiler. Soft water, with 25 ppm solids could be concentrated 40 times before reaching the critical point. The hard water above would require 20% blowdown while the soft water would only require 2%. With soft water, blowdown can possibly he held to once or twice per season. With hard water, blowdown may be necessary once a month or even once a week.

Since blowdown involves heat loss and wastes treatment chemicals, every attempt should be made to keep it to a minimum.

The installation of blowdown lines shall be in accordance with local, regional and national codes and guidelines. Authorities having jurisdiction should be consulted before installation is made.

Where low-pressure steam boilers are used solely for heating and where practically all of the condensate is returned to the boiler, blowdown only as often as concentration of solids require. Boilers used for process steam requiring high make-up should be blown down as required to maintain desired chemical concentration levels and to remove precipitated sediments.

H) WATER CAPACITY


Refer to Specification Sheet, Dimensional Arrangement Drawing or Bulletin for the water volume of your boiler in Section Fifteen.

I) MIXING AND HANDLING CHEMICALS

The chemicals, if liquid, should be diluted; or if solid, dissolved, in accordance with the suppliers' directions before adding them to the system.

NOTE: IF A SOLID TREATMENT IS USED, MAKE SURE IT IS FULLY DISSOLVED.

CAUTION: CARE MUST BE USED WHEN HANDLING CHEMICALS. THE DRY CHEMICAL OR CONCENTRATED SOLUTION SHOULD NOT BE PERMITTED TO COME IN CONTACT WITH SKIN OR CLOTHING.

J) TREATMENT OF LAYED-UP BOILERS

Your AF2, AF3 or CF3 Series boiler must be protected from corrosion when taken out of service for any length of time, such as lay-up for the summer.

1. Dry Method:

The boiler is drained, flushed and inspected. The surfaces are then thoroughly dried by means of hot air. If the boiler room is dry and well ventilated, the boiler may be left open to the atmosphere. An alternate procedure is to use a suitable moisture absorbent, such as a quicklime or silica gel, which would be placed in a suitable container in the boiler. The front (or rear) handhole opening could be used. The boiler is then tightly closed. Check and replace the lime or gel every two or three months.

2. Wet Method:

Drain, flush and inspect your boiler. Fill to the normal waterline, steam for short a time with the boiler vented to the atmosphere to expel dissolved gases. If the boiler is to be used to heat water or for reheat in connection with an air conditioning system, it may be left in this state ready to operate. If the boiler is to be idle for some time, it is preferable to fill the boiler completely. Your regular treatment would be used.

During the down time, if feasible, it is good practice in both steam and hot water boilers, to occasionally circulate the water with a pump to prevent stratification and insure that fresh inhibitor is in contact with the metal.

BIBLIOGRAPHY ASME BOILER AND PRESSURE VESSEL CODE

• Section IV Heating Boilers 1983 • Section VI Recommended Rules for Care and Operation of Heating Boilers 1983

CANADIAN STANDARDS ASSOCIATION

• CSA Standard B51-M1981 Code for the Construction and Inspection of Boilers and Pressure Vessels

McDONNELL & MILLER - ITT FLUID HANDLING DIVISION

• Training and Education Department Manual • Basic Safety Controls for Hot Water Space Heating Boilers • Basic Controls for Low Pressure Steam Boilers • Installation and Wiring Data for Steam Boilers Equipped with Boiler Feed Pumps • Service Guide Bulletin SL-SG • The Problem Solver Guide to McDonnell & Miller

NATIONAL BOARD INSPECTION CODE

• An American National Standard ANSI/NB-23 NATIONAL BOARD - BOILER BLOWOFF EQUIPMENT SPIRAX SARCO

• Steam Utilization Course • Steam and Condensate Services • Steam and Energy Conservation • Steam and Steam Trapping • Maintenance of Steam Traps

THE TRANE HEATING MANUAL

• Volume One - Hot Water Heating • Volume Two - Steam Heating

APPENDIX 'A'

Boilersmith Ltd. May 11, 1993156 Main St. S., Seaforth, Ont. N0K 1W0 Page 1 of 1

COMBUSTION AND FRESH AIR VENTING REQUIREMENTS FOR BOILER ROOMS

NOTE

FRESH AIR AND COMBUSTION AIR INLET VENTSSHALL BE INSTALLED IN CONFORMANCE WITHNATIONAL, REGIONAL AND LOCAL CODES ANDSTANDARDS AND/OR APPROPRIATE LEGISLATION.

Burners draw their combustion air from theboiler room. Therefore it is necessaryto replace this air through Fresh Air andCombustion Air Vents to avoid strongnegative pressure in the boiler room.Such negative pressure could affect theoperation of the burner.

NOTE

Exhaust fans for heating, ventilating andair-conditioning systems shall be locatedand installed so that their operation

a) does not adversely affect the draftrequired for proper operation of fuelfired appliances, and

b) does not allow the air in the airduct system to be contaminated by air orgases from the boiler-room or furnace-room.

Air Requirements and Air Vent Size

A safe approximation of the Fresh Air andCombustion Air required is 10 cfm perboiler horsepower (approximately 8 cfm forcombustion and 2 cfm for fresh air).

Considerations

At least Two Air Vents should be provided,one for Ventilation Air and one forCombustion Air. The Fresh Air Vent shouldbe supplied with a total free cross-sectional area of at least 10 percent ofthe area required for the Combustion AirVent but not less than 10 sq. inches. TheCombustion Air Vent should have a totalfree cross-sectional area of not less than1 sq. inch per 30,000 Btu's / hr but notless than one sq. ft.

Under no condition should the totalcombined FREE AREA of the Fresh Air andCombustion Air Inlet Vents be less thanone square foot.

The Fresh Air and Combustion Air InletVents should be located far enough abovethe ground that snow, debris, etc. willnot block the Vents, generally at alevel not exceeding 7 feet from theboiler room floor.

The areas calculated above are FREEAREA, not Total Area.

THE ABOVE METHOD OF DETERMINING VENTSIZES IS TO BE UTILIZED AS A GUIDE ONLYand DOES NOT CIRCUMVENT THE REQUIREMENTTO CONSULT NATIONAL, REGIONAL AND LOCALCODES AND STANDARDS AND/OR APPROPRIATELEGISLATION FOR REQUIRED AIR VENTSIZING.

THE ABOVE METHOD OF DETERMINING VENTSIZING SHOULD BE USED FOR NATURAL GASFIRED EQUIPMENT ONLY. THE RECOMMENDEDMINIMUM VENT SIZING FOR OIL FIREDEQUIPMENT IS GENERALLY LARGER.CONSULT NATIONAL, REGIONAL AND LOCALCODES AND STANDARDS AND/OR APPROPRIATELEGISLATION FOR REQUIRED AIR VENT SIZINGFOR OIL FIRED EQUIPMENT.

Boiler Room Pressure and Air Velocity

A slight negative pressure (vacuum) inthe boiler room is impossible to avoid.The areas determined by using the abovemay result in a velocity through the AirVents of greater than 250 fpm. As thevelocity through the Air Vents increasesthe negative pressure (vacuum) in theboiler room will also increase which mayadversely affect burner performanceunder certain conditions. Therefore,when the velocity through the Air Ventsexceeds 250 fpm, larger Vents than thosecalculated above may enhance burnerperformance.

A bird screen may be utilized, but not afine mesh screen as these are easilyclogged.

A rain hood or louvre is recommended.

No pipes for liquid should pass near thefresh air inlet vents because of dangerof freezing.

APPENDIX "B"

January 27, 1999 Page 1 of 6BOILERSMITH LTD.

