Bryan Boilers Boiler Forced Draft Steam Boilers User Manual

Installation  
Operation  
Service Manual  
for  
Forced Draft Steam  
Boilers  
BRYAN BOILERS  
783 N. CHILI AVENUE, PERU, INDIANA 46970  
Telephone: 765-473-6651 / Fax: 765-473-3074  
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MINIMUM CLEARANCES  
NOTE: These boilers are intended to be installed in a room which is large compared to the size of  
the boiler. They are not intended for alcove installation and are suitable for installation on non-  
combustible flooring only.  
D-SERIES  
F-SERIES1  
CL-SERIES  
K-SERIES  
RV, RW & AB SERIES  
DIMENSION  
WATER/  
STEAM  
OVER  
50#  
WATER  
STEAM  
OVER  
50#  
WATER  
STEAM  
OVER  
50#  
WATER  
STEAM  
OVER  
50#  
WATER  
/STEAM  
TO 50#  
STEAM  
OVER  
50#  
STEAM  
TO 50#  
/STEAM  
TO 50#  
/STEAM  
TO 50#  
/STEAM  
TO 50#  
A
B
18"  
24"  
18"  
48"  
24"  
36"  
24"  
36"  
96"  
24"  
18"  
48"  
18"  
18"  
18"  
48"  
96"  
36"  
36"  
36"  
24"  
48"  
24"  
24"  
24"  
24"  
36"  
24"  
24"  
24"  
18"  
48"  
24"  
24"  
24"  
36"  
24"  
24"  
24"  
24"  
24"  
48"  
24"  
24"  
32"  
24"  
48"  
24"  
24"  
32"  
CV & CH  
D
EL & ER  
1 - F-Series boilers are approved for installation on combustible flooring. Do not install on carpeting.  
A - Clearance above boiler  
B - Front of boiler  
CV - Clearance from gas vent, measured vertically above pipe  
CH - Clearance from gas vent, measured horizontally or below pipe  
D - From back of boiler  
EL - Left side of boiler  
ER - Right side of boiler  
These clearances are general minimum clearances. Local codes may dictate larger clearances.  
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1.4 BOILER CONNECTIONS  
1.4.1 GENERAL  
tank. This valve can then be adjusted to  
bypass excess pump capacity to better  
control the boiler feed rate.  
Do not run any pipes along the access panel  
side of the boiler. Maintain clearances as  
shown on the dimensional drawing for  
servicing of the boiler tubes. Provide at least  
36" from the gas train and burner, unless a  
larger dimension is indicated on the  
dimensional. All piping should be designed  
and installed to avoid any loadings on the  
boiler connections or piping.  
1.4.4 SAFETY RELIEF VALVE(S)  
A connection is provided in the top of the  
boiler for the relief valve. The relief valve  
discharge piping must be the same size as  
the relief valve discharge opening. Avoid  
over-tightening as this can distort valve seats.  
All piping from relief valve must be  
independently supported with no weight  
carried by the valve.  
1.4.2 STEAM SUPPLY CONNECTION  
A steam shut-off valve must be installed  
between each boiler and the steam main.  
This valve must be of the outside screw and  
yoke design to allow indication from a  
distance whether the valve is open or closed.  
1.4.4 BLOWDOWN CONNECTION  
Blowdown valve(s) must be full size of the  
connection on the boiler. Steam boilers 15  
psig and below require at least one blowdown  
valve. Higher pressure boilers require two  
blowdown valves with one or both valves  
being slow opening type. Each water column  
and float type low water cut-off must be  
equipped with a blowdown valve.  
1.4.3 FEEDWATER CONNECTION  
Install a check valve and a globe valve  
between the feed pump and the boiler. It is  
also recommended to install a globe valve  
between the feed pump and the receiver  
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1.5 GAS SUPPLY CONNECTION - FORCED DRAFT UNITS  
The installation must conform completely to the  
requirements of the authority having jurisdiction,  
or in the absence of such, requirements shall  
conform in the U.S. to the current National Fuel  
Gas Code, ANSI Z223.1-1984, or in Canada to  
the current Installation Code for Gas Burning  
Appliances and Equipment (CAN/CGA B149.1-  
M91), or Oil Burning Equipment (CSA B139-  
M91), and applicable regional regulations for the  
class; which should be followed carefully in all  
cases.  
Drip leg must be installed on gas supply piping.  
Consult the local gas utility company for  
inspection and authorization of all gas supply  
piping and flue connections.  
The regulator vent line must be vented to outside  
of building on any boiler equipment with electric  
gas pilot ignition.  
1.5.1 DRIP LEG  
1.5.3 VENTING OF GAS TRAIN COMPONENTS  
Gas pressure regulator - The regulator must be  
vented to the outside air, using minimum 1/4"  
tubing or pipe. The vent line should terminate in a  
downward direction to be free of restriction.  
A drip leg or sediment trap must be installed in  
the gas supply line. See Fig. 1.5A. The gas line  
must be connected to a supply main at least as  
large as the gas train connection at the boiler.  
This connection should be made with a union so  
that the boiler gas train components and burner  
may be easily removed, if necessary, for service.  
Diaphragm gas valves (V48A or V88A) - The vent  
line off of these gas valves must be vented to  
outdoors, the same as the regulator.  
1.5.2 GAS PIPING LEAK TEST  
After completion of the gas piping hookup, the  
installation must be checked for leaks, using a  
soap and water solution. Disconnect the boiler  
and gas train from the gas supply piping during  
any pressure testing of the gas supply system.  
Normally open vent valves - These valves must  
be piped to outdoors using pipe no smaller than  
that of the valve.  
Gas pressure switches - Vent these switches to  
outdoors using a minimum of 1/4" tubing or  
piping.  
FIGURE 1.5A: GAS BURNER CONNECTION  
NOTE: USE PIPE COMPOUND, WHICH IS RESISTANT TO THE ACTION OF LIQUID PETROLEUM  
GAS. DO NOT USE TEFLON TAPE.  
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1.6 ELECTRICAL CONNECTION  
IMPORTANT: All electrical connections must  
conform to the National Electrical Code and to all  
other applicable State and Local Codes. Forced  
details.  
Equipment Grounding - The boiler must be  
grounded in accordance with the American  
National Standard Electrical Code, ANSI/NFPA  
#70-1981.  
draft boilers may require  
a
high voltage  
connection. See boiler wiring diagram and  
equipment list for  
1.7 COMBUSTION AIR SUPPLY  
IMPORTANT: Positive means for supplying an  
ample amount of outside air, allowing complete  
combustion of the gas, must be provided.  
boiler is not equipped with a draft control device  
(so no air is required for draft control).  
COMBUSTION AIR OPENINGS  
REQUIRED:  
-
AREA  
Movable combustion air dampers, automatic or  
manually adjustable, must be electrically  
interlocked with the boiler to prevent boiler  
operation if the dampers are closed.  