STACKS AND BREECHING

NOTE

The Stack and Breeching shall beinstalled in conformance with national,regional and local codes and standardsand/or appropriate legislation.

The purpose of the stack and breeching is toconduct the products of combustion safely tothe atmosphere. In addition a well designedstack will provide sufficient draft to overcomefriction losses in the breeching and stack.

Considerations

On individual units, a direct verticalconnection off the flue gas outlet of the boiler(it is preferable to support thestack/breeching independent from the boiler)or a horizontal offset connection may beutilized.See Figure 1.

In the case of multiple boilers, it is alwaysbetter to utilize a separate stack for eachboiler. If this is not practical, See Figure 2for a Typical Multiple Boiler Installation withCommon Breeching.

BREECHING

Installation AND Construction of theBreeching shall be in conformance withnational, regional and local codes andstandards and/or appropriate legislation.

Changes in breeching direction, shape andflow area must be accomplished separatelyand as gradually as possible to eliminateturbulence which may adversely affect burnerperformance.See Figure 3.

The Breeching should be as short andstraight as possible without excessive bendsto minimize flow resistance.

A round breeching is preferred over a squareor rectangular breeching and stack.

Insulating the breeching will help to minimizeflue gas condensation which may result inexcessive corrosion. In addition the higherresultant stack temperature will aid inincreasing the available draft.

STACKS

Construction AND Installation of the Stackshall be in conformance with national,regional and local codes and standardsand/or appropriate legislation.

The following types of chimneys are suitablefor use with boilers as supplied byBoilersmith Ltd.

- Rectangular Brick Masonry Chimneys- Radial Brick Masonry Chimneys- Reinforced Concrete Chimneys- Metal Chimneys- Factory-Built, Type A Chimneys - Factory-Built Pressure Fired Chimneys

Factory-Built, Type B, L or Class 1 BH forNATURAL GAS FIRED APPLIANCES ONLYmay be used if the flue gas temperature isless than 500oF and a negative pressureexists at the flue gas outlet vent of theboiler.

APPENDIX "B"

January 27, 1999 Page 2 of 6

STACKS AND BREECHING

The walls of any chimney, gas vent or fluepipe shall be constructed to be gas-, smoke-and flame-tight.

A round stack is preferred over square stack.

Every chimney shall be capable of providingsufficient draft to vent properly the appliancesthat it serves.

The cross-sectional area of the flue pipe shallnot be less than the area of the flue outlet ofthe appliance, except that a taperedreduction in the section of the flue adjacent tothe chimney is permitted provided adequatedraft is maintained.

Insulating the stack will help to minimize fluegas condensation which may result inexcessive corrosion. In addition the higherresultant stack temperature will aid inincreasing the available draft.

A rain cap or hood should be used at the topof the stack to minimize the entrance of rainor snow.See Figure 4.

The top of every chimney shall be at least 3ft above the highest point at which it comes incontact with the roof, and 2 ft above a roofsurface or structure with a horizontal distanceof 10 ft from the chimney.See Figure 5.

Installation of the Stack shall be inconformance with national, regional andlocal codes and standards and/orappropriate legislation.

The stack should be higher than nearbystructures or geographical prominence sincethey could create down drafts or eddycurrent.

SIZING BREECHING AND STACK

A Breeching and stack should be sized onthe basis of maintaining a flue gas flow of 30ft/sec or less with the boiler operating atmaximum capacity.

In the case of a multiple boiler installationutilizing a common stack and breeching, thebreeching should be sized to maintain aconstant velocity of flow. The EquivalentDiameters of Breeching for Multiple BoilerInstallations to maintain a constant velocity offlow are shown in Chart 1.

For single boiler installations the SuggestedMinimum Breeching Size and Boiler OutletDiameters for Boilersmith Ltd. boilers isshown in Chart 2. It is generallyrecommended that the stack size selected belarger than the breeching diameter andshould not be selected smaller than the fluegas outlet supplied with the boiler.

EQUIVALENT DIAMETERS OF BREECHINGFOR MULTIPLE BOILER INSTALLATIONS

Required Equivalent Diameter of BreechingDiameter to maintain approximately the same(inches) flue gas velocity for one to five boilers (in inches)

one two three four five Boiler Boilers Boilers Boilers Boilers

6 8 10 12 14 8 12 14 16 18 9 13 16 18 20 10 14 18 20 22 12 16 20 24 26 13 18 22 26 30 14 20 24 28 32 16 22 28 32 36 18 26 32 36 40 20 28 34 40 44 22 32 38 44 50 24 34 42 48 54 26 36 44 52 58 28 40 48 56 62 30 42 52 60 68 32 45 56 64 72

CHART 1

MINIMUM BREECHING DIAMETER(inches O.D.)

BHP Minimum Breeching Boiler OutletDiameterDiameter

< 20 6 8 25- 30 8 8 30 8 10 40- 45 10 10 50- 60 10 12 65- 80 12 12 90-125 14 14135-155 16 18160-200 18 24215-255 20 24275-300 22 30315-350 24 30360 26 30380-400 26 36420-450 28 36500-515 30 42550-600 32 42

CHART 2

January 13, 1993 APPENDIX "C" Page 1 of 7

LIGHT OIL (No. 1 or No. 2) PIPING INFORMATION

CAUTION

The following informationpertains to two-pipe oilsystems for No. 1 or No.2 fuel oil which can beburned without pre-heating. Systemsdesigned for two-pipeoperation CANNOT be usedfor one-pipe operation.

Consult NATIONAL,REGIONAL and LOCAL Codesand Standards.

NOTE

C e r t a i n s i z e dboiler/burner units aresupplied with remote oilpump sets. The pumpdischarge piping is fieldinstalled for theseunits.

NOTE

Always provide a primingtee and plug in thesuction line at thehighest possible point toaid in priming the pumpand in expelling air.

GENERAL

The light oil burner, assupplied by Boilersmith Ltd.,comes complete with anindividual burner oil pump foreach burner. Theinterconnections involvingsuction line(s), returnline(s), and oil tank are fieldinstalled.

The proper field installationof the fuel oil piping and fueloil storage system is mostimportant to the success of anyburner operation. If suctionpiping is not air tight, or ifsuction and return piping arenot properly sized, burnerperformance will be impairedand not dependable.

Long or oversized inlet linesmay require the pump to operatedry during initial bleedingperiod. In such cases, thepriming may be assisted byinjecting light oil into thepriming tee located at thehighest point above the burner.

Installations putting fuel oilwhere it is exposed totemperature extremes should beavoided. The pour point limitfor No. 1 and No. 2 fuel oilsnot seasonally adjusted is 00Fand 200F, respectively.



NOTE

The auxiliary light oiltransfer pump should belocated as close aspossible to the oilstorage tank.

CAUTION

Maximum recommendedpressure on return sideof pump is 3 psig.

Consult the pumpm a n u f a c t u r e r ' sspecification sheet andinstall in accordancewith NATIONAL, REGIONALand LOCAL Codes andStandards.

CAUTION

IF an oil transfer pumpis used, the Maximumrecommended pressure onthe suction side of thepump is 3 psig.

Consult the pumpm a n u f a c t u r e r ' sspecification sheet andinstall in accordancewith NATIONAL, REGIONALand LOCAL Codes andStandards.

AUXILIARY LIGHT OIL PUMP

An auxiliary light oil transferpump should be used whereindividual burner pumps arebeyond the practical pumpinglimit. This pump should belocated as close as possible tothe oil tank and should besized to circulate twice themaximum oil consumption(preferably through a non-pressurized loop).

The oil transfer pump is usedto deliver oil to theindividual burner pumps under aslightly positive head througha circulating loop sized for nomore than 3 psig pressure drop.

The positive displacement gear-type light oil pump is of sucha design that its pump sealwill be damaged if the returnline pressure exceeds 3 psi.

OIL TANK

The oil tank should beinstalled in accordance withlocal, regional and nationalbuilding codes and standards.

LIGHT OIL PIPING

The individual burner light oilpump is a gear type, whichshould not pump at a vacuumgreater than 10 inches Hg or 10foot lift from the bottom ofthe oil storage tank to the



CAST IRON FITTINGSARE NOT ALLOWED

D O N O T U S ECOMPRESSION FITTINGS

DO NOT USE TEFLONTAPE

pump plus 100 feet horizontaland vertical run (includingequivalent length of pipe forfittings, valves, etc.).Although the pump is capable ofdeveloping higher inletvacuums, excessive vacuumoperation should be avoidedbecause of vapour binding,noisy pump operation, andexcessive pump wear. Coppertubing should be used inpreference to iron pipe, as itrequires less work, is neater,has less possibilities of leaksand does not scale off on theinside. For protection fromdents and bending, it isdesirable to run the tubing inconduit pipe or tile.

FLARE TYPE FITTINGS arerecommended, as the solderedtype may melt in case of fire.

Connections to buried tanksmust be made with swing jointsor copper tubing to prevent thepipes form breaking in case thetank settles. If localrequirements stipulate thatiron pipe be used, swing jointsmade up with elbows and nipplesseveral inches long should beused on both the suction andreturn lines as close to the

tank as possible.

The swing joints should be madeup so that they will tighten asthe tank settles. Non-hardening pipe joint compoundsshould be used on all threadedjoints.

All oil suction piping must betested for leaks beforeconnection to the individualburner pump. The oil suctionline between the pump andsuction inlet (closest possibleconnection at tank) should bepressure tested using air.There should be no noticeablepressure drop over a period ofseveral hours.

An alternate oil suction pipingtest consists of subjecting thesuction line to a vacuum of notless than 20 inches Hg forseveral hours without anoticeable drop.



NOTE

The total suction pipingloss of a system is thesum of the vertical liftloss and the total pipelength loss (horizontaland vertical).

Total pipe length loss isdetermined by adding thetotal straight lengthplus the equivalentstraight length valuesfor all other pipefittings, valves,strainers, filters, etc.

NOTE

Each Pump should have itsown individual suctionline.

OIL PUMP SUCTION AND RETURNLINE SIZING

The size of the oil linesuction line is dependent uponthe type of oil, amount oflift, length of suction lineand suction capacity of thepump.

On single pump installationsthe return line should be thesame size as the suction line.

Since most trouble in light oilsystems is attributed to leakyoil suction lines, on multiplepump installations each pumpshould have its own individualsuction line.

One return line may be used aslong as it is "appropriatelysized" since all pumps mayshare a common return line.

Refer to pump manufacturer'sbulletins for proper linesizing.

The lines from the tank to theburner should be sized fromdata contained in the pumpmanufacturer's specificationsheet, but in NO INSTANCEshould they be smaller than1/2" o.d. copper tubing.

Install tank slip fittings inthe top of the tank for boththe suction and return lineconnection. Push both suctionand return lines down throughthe fittings until they touchthe bottom of the tank and thenpull the suction line up threeinches and lock in positionwith a compression nut. Pullthe return line up six to seveninches from the bottom of thetank and lock in position witha compression nut.



NOTE

Hand valves must not beinstalled on dischargeside of pump or returnline without a bypassrelief to tank.

A check valve issometimes utilized toprevent oil spillage whenit becomes necessary todisconnect the returnline at the pump.

Do not use globe typevalves in the suctionline due to excessivepressure drop.

Use gate valves toisolate oil accessories.

OIL SHUTOFF VALVE

A hand shutoff valve should beprovided in the suction linenear the burner.

Fusible Valves (Melt Valves)are available. In the case ofan oil tank positioned higherthan the burner unit, andshould a fire develop, oilcould run out and intensify thefire. A fusible valve helps tominimize this risk.

NATIONAL, REGIONAL and LOCALCodes and Standards may requirethe use of fusible valves.

CHECK VALVE

Properly installed fuel oilsuction lines do not requirecheck valves for properoperation.

However, check valves are oftenused to compensate fordeficiencies in oil linepiping.

For example :

a) Not having the return linesubmerged in the oil in the oiltank.b) Having vacuum leaks in theline due to using compressionfittings, bad flare fittings,porous fittings, loose fittingsor leaky lines.

Disadvantages

Check valves increase theamount of vacuum the fuel unitmust overcome to supply oil tothe system and reduce thedistance supply lines can berun.

When installed near the fuelunit, check valves causeturbulence and stripping of airfrom the oil, resulting indirty and/or noisy combustion.

Do not use check valves ingravity feed (tank above pump)single- pipe systems, or insystem supplied by a boost ortransfer pump. Thermalexpansion can cause seriousproblems.



NOTE

Select a check valve ofthe soft seated typesuitable for No. 2 oil,which will seat tightlywith a low head.

NOTE

The Strainer/Filtershould be sized for thetotal pumping capacity ofthe oil pump, not thenozzle capacity.

NOTE

Always provide a primingTee and plug in theSuction Line at thehighest possible point toaid in priming and inexpelling air.If a check valve must be used

and the top of the oil tank isbelow the burner level, use alift type check valve withneoprene seat.

STRAINER/FILTER

An oil strainer/filter ofadequate capacity must be used.

It is our recommendation that astrainer/filter should not beless than 0.75" npt pipe size.

OIL SUCTION LINE

Suction piping should bepitched back to the tankslightly whenever possible andparticular care should be takennot to create an air trap inthe line. There is always aslight amount of air insuspension in oil, and if air

traps are present, they willgradually fill with air, andthe pump will lose its prime.

Removal of air is generallyvery difficult.

See the pump manufacturer'sinstructions for priming andventing.

A two-pipe system is requiredfor all installations. Boththe suction and return pipingshould be run in a trench underthe floor level where possible.

Other than at the oil pump,which generally has a smallersupply and return connectionthan the recommended pipingsize, DO NOT install valves,fittings, filters, etc. thathave an inside diameter or portsize smaller than the insidediameter of the oil suctionpiping.

Always leave provision on theoil suction line between thefilter and oil pump for theinstallation of a vacuum gauge.



CAUTION

Overhead suction linesshould be avoided unlessan auxiliary oilcirculating pump set isused.

Maximum standpipe heightabove the burner pump is7.5 feet unless specialdevices are installed toprevent hydraulic shockfrom causing pump sealleakage.

Always leave provision on thereturn line, near the pumpreturn connection, for theinstallation of a pressuregauge.

APPENDIX "D"

1

12 Ways To Avoid Boiler Tube CorrosionBy: H. F. HinstPlant MetallurgistTubular Products Division, Keystone PlantThe Babcock & Wilcox Company

Corrosion troubles in low pressure heating boilers -- which usually operate at a steam pressurebelow 15 psig or water pressures below 30 psig and are often of the horizontal fire tube type --often occur unnecessarily.

During the past 60 years we have had many occasions to examine boiler tubes todetermine the reason for their failure. In very few cases have any defective qualities in the tubingbeen the cause of the corrosion. In the vast majority of instances, the necessity for replacementhas been traced to conditions of environment.

In power boilers, it is a rare occurrence to find corrosion of the type common to heatingboilers. This is because operators of power boilers realize the importance of proper water and fireside conditions and take care to avoid such problems.