Openings directly through outside wall -  
One opening within 12 inches of the ceiling plus  
one opening within 12 inches of the floor. Each  
opening must have a minimum free area of 1  
square inch per 4,000 Btu of total input of all air  
using appliances in the room.  
Combustion air openings must never be blocked  
or obstructed in any manner.  
The boiler room must be at a positive or neutral  
pressure relative to the outdoors. A negative in  
the boiler room will result in downdraft problems  
and incomplete combustion due to lack of air.  
Example: A boiler room having two boilers with  
500,000 Btu input would require two openings  
through an outside wall, and each opening must  
have at least 250 square inches of free area.  
Openings through vertical ducts -  
One duct in the ceiling plus one duct terminating  
within 12 inches of the floor. Each opening must  
have a minimum free area of 1 square inch per  
4,000 Btu of total input of all air-using appliances  
in the room.  
Example: A boiler room having four boilers with  
250,000 Btu input would require two ducts, one in  
the ceiling and one terminating near the floor,  
each opening having at least 250 square inches  
of free area.  
WARNING!  
Failure to provide an adequate air supply will  
result in boiler damage and hazardous conditions  
in the building (fire and asphyxiation hazard as  
well as equipment damage).  
COMBUSTION AIR: Complete combustion of  
natural or propane gas requires approximately  
ten cubic foot of air (at sea level and 70 F) for  
each 1000 Btu of boiler input. In reality, additional  
air is required to achieve complete combustion.  
Air is also required for the proper operation of the  
appliance draft diverter or barometric damper.  
The combustion air opening recommendations  
below are designed to provide the air needed for  
atmospheric gas fired boilers which are equipped  
with either draft diverters or barometric dampers.  
Combustion air openings for boilers which are  
equipped with forced draft burners may be  
reduced to 70% of that required for atmospheric  
gas fired boilers. This is because the forced draft  
Openings through horizontal ducts -  
One duct opening within 12 inches of the ceiling  
plus one duct opening within 12 inches of the  
floor. Each opening must have a minimum free  
area of 1 square inch of per 2,000 Btu of total  
input for all equipment in the room. NOTE: No  
rectangular duct may have a dimension of less  
than 4 inches.  
Example: A boiler room having 1 million Btu total  
input would require two ducts, one in the ceiling  
and one near the floor, each opening must having  
at least 500 square inches of free area.  
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Ventilation Air: In addition to air needed for  
combustion, sufficient air must be supplied for  
ventilation, including air required for comfort and  
proper working conditions for personnel in the  
boiler room. In colder climates, provision should  
also be made to heat the boiler room, if  
necessary, for personnel comfort.  
disposal. The boiler room and the combustion air  
supply must not be exposed to the fumes. Such  
fumes include, but are not limited to, carbon  
monoxide, hydrogen sulfide, ammonia, chlorine,  
and halogenated hydrocarbons.  
NOTE:  
Halogenated  
hydrocarbons  
are  
particularly injurious and corrosive after exposure  
to high temperatures.  
CAUTION  
Protection from combustion air contamination:  
Where corrosive or flammable process fumes are  
present in the vicinity of the boiler room or the air  
stream for the combustion air supply, it is  
essential that suitable means be provided for their  
safe  
1.8 CHIMNEY, FLUE PIPE & DRAFT CONTROL - FORCED DRAFT BOILERS  
CODE COMPLIANCE  
ESTIMATING FLUE GAS FLOW RATE (ACFM)  
Flue gas volumetric flow rate in SCFM (standard  
cubic feet per minute) and ACFM (actual cubic  
feet per minute) can be estimated by using the  
information in 1.8.1A. Divide the Total Input of  
appliances connected to the chimney or vent by  
1000. Then multiply this result times the factor  
listed in the SCFM and ACFM table. The ACFM  
data is required for determining stack exit velocity  
and induced draft fan requirements.  
The installation must conform to the requirements  
of NFPA 54, the National Gas Code (ANSI  
Z223.1-1984), Part 7, "Venting of Equipment", or  
to the applicable requirements of all local building  
codes. For factory-built and listed chimney  
systems (such as type B vent), consult the  
system manufacturer's instructions for correct  
installation procedures. Gas vents may be of any  
of the construction types listed in this manual. No  
portion of a venting system may extend into or  
pass through any circulating air duct or plenum.  
ESTIMATING STACK EXIT VELOCITY  
First, determine the ACFM for the stack as  
described above. Multiply the total ACFM times  
the Velocity Factor from the Velocity Table in  
Table 1.8.1B for the stack diameter used. The  
result is the Stack Exit Velocity in feet per second.  
MINIMUM SAFE PERFORMANCE  
Venting systems must be designed to develop  
positive flow adequate to remove flue gases to  
the outside atmosphere. Guidelines are provided  
in this manual and in the National Fuel Gas Code,  
NFPA 54, for sizing and design of flue gas  
venting systems. For additional reference to good  
practice in vent design, refer to the "Chimney,  
Gas Vent, and Fireplace Design" chapter of the  
ASHRAE Equipment Handbook.  
ESTIMATING STACK EMISSIONS  
Table 1.8.1C lists approximate emissions of NOx  
(oxides of nitrogen) and CO (carbon monoxide).  
The table lists both the concentration, in parts per  
million (ppm), and the flow rate, in pounds per  
hour (PPH), of each compound: Divide the total  
input of appliances connected to the chimney or  
vent by 1,000,000. Then multiply this result times  
the value listed in the table for PPH emissions.  
OUTSIDE VENTS AND CHIMNEYS  
Outside uninsulated single wall pipe is not  
recommended for use in cold climates for venting  
gas-fired  
appliances  
since  
temperature  
differentials may cause corrosion in such pipe, as  
well as poor draft on start ups. When local  
experience indicates that condensate may be a  
problem, provisions should be made to drain off  
the condensate in the gas vent or chimney.  
MANUAL REFERENCES  
See Figure 1.8.1 for a graphics listing of  
applicable sections of this manual for each  
section of the vent system.  