The users of heating boilers are, first of all, usually not aware of the possibilities ofcorrosion. Often they have little idea what causes it and lack the know-how and experience tocombat it. Fortunately, scale is not a major factor in low pressure boilers, although a buildup ofscale at tube ends has occasionally resulted in failure by grooving next to the tube sheet.

Let us first consider the various mechanisms which lead to pitting or water side corrosionsince this is the most common type. This accounts for 75 percent of the tubes examined in ourlaboratory.

Steel does not corrode appreciably in dry air, but only in the presence of moisture.Likewise, steel will not corrode in clean, alkaline, freshly-boiled water, if air is kept away.

This has been proven to our satisfaction by placing samples of tubes in ordinary tap waterin flasks and boiling the water, causing the steam to condense and run back into the flask. Whenwe allowed the condensed drops of water to be free to contact the air, corrosion of the tubes tookplace. When we took the oxygen out of the air in the flask and condenser by running the airthrough pyrogallic acid (which is an oxygen-absorbing liquid), no corrosion of the tubes tookplace.

Oxygen and Velocity Factors

This proves that the presence of oxygen is an important factor in corrosion problems. It

APPENDIX "D"

2

was also found that if the heaters were shut down at night, the corrosion was much more rapidthan if the apparatus were kept boiling. In effect, some of the oxygen was excluded from the flaskby the steam space over the boiling water. In low pressure heating boilers, however, the returnwater usually enters at the bottom, which does not afford the oxygen reduction which would beobtained if it would drop through the steam space.

Pitting is probably the most destructive form of corrosion that affects the water side ofboiler tubes. Frequently, only a few pits are present and most of the surface is unattacked. Inother cases, the pits cover most of the surface, and as a further extreme, the pits all run togetherand the corrosion takes the form of uniform attack. The frequency of the pits is determined to alarge extent by the degree of acidity or alkalinity of the water.

Acidity and alkalinity are dependent upon the amount of hydrogen-ion concentrationfound in the water. Both would be expressed in terms of the pH scale. A strong acid solution --strong muriatic or sulfuric acid -- is rated as 1; a strong alkaline solution -- concentrated causticsoda -- is rated as 14. A neutral water has a pH value of 7.

Below a pH of 5, the water is actually sufficiently acid to dissolve the steel, and underthese conditions no pits form. Instead, the corrosion is relatively uniform and the steel graduallygets thinner until it is too weak to hold the pressure, or a small hole develops.

Between a pH 5 and 9.4, pitting takes place at a rate depending on the concentration ofoxygen in the water. Therefore, while operating the boiler, it is necessary that all air or as muchair as possible be excluded from the boiler water.

It has been shown that a strip of steel hung in the middle of a fast moving stream did notrust, while an identical piece hung in a stagnant pool along the edge of the same stream pittedbadly when connected to the first by a wire. This proves that velocity and air content have aneffect on the corrosion of steel. In most cases, the pitting in horizontal fire tube boilers takesplace along the top of the tubes on the outside, and it is our belief that this may in part be due tothe difference in velocity of the rising water and steam bubbles, creating an eddy effect along thetop of the tube and accelerating the corrosion, much as did the experiment of the flowing stream. In any event, pitting would not occur in this type of boiler if no oxygen were present in the water.

Practically all ground surface supplies of water contain dissolved air in quantitiesdepending on its source, time of exposure and its temperature. Cold water will retain more airthan warm water, as can be seen by filling a clear bottle with cold water from a tap and allowingit to stand overnight. Small air bubbles will form on the sides, demonstrating that as the waterwarms up the gas is liberated.

This release of the air in the form of bubbles creates a problem in a newly filled boiler. In

APPENDIX "D"

3

a new boiler, or in one which has been drained and refilled with cold water, as the water warmsup, air bubbles form on the tubes. In a very short time pits develop under these bubbles, due tothe difference in oxygen concentration under the bubbles and the oxygen concentration in thewater surrounding the bubbles. Penetration as high as 50 percent of the tube wall has beenknown to take place in one stagnant period of two weeks duration. Once these pits form, theyproceed rapidly even under operating conditions.

Why New Tubes Corrode

Sometimes a set of new tubes installed in a boiler has been found to last less than a year,whereas the former tubes lasted five to ten years. Obviously, something has changed. Often thetubes are blamed for the failure, when actually there have been changes associated with theoperation and maintenance of the boiler. A different method of starting up may have been used.Circumstances may have been such that the boiler was immediately fired when the old set oftubes were put in, while the new set may have been exposed to the fresh water for some time andair bubble pitting may have started, leading to the eventual failure of the tubes. The temperatureof the fill-up water may have been different; and, therefore, more air was present in the newinstallation. The composition of the fill-up water may have changed; a thin scale may have beenlaid down at the beginning of the life of the old tubes, which served as a protection. Changes inelectrical connections may have induced stray currents, leading to possible electrolytic corrosion. Small air or steam leaks around pipe joints and valves may have let air into the new setup. Airvents may have become plugged due to jarring of the piping. In short, any number of things mayhave happened and caused the failure.

A large number of boiler tube failures take place in the fall when starting up for winteroperation. These are due to both the air bubble pitting previously mentioned, and to oxygensucked into the system through packing and other sources.

Remove Air From Water

The bottle test shows that air can be removed by heating both the fill-up water and theregular feed water. After every filling, a steam boiler should be heated to bring the water to agood boil and the steam so produced should be vented off to carry the released gases out of theboiler. Before this boil out, water treating chemicals should be added so as to get good mixing. After the boil-out, the vents should be closed and the boiler used or cooled down if not needed.

In hot water systems, production of steam is not desirable, so the water temperatureshould be raised to 180° to 200° F for a short time to allow most of the air to be driven off through vents.

In larger boiler installations, air is removed from the feed water by heating it to the

APPENDIX "D"

4

boiling point and venting off the dissolved gases. In small installations, this is hardly practical.

However, in steam systems requiring large quantities of make-up water, it may bepossible to fit the return condensate tank with a steam coil to preheat the water to near the boilingpoint. This tank would have to be vented to release the gases.

Another method suggested by F. N. Speller, a noted authority on corrosion, is to pass thefeed water through a de-activator, which is a tank containing steel scrap, such as turnings orwires. The oxygen in the water attacks the steel in the tank so that corrosion properties areneutralized. The process is satisfactory if the tank is big enough to permit complete de-activationand if the scrap steel is renewed often enough. The practice is not frequently followed in steelheating boiler installations because other methods of control are usually more desirable.

In addition to the air carried in by make-up water, substantial quantities may be pulledinto the system during operation by the vacuum in the condensate line, or by the vacuum formedwhen the boiler is shut down or the fire is allowed to die off. In small heating boilers, warm daysduring spring and fall and even in the winter often result in cooling down a boiler and radiators.Condensing steam creates a vacuum which pulls air into the system through leaking pipeconnections, traps, vents, valves and packing. Proper maintenance of the entire heating system isa must.

Hot water systems should not suffer from air entering with make-up water because make-up water should not be required. We say should, but there are cases when it is required becausecleaning people are drawing off hot water, garage men are washing cars with it, circulatingpumps leak, floats become water-logged or automatic feed systems stick.

Systems are sometimes designed to be pressurized with compressed air in such a way thata large area of water is exposed, allowing dissolving of air to take place. We have seen systemswhere well water was pumped into a horizontal cylindrical tank which was pressurized with airacross its whole surface. Another system had hot water from three boilers pumped to anoverhead horizontal tank of about 5,000 gallons capacity, which was pressurized withcompressed air from a pump in another building. No one had any idea of how much air wasbeing pumped into this system. Eighty pounds of sodium sulfite (an oxygen scavenger) addedper day to this system could not keep up with the dissolved oxygen being pumped into it.