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FIG. 1.8.1: VENT DESIGN INSTRUCTION -  
REFERENCES  
TABLE 1.8.1A: ESTIMATING FLUE GAS VOLUMETRIC FLOW RATE  
Approximate Flue Gas VOLUMETRIC FLOW RATE  
(Per 1000 Btu/hr Input)  
(Multiply factor listed times boiler input in MBH)  
SCFM Per  
1000 Btu/hr  
INPUT  
ACFM Per  
1000 Btu/hr  
INPUT  
APPROXIMATE  
FLUE GAS  
BOILER TYPE  
TEMPERATURE  
Water & 15# Steam  
Gas Fired  
0.230  
0.230  
0.402  
0.402  
450 F  
450 F  
Oil Fired  
150# Steam  
Gas Fired  
0.230  
0.230  
0.425  
0.425  
500 F  
500 F  
Oil Fired  
TABLE 1.8.1B: STACK EXIT VELOCITY  
Estimated STACK EXIT VELOCITY Calculation  
(Multiply total ACFM times the velocity factor below velocity in feet per second)  
STACK INSIDE  
VELOCITY  
FACTOR  
STACK INSIDE  
VELOCITY  
FACTOR  
STACK INSIDE  
VELOCITY  
FACTOR  
DIAMETER (Inches)  
DIAMETER (Inches)  
DIAMETER (Inches)  
6
7
0.0849  
0.0624  
0.0477  
0.0306  
0.0212  
0.0156  
0.0119  
18  
20  
22  
24  
26  
28  
32  
0.00943  
0.00764  
0.00631  
0.00531  
0.00390  
0.00340  
0.00298  
34  
36  
38  
40  
48  
60  
0.00264  
0.00236  
0.00212  
0.00191  
0.00133  
0.00085  
8
10  
12  
14  
16  
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TABLE 1.8.1C: ESTIMATING FLUE GAS EMISSIONS  
Estimated Emissions (Volumetric Flow Rate Per Million Btu/hr Input)  
(Multiply PPH listed times boiler input divided by 1,000,000)  
BOILER  
TYPE  
PARTICULATES  
NOx  
CO  
SOx  
Hydrocarbons  
PPH per  
MMBH  
PPM  
PPH per  
PPM  
PPH per  
MMBH  
PPM  
PPH per  
PPM  
PPH per  
PPM  
MMBH  
MMBH  
MMBH  
Gas Fired  
Oil Fired  
N/A  
N/A  
20  
0.049  
50  
70  
0.194  
0.018  
200  
18  
N/A  
N/A  
290  
0.010  
10  
4
0.020  
0.068  
0.286  
0.004  
1.8.2 CLEARANCES  
The vent system and draft control devices must  
be installed so as to achieve the clearances to  
surfaces outlined in Table 1.2.1, Minimum  
Clearances chart, in this manual. See also Table  
1.8.9 for vent clearances. All clearances must  
comply with the National Fuel Gas Code  
(NFPA54), and with all  
local and state building codes. The clearances  
described in this manual are intended to be  
general guidelines only, additional requirements  
may occur because of local building design  
regulations.  
1.8.3 BOILER ROOM PRESSURIZATION  
The boiler room must be supplied with adequate  
air for combustion and for proper operation of  
draft control devices (barometric dampers or draft  
diverters) as outlined in "Combustion Air Supply",  
Section 1.7 of this manual.  
WARNING  
THE BOILER ROOM MUST BE MAINTAINED  
AT A POSITIVE OR NEUTRAL PRESSURE  
(RELATIVE TO OUTDOORS) AT ALL TIMES.  
EXHAUST FANS OR CONNECTIONS FROM  
THE BOILER ROOM TO ZONES OF NEGATIVE  
INDUCED DRAFT FAN WILL BE REQUIRED.  
FURTHER, THE BOILER MUST BE PROVIDED  
WITH A BAROMETRIC DRAFT CONTROL -  
NOT WITH A DRAFT DIVERTER. THE FAN  
MUST BE INTERLOCKED WITH THE BOILER  
AND A DRAFT PROVING SWITCH MUST BE  
INSTALLED TO PREVENT OPERATION OF  
THE BOILER IF THE FAN SHOULD FAIL TO  
OPERATE.  
PRESSURE  
(AIR  
DUCTS,  
NEGATIVE  
PRESSURE ROOMS, ETC.) WILL CAUSE  
NEGATIVE PRESSURE IN THE BOILER  
ROOM. SUCH CONDITIONS WILL CAUSE  
HAZARDOUS OPERATION OF THE BOILER  
AND INTRODUCTION OF COMBUSTION  
PRODUCTS INTO THE BUILDING AIR.  
IT ALSO MAY BE ADVISABLE TO INSTALL AN  
AUTOMATIC VENT DAMPER IN THE VENT  
SYSTEM  
TO  
PREVENT  
BACKFLOW  
IF THE BOILER ROOM MUST BE UNDER A  
NEGATIVE PRESSURE AT ANY TIME, AN  
THROUGH THE VENT SYSTEM DURING  
BOILER OFF CYCLES. SEE FOLLOWING  
SECTION ON AUTOMATIC VENT DAMPERS.  
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1.8.7 ACCEPTABLE VENT TYPES  
LISTED GAS VENTS  
installed in accordance with nationally recognized  
building codes or standards.  
Listed gas vents must be applied only on those  
applications for which they are listed. Type B gas  
vents are NOT listed for use on forced draft  
appliance vent systems.  
MASONRY CHIMNEYS FOR RESIDENTIAL  
APPLICATIONS MUST BE LINED WITH FIRE-  
CLAY FLUE LINING (KX C315 OR THE  
EQUIVALENT) WITH THICKNESS NOT LESS  
THAN 5/16 INCH OR WITH A LINER OF OTHER  
APPROVED MATERIAL THAT WILL RESIST  
CORROSION, SOFTENING OR CRACKING  
FROM FLUE GASES AT TEMPERATURES UP  
TO 1800 F.  
Installation of these vents must comply with the  
vent listing, with the vent manufacturer's  
instructions and with complete adherence to the  
codes and clearances as outlined previously.  
PRESSURIZED VENT SYSTEMS  
Some Bryan Boilers (unless specifically fitted for  
the application) are not suitable for operation on a  
pressurized vent systems. Refer to Section 2 of  
this manual for the allowable range of vent  
pressure for each series. The RV, RW, and AB  
series boilers are designed for pressurized vent  
systems. All others require a neutral pressure.  
EXISTING  
CHIMNEYS  
SHOULD  
BE  
INSPECTED FOR UNSAFE CONDITIONS,  
SUCH AS DETERIORATED MASONRY AND  
EXCESSIVE SOOT OR OTHER BLOCKAGE OR  
POTENTIAL BLOCKAGE. SEE ALSO SECTION  
1.8.6.  
EXISTING CHIMNEYS MUST BE PROPERLY  
SIZED FOR THE FLUE GAS LOADING TO BE  
USED. THAT IS, IF AN EXISTING CHIMNEY IS  
USED FOR A SMALLER TOTAL INPUT THAN  
ITS ORIGINAL DESIGN, A LINER OR VENT IS  
REQUIRED. THE USE OF A PROPERLY SIZED  
GAS VENT OR LINER WILL PREVENT  
DETERIORATION OF THE CHIMNEY DUE TO  
THE EXCESSIVE CONDENSATION WHICH  
RESULTS ON OVERSIZED SYSTEMS.  
SINGLE-WALL METAL PIPE  
Single-wall metal pipe must be of galvanized  
sheet or other approved non-combustible  
corrosion resistant material, with minimum  
thickness per Table 1.8.7, from the National Fuel  
Gas Code. Single-wall metal pipe should be  
insulated to prevent excessive heat in the boiler  
room and to avoid ignition and spillage problems  
as well as corrosion from excessive  
condensation.  
MASONRY, METAL AND FACTORY BUILT  
CHIMNEYS  
WARNING  
UNDER NO CIRCUMSTANCES SHOULD THE  
FLUE PIPE BE CONNECTED TO THE  
CHIMNEY OF AN OPEN FIREPLACE.  
Installation of factory built vents and chimneys  
must comply with the vent listing, with the vent  
manufacturer's instructions and with adherence to  
the codes and clearances as outlined herein.  
Masonry or metal chimneys must be built and  
TABLE 1.8.7A  
TABLE 1.8.7B  
WATER BOILER & STEAM BOILERS TO 50 PSIG  
(STEAM BOILERS OVER 50 PSIG)  
Diameter of  
Connector, Inches  
Minimum Thickness,  
Inch (Gauge)  
Diameter of  
Connector, Inches  
Minimum Thickness,  
Inch (Gauge)  
6 to 10  
10 to 12  
12 to 16  
16 +  
0.023 (24)  
0.029 (22)  
0.034 (20)  
0.056 (16)  
14 and less  
14 to 16  
16 to 18  
18 +  
0.053 (16)  
0.067 (14)  
0.093 (12)  
0.123 (10)  
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1.8.5 VENT CONNECTORS (HORIZONTAL RUNS)  
CONSTRUCTION  
Supports should usually be overhead hangers, of  
Vent connectors may be of any of the acceptable  
constructions listed in this manual.  
load bearing capacity appropriate for the weight  
involved.  
AVOID UNNECESSARY BENDS  
LOCATION  
The vent connector must be installed so as to  
avoid turns or other construction features which  
create excessive resistance to flow of flue gases.  
When the vent connector used for an appliance  
having a draft hood must be located in or pass  
through a crawl space or other area difficult to  
access or which may be cold, that portion of the  
vent connector must be of listed double wall Type  
B gas vent material, or of material having  
equivalent insulation qualities. Single wall metal  
pipe used as a vent connector must not pass  
through any floor or ceiling.  
JOINTS  
Vent connectors must be firmly attached to draft  
diverter outlets or boiler flue collars by sheet metal  
screws or other approved means. Vent connectors  
of Type B vent material must be assembled in  
accordance with the vent manufacturer's  
instructions. Joints between sections of connector  
piping must be fastened using sheet metal screws  
or other approved means.  
CHIMNEY CONNECTION  
In entering a passageway in a masonry or metal  
chimney, the vent connector must be installed  
above the extreme bottom to avoid stoppage.  
Means must be employed which will prevent the  
vent connector from protruding so far as to restrict  
the space between its end and the opposite wall of  
the chimney. A thimble or slip joint may be used to  
facilitate removal of the vent connector. The vent  
connector must be firmly attached to or inserted  
into the thimble or slip joint to prevent the vent  
connector from falling out.  
SLOPE OR VENT CONNECTOR  
The vent connector must be installed without any  
dips or sags and must slope upward at least 1/4  
inch per foot.  
LENGTH OF VENT CONNECTOR  
The vent connector must be as short as possible  
and the boiler as close as practical to the chimney  
or vent.  
The horizontal run of an uninsulated vent  
connector to a natural draft chimney or vent  
servicing a single appliance must not be more than  
75% of the height of the chimney or vent above  
the vent connector.  
The horizontal run of an insulated vent connector  
to a natural draft chimney or vent servicing a single  
appliance must not exceed 100% of the height of  
the chimney or vent above the vent connector.  
DAMPERS  
Manually operated dampers must not be placed in  
the vent connector. This does not exclude the use  
of fixed baffles, locking quadrant dampers which  
are welded in a fixed position, or automatic vent  
dampers (when properly installed and interlocked  
with the boiler gas controls).  
USE OF THIMBLES  
Vent connectors made of single wall metal pipe  
must not pass through any combustible wall  
unless they are guarded at the point of passage by  
ventilated metal thimbles 6" larger in diameter than  
the vent connector. This may be done only on  
water boilers and steam boilers rated for operation  
at no higher than 50 psig.  
SUPPORT OF VENT CONNECTOR  
The vent connector must be supported in  
accordance with the vent manufacturer's  
instructions and listing and with all applicable  
codes. Support should also be independent of the  
boiler or the draft diverter (when used). The vent  
connector must be supported for the design and  
weight of the material employed to maintain  
clearances, prevent physical damage and  
separation of joints, and to prevent sagging of the  
vent connector.  
SINGLE WALL METAL VENT PIPE USED TO  
VENT STEAM BOILERS OPERATING OVER 50  
PSIG MUST NOT PASS THROUGH WALLS OR  
PARTITIONS  
CONSTRUCTED  
OF  
COMBUSTIBLE MATERIAL.  
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1.8.6 CHIMNEY & VENT CONSTRUCTION (VERTICAL SECTION)  
INSTALLATION  
SYSTEMS  
OF  
FACTORY  
BUILT  
Alternatively, a non-ventilating thimble not less  
than 18" above and 6" below the roof (with the  
annular space open at the bottom and closed at  
the top) may be used.  
Listed gas vents and factory built chimneys must  
be installed in accordance with their listings and  
the manufacturer's instructions. Vents and  
venting systems passing through roofs must  
extend though the roof flashing, roof thimble or  
roof jack.  
INSPECTIONS OF CHIMNEYS  
Before connection of a vent connector to a  
chimney, the chimney passageway must be  
examined to ascertain that it is clear and free of  
obstructions. Cleanouts must be constructed  
such that they will remain tightly closed when not  
in use. Tee fittings used as cleanouts or  
condensate drains must have tight fitting caps to  
prevent entrance of air into the chimney at such  
points. When an existing masonry chimney is  
unlined and local experience indicates that vent  
gas condensate may be a problem, an approved  
liner or another vent must be installed. When  
inspection reveals that an existing chimney is not  
safe for the intended application, it must be rebuilt  
to conform to nationally recognized standards,  
relined with a suitable liner, or replaced with a gas  
vent or chimney suitable for the appliances to be  
attached.  
INSTALLATION OF MASONRY OR METAL  
CHIMNEYS  
Masonry or metal chimneys must be built in  
accordance with nationally recognized building  
codes and standards.  
INSTALLATION OF SINGLE WALL GAS VENTS  
Single wall metal pipe may be used only for runs  
directly from the space in which the appliance is  
located through the roof or exterior wall to the  
outer air. A pipe passing through a roof must  
extend without interruption through the roof  
flashing, roof jack or thimble. Single wall metal  
pipe must not originate in any unoccupied attic or  
concealed space. Additionally, it must not pass  
through any attic, inside wall, concealed space or  
through any floor. Minimum clearance must be  
maintained between the single wall metal pipe  
and any combustible surface as outlined in Table  
1.8.9.  
SUPPORT OF CHIMNEYS AND VENTS  
All portions of chimneys must be adequately  
supported for the design and weight of the  
materials employed. Listed factory built chimneys  
must be supported and spaced in accordance  
with their listings and the chimney or gas vent  
manufacturer's recommendations.  