Any pressurizing of this type should be in an offshoot of the system, not in the mainstream. If it must be in the main stream, nitrogen gas should be used for pressurizing.

Obviously, there are many ways air can get into boiler water; it's difficult to keep it out. Fortunately, however, there are methods for rendering it inactive.

APPENDIX "D"

5

How To Remove Oxygen

One method of removing oxygen from boiler water is through the use of an oxygen-absorbing chemical such as sodium sulfite. If only small quantities of oxygen are present, theaddition of this chemical is practical. It is impractical, however, to try to remove large amountsof oxygen by using this chemical in large quantities, because constant additions would causefoaming. Control of alkalinity of the water must be maintained in conjunction with the use ofsodium sulfite. The pH should be 9.5 or higher.

Hydrazine is a chemical frequently used in large utility boilers to remove dissolvedoxygen. However, it is not recommended for heating boilers because it must be closelycontrolled. Very seldom is such chemical control available in these installations.

Inhibitors are a class of chemicals which deposit a coating on the surface of the steel orreact with it in some way to protect it against attack. These inhibitors, usually composed mainlyof sodium chromate, are available from most water treating companies. When added to the waterin the recommended quantities, they will protect the boiler surfaces during either operations orstandby. Since they are harmful if taken internally, and may stain other products, they should notbe used wherever the steam is to be used for process work. These compounds have theadvantage of imparting a yellow color in the water, which the boiler user can see in the gageglass, and thus readily determine if more is needed.

Some trouble has been experienced from use of these compounds in hot water systemsdue to the formation of sodium chromate crystals in pump seals, resulting in leakage. Concentrations lower than the 2.2 pounds per 100 gallons recommended for steam boilers havebeen suggested for hot water boilers.

The value of this compound, and of another inhibitor containing sodium nitrite andsodium nitrate, was established in a series of tests performed at the Babcock & Wilcox Research& Development Center. These tests proved that both the sodium chromate and the sodiumnitrite-nitrate inhibitor were effective not only in preventing attack by dissolved oxygen, but alsoin stopping further attack after it had started. There are some limitations on the amount ofchlorides or sulfates that can be tolerated, but these are seldom a factor in waters used in heatingboilers.

A few years ago, there was a flurry of "gadget" type water conditioning cure-alls beingoffered. One such device, designed to fit into a supply line, was purchased and tested. It provedineffective in either preventing or stopping corrosion of the tubes.

Don't Drain Chemicals

APPENDIX "D"

6

Many boiler owners completely drain their boilers once or twice a season under amistaken belief that the water in the boiler is dirty. Actually, this practice, and the practice ofperiodically draining small quantities of water from the boiler, should be discouraged. It causesloss of chemicals and requires make-up water, which brings in more oxygen. However, ifadditional chemicals are added each time to compensate for losses, little harm will be done. Insurance companies require periodic tests of the low water cut-off, and at such time protectionshould be insured by the addition of such chemicals.

Instead of inhibitors, alkalizers such as caustic soda may be used. It is recommended that2 oz. of caustic soda per 100 gal. of boiler water be added at the time of a fill up. This will insurea pH of 11 to 11.5, which will greatly reduce the pitting effect of dissolved oxygen. Some prefera lower concentration, down as low as 1.3 oz. per 100 gal.; but, except for the possibility offoaming, the larger quantities can do little harm, and act as a safety factor should losses takeplace by draining. However, alkalizers will not stop pitting once it has started.

In new boilers, or in old boilers which have been retubed, a boiling out using cleaningcompounds is suggested. This is necessary to remove oils and other coatings put on the tubes bythe manufacturer prior to shipment or storage. These materials are put on the tubes to protectthem from rusting during storage and transit, and have no place in a boiler. Since they mayshield portions of the tube from direct contact with the water, pitting may be accelerated. A goodboil-out is recommended, using a cleaning compound such as one of the newer detergents, or amixture of 2-1/2 lb. of caustic soda and 2-1/2 lb. of soda ash per 100 gal. of boiler water.

Fire Side Corrosion

Approximately 15 percent of the tubes we have examined have failed by fire side attack. Corrosion on the fire side of boiler tubes is caused by moisture condensing from the atmosphereduring periods of shutdown, or from flue gas condensation during operation. This type ofcorrosion is especially troublesome in boiler installations near bodies of water, or where theatmosphere is otherwise humid. Fire side corrosion is accelerated by the use of high sulfur fuels. Sulfur gases may condense on tube surfaces during operation; depending upon the kind of fuel,its sulfur content and the methods of firing.

Accumulations of soot on the tubes should be periodically removed. Soot attractsmoisture; and air, moisture and steel together result in attack of the tubes. Cleaning may bedaily, weekly or monthly, depending on the fuel used and the method of firing.

Some hot water boilers -- for example, those in greenhouses -- may operate at watertemperatures of 140oF to 150oF. Under such conditions, the condensing gases from coal or oilfiring form sulfurous acid which attacks the tubes and results in a more uniform type ofcorrosion. If the percentage of sulfur in the fuel is high, this situation is worse. Even in the

APPENDIX "D"

7

absence of sulfur compounds, corrosion may occur during shutdown periods because of highhumidity in the air. When shutting down the boiler under such conditions, the fire side tubesurfaces should be brushed and flushed to remove the winter's accumulation of soot and otherproducts of combustion. This should be followed by blowing air through to dry out thesesurfaces. A light coat of oil should be applied for further protection. Also, in extremely humidlocations, the stack should be disconnected, or at least the damper should be closed, and a tray ofunslaked lime placed in the ash pit to keep the fire side dry. This lime must be renewedwhenever it becomes mushy, so the drying effectiveness will not be lost.

Many samples of scale removed from fire side surfaces have been found to be acid whenmixed with water. The presence of this acid may cause the tube metal to eat away to eventualfailure.

Often, boiler rooms are in damp cellars, some with water on the floor constantly. Duringthe summer months, in particular, humid air tends to build up in basements, causing clothes andleather to mildew from the dampness. Similarly, humid air may have ready access to the fire sideof boiler tubes in basement installations if the tubes are not properly protected.

Even with gas firing of hot water boilers, serious fire side attack can take place. Someinstallations employ outdoor-indoor thermometers to control system water temperatures asoutdoor temperatures fluctuate. Low water temperatures can result in condensation of moisturefrom the flue gas and lead to serious corrosion of the tubes. High water temperatures reduce theprobability of attack.

Some horizontal tube boilers suffer from a mechanism called "necking" and "grooving." This shows up as a circumferential groove around the outside of the tube where it enters the tubesheet. It usually occurs at the beginning of the first pass, which is the hottest end of the tubes. Inall cases, there is some corrosion in evidence in other areas, but it concentrates at the endsbecause of strains from two sources. When tubes are rolled in, some unavoidable expansiontakes place back of the tube sheet. Secondly, when a boiler heats up, the metal in the tubesexpands and lengthens. Consequently, strains are set up at the ends, which are fixed in the tubesheets. Sometimes these expansions are so severe that the tubes loosen in the sheets. Scaleforming at the tube ends tends to flake off, exposing fresh steel to further attack. This problemcan be reduced by more gradual firing, more gradual changes in temperature, and maintaining theboiler water free of oxygen and under proper control.

Following the precautions and controls described in this article should result in manyyears of trouble-free, economical operation.