When a single wall metal pipe passes through an  
exterior wall constructed of combustible material,  
it must be guarded at the point of passage by a  
ventilated thimble as described under "Use of  
Thimbles" in Section 1.8.8 of this manual.  
THE GAS VENT OR CHIMNEY MUST BE  
SUPPORTED INDEPENDENTLY OF THE  
BOILER TOP OR DRAFT DIVERTER.  
MINIMUM REQUIRED DISTANCE FROM COMBUSTIBLE MATERIAL  
EQUIPMENT TYPE  
Listed Vent  
not permitted  
not permitted  
Single Wall Metal Pipe  
Factory Built Chimney  
as listed  
Water and 15 psig Steam Boilers  
All Steam Boilers over 15 psig  
18"  
36"  
as listed  
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1.8.7 MARKING OF GAS VENTS  
In those localities where solid and liquid fuels are  
used extensively, gas vents must be plainly and  
permanently identified by a label reading:  
"This gas vent is for appliances which  
burn gas only. Do not connect to  
incinerators or solid or liquid fuel burning  
appliances."  
The authority having jurisdiction must determine  
whether their area constitutes such a locality.  
This label must be attached to the wall or ceiling  
at a point near where the gas vent connector  
enters the wall, ceiling or chimney.  
1.8.8 VENTING MULTIPLE APPLIANCES ON A COMMON VENT  
COMMON GAS VENT  
PRESSURIZED  
CONNECTORS  
DO NOT CONNECT THE FLUE OF AN  
APPLIANCE VENTED BY NATURAL DRAFT TO  
A VENT SYSTEM WHICH OPERATES UNDER  
A POSITIVE PRESSURE.  
VENTS  
OR  
VENT  
When two or more openings (for vent connectors)  
are provided in a chimney or gas vent, the  
opening should be at different levels. They should  
never be opposite one another.  
When two vent connectors enter the same gas  
vent or chimney, the smallest of the two should  
enter at the highest position possible.  
SOLID FUEL APPLIANCE VENTS  
Gas appliances must not be vented to a vent or a  
chimney which serves a solid fuel burning  
appliance.  
1.8.9 VENT AND CHIMNEY TERMINATIONS  
HEIGHT ABOVE ROOF OR OBSTACLE  
WATER BOILERS AND LOW PRESSURE  
STEAM BOILERS: No less than 3 feet above the  
roof and no less than 2 feet above any parapet or  
obstacle closer than 10 feet from the vent outlet.  
CLEARANCE FROM PUBLIC WALKWAYS  
The vent exit of a mechanical draft system must  
be at least 7 feet above grade when located next  
to public walkways.  
HIGH PRESSURE (OVER 15 PSIG) STEAM  
BOILERS: No less than 10 feet higher than any  
portion of any building within a distance of 25 feet  
from the vent.  
PROTECTION OF BUILDING MATERIALS  
FROM  
POSSIBLE  
CORROSION  
OR  
DISCOLORATION FROM FLUE PRODUCTS  
The products of combustion from gas or oil  
contain potentially corrosive gases and high  
temperatures. For this reason, the chimney or  
vent exit must be designed to prevent exposure  
of the building materials to the flue products.  
Failure to do so may result in deterioration or  
discoloration of building materials.  
MINIMUM HEIGHT ABOVE DRAFT CONTROL  
Chimneys and gas vents must extend at least 5  
feet above the highest connected barometric draft  
control or any appliance flue outlet.  
CLEARANCE FROM AIR INLETS  
The vent or chimney must terminate no less than  
3 feet above any forced air inlet within a distance  
of 10 feet. It must terminate no less than 1 foot  
above, or 4 feet below, or 4 feet horizontally from,  
any door, window or gravity air inlet into a  
building.  
VENT SUPPORT  
The gas vent or chimney must be securely  
positioned and supported. Guy wires or other  
reliable means must be used to prevent  
movement of the vent.  
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PROTECTION AGAINST BLOCKAGE OR  
OBSTRUCTION  
The chimney or vent exit design must prevent any  
possibility of blockage by snow or any other  
obstruction.  
Listed gas vents must be terminated with a listed  
cap, approved for use with the particular gas  
vent.  
Listed vent caps or roof assemblies must have a  
rated venting capacity no less than the vent.  
VENTILATING  
SYSTEMS  
HOODS  
AND  
EXHAUST  
Single wall vents must terminate in an approved  
cap which does not obstruct the exit. The  
preferred type of cap for natural draft vented  
atmospheric boilers is the Briedert Cap. This is  
because of the protection this cap provides  
against wind-generated downdrafts.  
Ventilating hoods or exhaust systems may be  
used to vent atmospheric gas appliances. When  
these are used, however, such mechanical  
exhaust devices must be electrically interlocked  
with all appliances on the vent system. The circuit  
must prevent the operation of any appliance on  
the system if the hood or exhaust system is not in  
operation.  
Where there is no concern of high winds or  
turbulence at the vent exit, a low resistance  
conical cap may be used. See Fig. 1.8.12B for  
typical dimensions. The diameter of this type cap  
should be twice the vent diameter. The cap must  
be securely positioned on the vent such as to  
provide a clearance of one vent diameter above  
the vent exit.  
STACK CAPS  
EVERY GAS VENT MUST BE SUPPLIED WITH  
AN APPROVED VENT CAP WHICH WILL  
PREVENT THE ENTRANCE OF RAIN OR  
OTHER PRECIPITATION INTO THE VENT.  
FAILURE TO PROVIDE SUCH A CAP MAY  
CAUSE SEVERE BOILER CORROSION,  
COMBUSTION PROBLEMS, OR BOTH.  
FIG. 1.8.12B: LOW RESISTANCE VENT CAP  
1.8.10 AUTOMATIC VENT DAMPERS  
ONE APPLIANCE ONLY  
INSTALLATION  
An automatic vent must be installed such that it  
serves only one appliance vent - that to which it is  
properly interlocked.  
The damper installation must comply with  
Appendix I, J, or K of the National Fuel Gas  
Code, NFPA 54. The installation must also  
comply with the automatic vent damper listing,  
the damper manufacturer's instructions and all  
applicable local or state building codes.  
LISTING REQUIREMENTS  
Automatic vent dampers, if used, must be of a  
listed type.  
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AUTOMATIC VENT DAMPERS MUST BE  
INSTALLED ONLY BY QUALIFIED SERVICE  
TECHNICIANS. FAILURE TO PROPERLY  
INSTALL A VENT DAMPER WILL CREATE A  
SEVERE HAZARD.  
PERFORMANCE TEST  
The automatic vent damper must be tested after  
installation to assure its proper and safe  
operation.  
AUTOMATIC VENT DAMPERS MUST BE IN  
THE OPEN POSITION AT ANY TIME THE  
APPLIANCE MAIN GAS VALVE IS ENERGIZED.  
1.8.14 SIZING OF CHIMNEY AND VENT  
IMPORTANT  
the gas input. Consult the factory or the local  
Bryan Representative for the proper parts. For  
the purpose of vent system sizing, assume full  
input and determine sizing as if at sea level. The  
derate factor of 4% per 1000 feet above sea  
level accounts for the increased volume per  
Btu/hr of flue products at high altitude.  
The flue system calculations which follow in  
Section 1.8.15 are applicable to double-wall or  
insulated single wall breechings (vent connectors)  
and stacks (vents). Do not apply these  
calculations to uninsulated vent systems.  
HIGH ALTITUDES  
At altitudes of 2000 feet and higher, atmospheric  
boilers must be derated. The amount of derate  
required by the National Fuel Gas Code is 4% per  
1000 feet above sea level. Boilers which are  
shipped from the factory prepared for these  
altitudes have the gas orifices properly sized for  
this derate. The altitude and gas Btu content for  
which the boilers have been constructed is listed  
on the Equipment List/Submittal Data in the boiler  
manual. The boilers will also be provided with a  
label indicating that they have been prepared for  
high altitude. If a boiler is to be installed at an  
altitude other than that for which it was factory  
built, orifices must be replaced to properly adjust  
INDUCED DRAFT FANS  
Occasionally, the characteristics of an installation  
are such that a natural draft vent system will not  
suffice. In such cases, induced draft may be  
used. The vent system is then sized with an  
available "pumping" action equal to the total  
theoretical draft plus the static pressure capability  
of the induced draft fan. This will result in a  
smaller diameter vent than for a natural draft  
system. Sizing of induced draft fans should be  
done using the recommendations of the fan  
manufacturer and the ASHRAE Handbook.  
FIG. 1.8.14: SUGGESTED APPLIANCE VENTING PROCEDURE  
MULTIPLE APPLIANCE INSTALLATIONS  
individual venting is not possible, boilers may be  
vented to a common breeching (vent connector).  
See Fig. 1.8.14B for recommended design of  
such a system. Note that connections of  
individual boiler or appliance vents into the  
common breeching should  
Bryan recommends that boilers and other gas  
appliances be individually vented when possible.  
See figure 1.8.14A. Individual venting provides  
better draft control and fuel efficiency, and is less  
likely to cause condensation in the system. When  
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be done with 45  
elbows and not by  
provide a relatively constant flue gas velocity  
through the vent system. Using a constant  
diameter breeching will often result in poor draft  
at the outermost appliances.  
"bullheading" directly into the vent connector at  
90 angles. "Bullhead" connections generally  
cause excessive turbulence and poor draft  
conditions. On vent connectors serving multiple  
appliances, the diameter of the piping should be  
increased at each appliance's entrance so as to  
1.8.12 QUICK SELECTION FOR VENT SIZING CHARTS  
GENERAL  
must be checked against such local  
These charts were generated using the  
procedure described in Chapter 26 of the  
ASHRAE Equipment Handbook (1979). The  
results are consistent with those of the National  
Fuel Gas Code.  
requirements.  
RECTANGULAR VENTS  
Vent systems may be rectangular as well as  
circular. Table 1.8.15F has been provided to give  
the circular equivalent of rectangular duct. These  
equivalent values account for the higher pressure  
drop per cross section area for rectangular ducts.  
The sizing herein is applicable to vent systems  
utilizing double wall listed Type B vent as well as  
single wall insulated vent with insulation  
equivalent to double wall insulating value.  
STEP 1: EQUIVALENT INPUT  
CONTROL FACTOR  
-
DRAFT  
Determine the boiler (system) Draft Control  
This sizing procedure is not applicable to vent  
systems utilizing single wall uninsulated vents or  
vent connectors.  
Factor, F1, from Table 1.8.15A.  
Determine the boiler (or total system) input in  
MBH. This is done by dividing the boiler (or total  
system) input in Btu/hr by 1000.  
The sizing information given herein is intended as  
a general recommendation only. Vent sizing and  
installation must comply with local codes.  
Multiply the total input times factor F1.  
The responsibility for assurance of such  
compliance is that of the system designer and/or  
the system installer. All sizing and installation  
The equivalent input, I, (without altitude  
correction) is then:  
I = MBH x F1  
eq. 15A  
TABLE 1.8.15A: DRAFT CONTROL FACTOR F1  
Multiply factor time input in MBH  
Boiler Type  
Factor, F1  
1.000  
Atmospheric with Draft Hood  
Atmospheric with Barometric  
Forced Draft Gas or Oil  
0.741  
0.602  
STEP 2: EQUIVALENT INPUT - ALTITUDE  
FACTOR  
Determine the boiler (system) Altitude Correction  
Factor, F2, from Table 1.8.15B.  
The altitude correction factor, F2 for atmospheric  
boilers is equal to 1, because their inputs are  
already derated for altitude.  
The equivalent input, I, with corrections for  
altitude is:  
Multiply the boiler (or total system) input times  
factors, F2 and F1 for the equivalent input.  
I = MBH x F1 x F2  
eq. 15B  
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Table 1.8.15B ALTITUDE CORRECTION FACTOR, F2  
(Multiple factor times sea level input, MBH)  
Altitude (ft)  
Factor, F2  
Altitude (ft)  
Factor, F2  
0 to 1999  
2000  
2500  
3000  
3500  
4000  
4500  
5000  
5500  
1.00  
1.075  
1.096  
1.116  
1.136  
1.157  
1.180  
1.202  
1.25  
6000  
6500  
7000  
7500  
8000  
8500  
9000  
10000  
1.247  
1.272  
1.296  
1.322  
1.346  
1.373  
1.399  
1.453  
STEP 3: SELECT TRIAL DIAMETER  
STEP 4: CALCULATE SYSTEM K-FACTOR  
The system "k-factor" accounts for the pressure  
drop through fittings and vent piping. It is  
calculated by adding up the individual k-factors  
for each of the fittings plus the k-factor for the  
vent pipe(s).  
Determine the NET STACK HEIGHT for the vent.  
(The net stack height is the vertical distance from  
the top of the atmospheric boiler draft control to  
the top of the stack. On forced draft boilers it is  
the distance from the boiler flue connection to the  
top of the stack.)  
From Table 1.8.15D find the k-factors for each of  
the elbows, tee fittings, draft regulators, etc. in the  
system. Then calculate the vent piping k-factor  
from the formula:  
Find the vent of TRIAL STACK DIAMETER. Enter  
Table 1.8.15C at the Net Stack Height column  
equal to the system net stack height. Then  
proceed down the column to the input which is  
just larger than the equivalent to an input which is  
just larger than the Equivalent Input of the  
system. Read the Trial Stack Diameter in the left  
hand column.  
kpiping = 0.4 x L/D  
eq. 15C  
L = total length of piping in feet  
D = diameter of piping in inches  
Add all the k-factors together to determine the  
total system k-factor:  
ktotal = kpiping + kfittings  
eq. 15D  
NOTE: This is only a trial diameter. Proceed to  
Step 4 to calculate the system k-factor to  
determine the actual stack diameter required.  