APPENDIX "D"

8

Follow These Rules

Out-of-Service Factors

1. Boil out the boiler with an alkaline cleaner after installing new tubes to remove oil orother coatings from the tube surfaces. These protective coatings are commonly applied tonew tubes to prevent rusting during storage and transit, and will cause corrosion if left onthe tubes during operation of the boiler.

2 Bring a steam boiler to a good steam output as soon as it is filled to deaerate the water. Heat the water in a hot water boiler to 180oF for the same reason. A temperature of 180oFwill not remove all the air, but the majority will be driven off.

3. Add sodium chromate or sodium nitrite - nitrate inhibitors to the water in the quantitiesrecommended.

4. In greenhouses or in damp locations, put a tray of unslaked lime in the ash pit to absorbmoisture, and close the boiler. Inspect this lime occasionally and renew when it becomesmushy.

In-Service Factors

1. Keep all boiler and system fittings airtight.

2. Add sodium chromate or sodium nitrite - nitrate inhibitors to the water in the quantitiesrecommended.

3. Preferably, use a fuel with low sulfur content to avoid the corrosive action of sulfur gases.

4. Brush, flush and dry out the insides of fire tubes as often as possible to remove soot andother products of combustion, and to prevent the accumulation of moisture andcondensed sulfur gases.

5. Use sodium sulfite regularly in the boiler feed water to remove dissolved oxygen.

6. Use suitable feed water heater or deaerator to reduce the oxygen content of the boiler feedwater.

7. Prevent water leakage and avoid draining water from the system. Addition of make-upwater results in loss and dilution of the treatment, and introduces air into the system.

8. Don't pressurize a hot water system with compressed air over large areas of water.

Safer maintenance of steel heating boilers

A modest investment in a sound maintenance program for steel heatingboilers can return dividends to both owners and operators.

For owners this can mean less expenditures for repairs, moreefficient operations, and longer life for the equipment. Most of all,a planned program, properly executed, can reduce the likelihood of anaccident capable of curtailing production or even closing down theplant.

For operators, maintenance results in safer operations -- reasonenough to adopt the program -- and a generally improved workingschedule. Many minor difficulties that frequently lead to majorproblems can be avoided.

General characteristics

Most steel heating boilers possess characteristics similar enoughto afford a general discussion of maintenance practices in a singlearticle. However, some belong to service or size categories thatrequire special maintenance--for example, very large fire tube andwater tube boilers--and can therefore be included here only as generalpractices apply. For the most part this article is concerned withsteel boilers in moderate size factories, schools, and officebuildings.

Any discussion of heating boiler maintenance is incomplete ifconnected equipment is not included, especially closely associatedmajor equipment such as the heating system. Accident reports show thatboilers often become victims of troubles originating somewhere else.No amount of care of boilers alone can prevent such accidents.

Most service and maintenance should be performed during idleseasons, when equipment is available for examination, testing andrepair; some must be completed immediately following in-servicetesting that discloses defects.

Cleaning practices

Some owners and operators of boilers are of the opinion thatcleaning of the external and internal surfaces of the boiler may beaccomplished anytime during the idle season. Therefore, the boilerreceives little or no attention while it is out of use, and cleaningis virtually forgotten until just prior to the heating season.

To be most beneficial and to keep corrosion at a minimum it isimportant that all cleaning be performed at the start of the idleperiod. By so doing the working life of the equipment can be extended.Preparation for the idle season should first include proper cleaningof the boiler. External cleaning should receive priority.

As soon as possible after the close of the heating season, sootand ashes should be removed from the fire side surfaces of the boiler.Otherwise, moisture from the atmosphere or from a leak in the boilermay combine with chemicals, especially sulphur compounds from the

fuel, to form an acid that will quickly corrode the boiler plates.Damp ashes behind furnace brickwork should be given special attention.Moist soot in chimney connections and fire tubes poses a threat to theserviceability of metal that was already relatively thin when it wasnew. External cleaning must be prompt and thorough.

Internal cleaning, by comparison, usually requires little effort.Heating boilers use only small amounts of makeup water and littlescale is produced. However, these boilers often are found to containdeposits of sediment, largely rust from the heating system, that maybecome troublesome if left inside. It can form dams that will createpuddles in hard-to-see parts of water legs. This moisture promotescorrosion, To do a necessarily thorough job of cleaning, all washoutplugs and hand hole or manhole plates should be removed.

In addition, certain attachments to boilers are likely to collectdeposits that must be removed periodically. Connecting lines for watercolumns, low-water fuel supply cutouts, and emergency water feeders --including the chambers for the cutouts and the feeders -- at timesbecome clogged. The clean-out plugs in the connecting line fittingsshould be removed and the chambers should be opened. After the linesand chambers are cleaned they should be left open if an internalinspection of the boiler is scheduled during the idle season.

Idle season lay-up

Two methods, the dry and the wet for storing a boiler duringextended idle periods are recognized. The advantages or disadvantagesof each depend somewhat on the boiler size, type, kind of service, andlength of idle season.

If the idle season is two or three months long, users of moststeel heating boilers prefer the dry method. It entails little effort.It keeps the boiler prepared for inspection by the authorizedinspector; and it prevents internal corrosion reasonably well in mostinstances.

After the cleaning and inspection is finished, the boiler isprepared further by blotting, sponging, siphoning, or otherwiseremoving all collections of water from the bottom of water legs andother low places. A vent opening for air circulation should beprovided in or near the top of the shell, even if the removal of asafety valve or other connection becomes necessary.

Usually, the foregoing meets the needs of small boilers, thosethat are too small for manholes, but forced drying with heat often isrecommended. Only an experienced engineer should consider such anundertaking.

After the drying operation is completed, a drying agent may beplaced inside, and the boiler may be closed. Two pounds of quick lime,ten pounds of silica gel, or the equivalent of some other desiccant,for each thousand gallons of boiler water capacity will suffice inmost instances.

The wet method has at least one advantage over the dry method ofstorage: the boiler requires little preparation for service, andtherefore it may be fired soon after it is needed. When cleaning andinspection are completed, the boiler is closed and is filled to thetop with water that has been treated to prevent corrosion.

Owners of small heating plants are advised to get instructionsfrom a qualified boiler water chemist if the wet method of storage isused. If corrosion is to be controlled, proper lay-up procedures mustbe observed.

While in storage by either the dry or the wet method, a boilershould be treated with reasonable care. The furnace must never be usedas a receptacle for trash, especially not if it is to serve later asan incinerator for the collected trash. To prevent such abuse byothers, the person in charge should either fasten a warning sign tothe firing door or should place a lock on the boiler room door, orboth. To avoid almost certain damage that would result from firing anempty boiler, appropriate fuses in the firing system should be removedor other means should be adopted for keeping the unwitting or would-beoperator from firing the boiler.

Maintenance and service

As soon as possible after the boiler has been prepared for anidle period, attention should be directed toward the heating systemand associated equipment. The kind and extent of the service effort tobe applied is frequently determined by experience -- the type ofexperience, unfortunately, that makes itself known most forcefully viaboiler accidents.

The type of boiler accident known as a low water accident occursif the fuel continues to burn in the furnace of the boiler when theboiler water level falls below the minimum safe point of operation.From a frequency point of view it outstrips all other types of boileraccidents. Usually, heating boilers require little makeup water. Thismeans that most such accidents happen because something stops thesupply of return water.

Condensate return pumps, though not the greatest source oftrouble, fail in service for many reasons, resulting in low wateraccidents. Pumps fail to deliver water when they become steam bound orwhen bearings burn out. and moving parts in time become so worn thatthe pump can no longer carry its load. At times, moreover, the pumpsand return lines freeze during cold snaps only because those in chargeforgot to replace nearby broken windows.