NOTE: On multiple appliance systems, multiply  
the k-factor times 1.5. This is required only on  
atmospheric boiler vent systems, not on forced  
draft systems.  
Table 1.8.15D: Vent Fitting k-Factors  
Vertical Draft Hood  
Barometric Draft Control  
1.50  
0.50  
Low Resistance Cap  
Round Elbow, 90 deg F  
Round Elbow, 45 deg F  
0.75  
0.30  
Converging Exit  
Cone  
(D1/D2)4 - 1  
(D1 is larger than D2)  
Tee or 90 degF Breeching  
Y Breeching  
1.25  
0.75  
Tapered Reducer  
1 - (D2/D1)4  
(D1 is larger than D2)  
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STEP 5: CORRECT EQUIVALENT INPUT FOR  
SYSTEM K-FACTOR  
Multiply the equivalent input calculated in Step 2  
times factor F3 from Table 1.8.15E. This step will  
yield a new equivalent input, I:  
The capacities listed in Table 1.8.15C are based  
on a system k-factor equal to 7.5. For any other  
k-factor, the vent capacity must be adjusted. This  
is accomplished by adjusting the equivalent input  
for the system using a k-factor correction factor,  
designated F3.  
I = MBH x F1 x F2 x F3 eq. 15E  
Using this adjusted equivalent input, check the  
stack diameter by following Steps 2 thru 3 again.  
If the stack diameter remains the same, the sizing  
is complete. If not, redo Steps 4 thru 5 etc. until  
Refer to Table 1.8.15E for the equivalent input  
correction factor which applies to the k-factor  
calculated in Step 4. This factor is designated as  
F3.  
an  
acceptable  
result  
is  
achieved.  
Table 1.8.15E: K-Factor Equivalent Input Correction Factor F3  
K- Factor F3 K- Factor F3 K- Factor F3  
K- Factor F3  
K- Factor F3  
1.00 0.37  
1.50 0.45  
2.00 0.52  
2.50 0.58  
3.00 0.63  
3.50 0.68  
4.00 0.73  
4.50 0.77  
5.00 0.82  
5.50  
6.00  
6.50  
7.00  
7.50  
8.00  
8.50  
9.00  
9.50  
0.86  
0.89  
0.93  
0.97  
1.00  
1.03  
1.06  
1.10  
1.13  
10.00  
10.50  
11.00  
11.50  
12.00  
12.50  
13.00  
13.50  
14.00  
1.15  
1.18  
1.21  
1.24  
1.26  
1.29  
1.32  
1.34  
1.37  
14.50  
15.00  
15.50  
16.00  
16.50  
17.0  
17.50  
18.00  
18.50  
1.39  
1.41  
1.44  
1.46  
1.48  
1.51  
1.53  
1.55  
1.57  
19.00  
19.50  
20.00  
20.50  
21.00  
21.50  
22.00  
22.50  
23.00  
1.59  
1.61  
1.63  
1.65  
1.67  
1.69  
1.71  
1.73  
1.75  
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Stack  
Diam.  
(in.)  
Table 1.8.15C: Approximate Stack Capacities (MBH)  
(Based on Atmospheric Boiler with Draft Hood)  
5
7
10  
12  
150  
15  
20  
25  
30  
35  
40  
280  
45  
50  
320  
60  
70  
80  
90  
100  
450  
125  
510  
150  
550  
200  
640  
6
100  
120  
140  
170  
200  
220  
250  
270  
300  
350  
380  
400  
430  
7
130  
160  
190  
210  
240  
270  
310  
340  
360  
390  
410  
430  
480  
510  
550  
580  
620  
690  
760  
870  
8
180  
210  
250  
280  
310  
360  
400  
440  
480  
510  
540  
570  
620  
670  
720  
760  
810  
900  
990  
1140  
1450  
1790  
2580  
3510  
4590  
5810  
7170  
8680  
10330  
12120  
14060  
16140  
18360  
20730  
23240  
41320  
52290  
64560  
92970  
9
220  
270  
320  
350  
390  
450  
510  
560  
600  
640  
680  
720  
790  
850  
910  
970  
1020  
1260  
1820  
2480  
3240  
4100  
5070  
6130  
7300  
8570  
9940  
11410  
12980  
14650  
16430  
29210  
36970  
45650  
65740  
1140  
1410  
2040  
2770  
3620  
4590  
5670  
6860  
8160  
9580  
11110  
12760  
14510  
16390  
18370  
32660  
41340  
51040  
73500  
1250  
1550  
2330  
3040  
3970  
5030  
6210  
7510  
8940  
10490  
12170  
13970  
15900  
17950  
20120  
35780  
45290  
55910  
80510  
10  
12  
14  
16  
18  
20  
22  
24  
26  
28  
30  
32  
34  
36  
48  
54  
60  
72  
280  
330  
400  
430  
490  
560  
630  
690  
750  
800  
850  
890  
980  
1060  
1520  
2070  
2710  
3430  
4240  
5130  
6110  
7170  
8310  
9540  
10860  
12260  
13750  
24400  
30930  
38190  
55000  
1130  
1630  
2220  
2900  
3670  
4530  
5480  
6530  
7660  
8890  
10200  
11610  
13110  
14700  
26130  
33070  
40830  
58800  
1200  
1730  
2350  
3070  
3890  
4810  
5820  
6920  
8130  
9430  
10820  
12310  
13900  
15590  
27710  
35080  
43310  
62360  
400  
480  
570  
630  
700  
810  
910  
1000  
1360  
1770  
2250  
2770  
3360  
4000  
4690  
5440  
6250  
7110  
8020  
9000  
1080  
1470  
1920  
2430  
3000  
3630  
4320  
5070  
5880  
6750  
7680  
8670  
9720  
1150  
1570  
2050  
2590  
3200  
3880  
4610  
5420  
6280  
7210  
8210  
9270  
10390  
1220  
1660  
2170  
2750  
3400  
4110  
4900  
5750  
6660  
7650  
8710  
9830  
1290  
1750  
2290  
2900  
3580  
4340  
5160  
6060  
7030  
8070  
9180  
10360  
1410  
1920  
2510  
3180  
3920  
4750  
5650  
6640  
7700  
8840  
10050  
11350  
12730  
22630  
28640  
35360  
50920  
550  
650  
780  
860  
960  
1110  
1450  
1830  
2260  
2740  
3260  
3830  
4440  
5100  
5800  
6550  
7350  
1240  
1620  
2050  
2530  
3060  
3650  
4280  
4970  
5700  
6490  
7320  
8210  
720  
850  
1020  
1290  
1600  
1940  
2300  
2710  
3140  
3600  
4100  
4630  
5190  
9230  
1120  
1420  
1750  
2120  
2530  
2960  
3440  
3950  
4490  
5070  
5670  
10120  
1250  
1590  
1960  
2370  
2820  
3320  
3850  
4420  
5020  
5670  
6360  
910  
1080  
1340  
1620  
1930  
2260  
2630  
3010  
3430  
3870  
4340  
7730  
1130  
1370  
1630  
1910  
2220  
2550  
2900  
3270  
3670  
6530  
8260  
10200  
14700  
11020 11620  
19600 20660  
24800 26140  
30620 32280  
44100 46480  
11310 13060 14600 16000 17280 18470  
14320 16530 18480 20250 21870 23380  
17680 20410 22820 25000 27000 28870  
25460 29400 32870 36000 38890 41570  
9780 11690 12810  
12070 14430 15810  
17390 20780 22770  
NOTE: The above vent input capacities in MBH (thousands of Btu/hr) are sea level ratings for double wall or insulated vents allowing for a system K factor of  