The piping and other parts of the connected heating system causereturn water losses for reasons less subtle than wintertime freezing.Usually piping corrodes internally. Sometimes it makes its presenceknown by causing minor leakage at some threaded joint in an openplace, where fortunately it may be found before some form of waterdamage results or a low water accident happens. When the steam fittermakes the repair, he often finds that all adjacent piping requiresreplacement. Internal corrosion penetrates the pipe wall and corrosionproducts clog pipes and fittings. In time, these products can beexpected to interrupt the return flow of condensate. Also, if eitherthe supply or return piping passes unprotected through coal bins orunderground, failure from external corrosion will occur eventually.

Traps in heating systems also contribute to water lossdifficulties. Defective traps pass steam to the return system, and thesteam escapes through the vent on the condensate return tank. Steam inthis tank may also heat the condensate enough to cause steam bindingof the return pump. If the emergency water feeder should fail (itoften does through lack of use), or if the boiler has no emergency

water feeder, the steam loss might well result in a deficiency ofboiler water.

Defective vents on the piping, especially those installed inisolated places, also may waste steam in amounts large enough to lowerthe boiler water level in time.

Expansion tanks on hot water heating systems require periodicattention too. At least once a year, preferably before the start ofeach heating season, they should be drained. Otherwise, they maybecome waterlogged and cause the water relief valves on the boilers todischarge each time the water undergoes thermal expansion. The causeof such a discharge has been misunderstood occasionally and hasinduced uninformed operators to tighten relief valve springs or toplug discharge ends of escape pipes, an obviously dangerous "cure".

The firing system, particularly the burner for the boiler, isanother part that must have attention, and many users contract withservice organizations to check and maintain it. Failure to keep it inorder may result in loss of heat during a cold period or, worse still,in a furnace explosion as a result of a delayed ignition ofaccumulated fuel.

If the fuel is gas or oil, a few general remarks on common faultsfound during inspections will indicate what to expect. Ignitionelectrodes may burn, become coated, or become displaced. Ignitiontransformers may deteriorate or fail completely. Fuel lines leak,.fuel strainers become stopped, and fuel valves leak or fail to closewhen dirt lodges between discs and seats. Air-fuel ratios drift untilthe flames stifle when someone closes the last open window or door tothe boiler room, thus eliminating needed combustion air. Many ownersand operators have learned too late that a permanent opening to theoutside is required and must be installed so that it won't causewintertime freezing of condensate return lines.

Fast-acting, modern flame-failure safety devices serve a definitepurpose. No one can estimate how rapidly boiler accident frequencywould increase without them. But like all safety devices, combustionsafeguards are not foolproof. Not only are the electronic partsthemselves certain to fail now and then, but non-electronicparts--valves, burners, pressure regulators, piping--if neglected, aresure to produce accidents and outages at least occasionally.

Safety devices of all kinds require attention. Safety valves headthe list of such devices that must be kept in working order. In recentyears inspectors have traced the causes of a number of boilerexplosions, some that have injured and killed, to valves with movingparts that had "frozen" in place from neglect and disuse.

Section VII of the ASME Boiler and Pressure Vessel Code proposesa way to avoid such troubles with safety valves on lower pressurepower boilers. It suggests that the boiler pressure be raised highenough at least once a year to pop each valve. It further suggeststhat the safety valve disc be raised to the full open position severaltimes a year by using the lift lever.

Safety valves on heating boilers deserve no less care. Apre-season popping-pressure test and a monthly lift-lever test seemlittle enough effort to expend on such a vital device. Give it a fullpopping-pressure blow before the heating season starts; also, raisethe boiler pressure to within five psi of the popping-pressure andpull the lift lever until the valve opens fully. This should be done

no less than once a month throughout the heating season.

Low-water fuel supply cutouts, and the lines connecting them toboilers, follow safety valves in importance only because low wateraccidents, the kind the cutouts should prevent, kill or injure fewerpeople than do boiler explosions.

As a defense against these forms of distress, low-water fuelsupply cutouts on steam heating boilers (they serve as well on hotwater heating boilers, if maintained) stop burners or fuel flow whenthe boiler water level falls too far. They do, that is, when kept up,but they have many parts that otherwise can and often do fail eitherelectrically or mechanically.

Tests to detect these faults merit a place in the boiler serviceschedule. A real test of a low water cutout takes but little of theoperator's time. Reasonably often, say once a month, he must remain onconstant watch while, by some convenient means. the boiler water levelis lowered slowly until the burner stops, or until it should butdoesn't stop. If it does stop when the water level reaches the cutoutset point, the cutout may be regarded as having passed the test, andthe boiler may be filled and otherwise prepared so that it will resumenormal service. But if the cutout doesn't stop the burner, the causeof failure must be found and corrected without delay.

The low-water fuel supply cutout also requires regular serviceduring both the heating and the idle seasons. Once a week while theboiler is under pressure, the operator should flush the float chamber(if the cutout is a chamber type) thoroughly enough to removecollected sediment. Naturally, the blow down valve must be opened wideenough to flush all the water from the chamber and to extinguish thefire. If it doesn't extinguish the fire the cutout should be testedand, if necessary, repaired. Like other parts of control and safetysystems for modern, automatically fired boilers, cutouts might well betoo complex for most boiler operators to service. The need forthorough service by an experienced serviceman can't be over-stressed.

Most frequent type of accidentis burning and not explosion

Fire Tube Boilers Water Tube Boilers Cast Iron Boilers

Type of Accident Percent Type of Accident Percent Type of Accident Percent

Tearing Asunder 19.0%(Explosion, Rupture)

Tearing Asunder 50.0%(Explosion, Rupture)

Tearing Asunder 5.9%

Crushing (Collapse) 5.0%

Burning 70.0%(Overheating)



Bulging 2.5% Bulging 2.5%

Cracking 3.5% Cracking 1.0% Cracking 92.4%

100.0% 100.0% 100.0%

Contrary to common belief, the most frequent type of accident toheating and power boilers is not explosion. Although explosions are anever-present threat to operation, the most frequent type of accidentis burning, that is, overheating because of a deficiency of water.Burning not only accounts for the largest number of accidents but alsothe largest total dollars in any boiler accident classification.

This frequency table on types of accident classifications is basedon an analysis of the type of accident, the specific part of the objectthat failed, and the primary cause of failure. It is also designed toprovide statistical information to indicate the general directiontoward which accident prevention efforts can best be directed.

The higher percentage of water tube boilers in the tearing asundercategory, as compared to the percentage of fire tube boilers, isaccounted for by the fact that most tube failures in water tube boilersare classified as tearing asunder cases even though burning(overheating) may have been a contributing factor.

The cracking category is confined to the cracking of cast metalparts. In the case of cast iron boilers, however, it is by far the mostcommon type of occurrence. In many cases of cracking, overheating isa contributing factor although the final occurrence is cracking.

Safety check list for boilers

1. Test controls and safety devices regularly. Correct any defectsimmediately.

2. Keep controls and safety devices in proper working condition. Forexample, blow down the chambers of the low-water fuel supplycutout and operate the lift lever of the relief or safety valveregularly, while the boiler is in service.

3. Have a reliable service organization check and service theequipment periodically, both during and between heating seasons.

4. As soon as possible at the end of each heating season, drain theboiler and clean it both internally and externally. Remove allclean-out plugs. Open and clean the chamber of the low-waterfuel supply cutout. Repair furnace brickwork and lay-up theboiler.

5. Examine and repair heating system components and boiler auxiliaryequipment.

6. Don't leave broken windows or other openings that may permitwintertime freezing.

7. Don't block the combustion air supply opening for the fuelburning systems.

8. Don't use the boiler furnace as a trash receptacle orincinerator during the idle season.

9. Don't leave the boiler room accessible to unauthorized persons.

10. Don't leave the boiler during the idle season so that the burnercan be operated in a routine way by an unqualified operator.

By W. H.. Russell, The Hartford Steam Boiler Inspection and InsuranceCo. Photos and datacourtesy of The Boiler Inspection and Insurance Co of Canada.CPE:/ PE & M -- March, 1966

APPENDIX "F"

Treatment & Controlof

Feed & Boiler Feed Water

INTRODUCTION:

In other than exceptional circumstances, a natural water is not suitable forboiler feeding unless it is suitably treated, since the use of an untreatedwater can cause foaming and priming, corrosion of the metal, and restrictionof the water spaces due to scale deposition. Serious scaling may result inultimate failures of generating tubes and distortion of the tube plates withsubsequent leakage at tube joints. It also reduces the heat transfer andconsequently the efficiency of the unit.

Because of the very great differences in the composition of natural water fromvarious sources and localities, it is quite impossible to prescribe anystandard form of treatment. It must normally be based on the composition ofthe water supply available and, where there are alternative supplies, it isusually advantageous to use the supply which is most easily treated.

The notes which follow are not intended to be instructions, but merely a guideto the treatment and control, and the boiler user is advised to adopt theservice and guidance of a specialist company supplying water treatmentchemicals.

TYPE OF TREATMENT:

Generally speaking, natural water can be divided into two classifications:-

(I) Water of Low Hardness, which contains hardness salts of calcium andmagnesium in amounts up to about 150 parts per million.

(II) Hard Water, which may contain hardness salts in quantities up to 500parts per million or more.

In the case of soft water, defined in Group (I), "internal treatment" willgenerally be satisfactory, but, as different water requires differentchemicals, the specific treatment for a given installation can only bedetermined properly by an examination of the water supply. "InternalTreatment" comprises the addition of chemicals to the water entering theboiler and, in this case, the reactions occur in the boiler, hardness saltsbeing precipitated as sludge which has to be removed by blowing down.

A properly balanced treatment will convert all the hardness salts into a soft,easy-flowing sludge and render the boiler water alkaline to phenolphthalein,a condition which is necessary as a protective against “on load" corrosion.

Hard water defined by Group (II) presents a more difficult problem becauseinternal treatment may produce so much sludge in the boiler as to make itscontrol difficult. Suspended sludge may promote foaming in the boiler andcarry-over of boiler water into the steam mains and, where possible, the watershould be softened before it is fed to the boilers. Choice of the processwill depend on the composition of the raw water supply. In many cases, whereboilers are installed in factories or institutions, etc., where the water forprocess or domestic supplies has to be softened, it is very probable that thetreated water will be suitable for boiler feeding after the application of aninternal treatment, as described for soft water in Group (I). Therefore, thesenotes concentrate on “internal” treatment. Internal treatment, chemicals ormixtures usually employed invariably contain some or all of the followingchemicals, the purpose of which is described:

APPENDIX "F"

Sodium Phosphate - which precipitates calcium and magnesium hardness salts assoft calcium and magnesium phosphate.

Sodium Aluminate - used as a coagulant.

Tannins - which render the precipitates free-flowing and, by surface actionon the boiler metal, act as a protection against corrosion. They also have theproperty of absorbing oxygen from the boiler water.

Starch - used in some cases as alternative to tannin or with tannin. It is acoagulant and has the property that it can absorb slight traces of oil whichmay get into the boiler water.

Alkali - usually caustic soda ash, the purpose of which is to impartalkalinity to the boiler water.

Sodium Sulphate - used when a water deficient in naturally occurring sodiumsulphate, in order to provide a sodium sulphate/caustic soda minimum ratio of2.5 for protection against caustic cracking.

CONTROL OF TREATMENT AND BOILER WATER CONDITIONS:

The normal treatment will be the continuous addition of the chemicals to thefeed water in sufficient quantity to precipitate the hardness salts in theboiler water.

Correct treatment will ensure that the feed is always alkaline with a phbetween 8.5 and 9.5. The quantity of chemicals to be added will be determinedby simple test on the boiler water and, briefly, these tests are:

Hardness - The hardness should always be zero. Presence of hardness is anindication of scaleforming conditions and the chemical dose should besufficient to ensure its absence.

Phosphate - The phosphate residual in the boiler water should be not normallyless than 50 and not more than 100 parts per million, expressed as tri-sodiumphosphate. It is the most important test for the adequacy or otherwise of thetreatment, as, in the presence of a phosphate residual to the degreespecified, hardness in the boiler water cannot exist.

Alkalinity - The total alkalinity of the boiler water, expressed as calciumcarbonate, should not be less than 15-20% of the total dissolved solidsconcentration.

Total Dissolved Solids - The total dissolved solids in the boiler water,resulting from the concentration of the dissolved solids in the feedwater,plus the addition due to the treatment chemicals, should not be allowed toexceed 2,000 to 4,000 parts per million. This figure is, however, influencedby several factors, eg., water level, changes in load, and the amount andphysical condition of the suspended matter in the boiler water. Experiencewill indicate whether it can be increased or whether it must be decreased.

Method of carrying out the tests and recommendations for the necessaryapparatus will generally be provided by the supplier of the water treatmentchemicals.

APPENDIX "F"

Blowing Down - The frequency of blowing down which is necessary to maintainthe boiler reasonably clear of deposited sludge and within the concentrationspecified for the total dissolved solids in the boiler water will be governedby the composition of the raw water and the amount of chemicals added. Powerboilers should be blown at least once per day and preferably lesser amountstwice or three times per day. To ensure the removal of the maximum amount ofsludge, the blowdown valve should be opened momentarily several times with ashort pause between operations, so that the disturbance in the vicinity of theblowdown outlet can die down and further sludge move into position ready tobe flushed out at the next operation.

If the dissolved solids content in the feed water is high, it may be advisableto have a continuous blowdown, but, as this is not so effective in the removalof sludge, the regular operation of the intermittent blowdown cannot beeliminated.

It is also most important that the feed water regulators be blown down atleast once per day to ensure that the float chambers are clear of sludge.

Heating boilers should seldom be blown down and then only on the advice of awater treatment consultant.

Sodium Sulphate/Caustic Soda Ratio:

As scale deposits, which are likely to occur in the boiler if water treatmentis faulty, may cause cracking of the tube plates with possible consequentleakage at tube seats, it is good precaution to maintain the advised sodiumsulphate/caustic soda ratio of 2.5 as a protection against possibleintergranular cracking of the tube plate in stressed areas.

If included in the chemical mixture, it will be in correct proportion to thealkali to provide the necessary sodium sulphate/caustic soda ratio and underthese conditions tests will not be required for routine control.

Idle Boilers:

If at any time a boiler is off load for more than a few days, precautionsshould be taken to protect it against corrosion during such periods. For anextended length of time, the boiler should be emptied, hosed out to removesludge and then dried thoroughly. Trays of quick lime should then be placedin the drum, after which the drum should be closed up.

Alternatively, if a boiler is to be held ready for immediate use, it shouldbe emptied and cleaned and then be filled completely with feed water which hasbeen made alkaline by the addition of caustic soda and to which sodiumsulphite to the extent of 100-150 parts per million has been added as anoxygen absorbent. Air cocks should be closed and the water tested from timeto time for caustic soda and sodium sulphite residual.

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