7.5. Apply the correction factors for altitude, other k-factors and boiler draft control correction factors.  
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Table 1.8.15F: CIRCULAR EQUIVALENTS OF RECTANGULAR BREECHINGS & STACKS  
WIDTH  
HEIGHT (INCHES)  
(INCHES)  
6
7
8
8
9
8
8
9
10 12 14 16  
10 10  
10 11 11 12  
18  
11  
13  
15  
16  
17  
19  
20  
21  
22  
23  
24  
24  
25  
27  
29  
31  
33  
34  
20  
11  
13  
15  
17  
18  
20  
21  
22  
23  
24  
25  
26  
27  
29  
31  
33  
35  
37  
22  
12  
14  
16  
18  
19  
20  
23  
24  
25  
26  
27  
28  
31  
33  
35  
37  
39  
39  
24  
12  
15  
17  
18  
20  
21  
23  
24  
25  
26  
27  
28  
29  
32  
34  
37  
39  
40  
26  
13  
15  
17  
19  
21  
22  
24  
25  
26  
27  
28  
29  
31  
33  
36  
38  
40  
42  
28  
13  
16  
18  
20  
21  
23  
24  
26  
27  
28  
29  
31  
32  
35  
37  
40  
42  
44  
30  
14  
16  
18  
20  
22  
24  
25  
27  
28  
29  
31  
32  
33  
36  
39  
41  
44  
46  
36  
15  
15  
17  
20  
22  
24  
26  
27  
29  
31  
32  
35  
36  
39  
42  
45  
48  
50  
42  
16  
19  
21  
23  
26  
28  
29  
31  
33  
34  
36  
37  
39  
42  
46  
49  
52  
55  
48  
17  
20  
22  
25  
27  
29  
31  
33  
35  
37  
38  
40  
41  
45  
49  
52  
56  
59  
54  
17  
21  
23  
26  
29  
31  
33  
35  
37  
39  
40  
42  
44  
48  
52  
56  
59  
62  
60  
18  
21  
24  
27  
30  
32  
34  
37  
39  
40  
42  
44  
46  
50  
55  
59  
62  
66  
6
8
9
8
10  
12  
14  
16  
18  
20  
22  
24  
26  
28  
30  
36  
42  
48  
54  
60  
10 11 12 13 14  
11 12 13 14 15  
10 11 13 14 15 16  
10 12 14 15 16 17  
11 13 15 16 17 19  
11 13 15 17 18 20  
12 14 16 18 19 20  
12 15 17 18 20 21  
13 15 17 19 21 22  
13 16 18 20 21 23  
14 16 18 20 22 24  
15 17 20 22 24 26  
16 19 21 23 26 28  
17 20 22 25 27 29  
17 21 23 26 29 31  
18 21 24 27 30 32  
1.8.16 SPECIAL APPLICATIONS  
FLUE GAS ECONOMIZERS  
HIGH EFFICIENCY APPLIANCES  
When applying flue gas economizers, care must  
be taken to assure that:  
1. Proper draft must be maintained. This requires  
that the gas side pressure drop be considered  
and that the economizer exchanger must be  
designed so as to allow cleaning.  
2. The vent system materials must be considered,  
regarding resistance from corrosion, which might  
result from the lower flue gas temperature.  
3. In general, it is recommended that the boiler  
manufacturer be consulted when a flue gas  
economizer is to be added.  
High efficiency appliances require special  
consideration in vent design because of the  
reduced stack gas temperatures. Under no  
circumstances can a condensing type appliance  
be vented into the same vent system with other  
appliances. The vent system for such appliances  
must be provided by or specified specifically by  
the manufacturer of the condensing appliance.  
High efficiency non-condensing appliances  
should  
generally be installed only on vent  
systems that are resistant to corrosion from flue  
gas condensate. This generally requires stainless  
steel vent construction.  
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1.9 BURNERS AND GAS TRAIN - FORCED DRAFT BOILERS  
GENERAL  
Oil supply lines must be sized for the circulation  
Refer to separate manual on the forced draft  
burner for start-up and adjustment procedures.  
Do not attempt to start burner when excess oil  
has accumulated, or when the combustion  
chamber is full of gas, or if chamber is very hot.  
rate of the burner pump. This is referred to as the  
suction gear capacity of the pump. If a transfer  
pump is used, it must have a pumping capacity  
no less than the total suction gear capacity of all  
burner pumps on the system. Refer to Burner  
Manual for the suction gear capacity of standard  
oil pumps. Two-pipe oil systems are  
recommended in all cases, although a one-pipe  
system might be acceptable on smaller boilers  
(under 6 gph). Two-pipe systems tend to have  
fewer problems with air entrainment in the oil. Air  
in the oil will cause nuisance problems and  
delayed ignition.  
FUEL CONNECTIONS  
Gas supply connections must comply with the  
National Fuel Gas Code (NFPA54). Oil supply  
connections must comply with NFPA31. Any  
additional local or state codes must also be  
adhered to.  
1.10 PROCEDURES TO BE FOLLOWED BEFORE PLACING BOILER IN  
OPERATION  
1.10.1 HYDROSTATIC TEST OF BOILERS AND  
SYSTEM  
although the boiler is hydrostatically tested at the  
factory, minor leaks in fittings and at attachments  
can develop from shipping vibration or from  
installation procedures. It is often necessary to  
retighten such fittings after the installation and  
after the boiler has been operated for some time.  
Replace tube access panels before proceeding to  
start boiler.  
After completing the boiler and burner installation,  
the boiler connections, fittings, attachments and  
adjacent piping must be inspected for leaks by  
filling the unit with water. The pressure should be  
gradually increased to a pressure just below the  
setting of boiler safety relief valve(s).  
Remove the boiler tube access panels (see  
dimensional drawing in this manual). Inspect the  
tube to header joints to be certain that all tube  
fittings are sealed. This is necessary because,  
1.10.2 TEST OF GAS PIPING  
Reference gas system test under Section 1.5,  
"Gas Connection", in this manual.  
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START-UP AND OPERATION  
STEAM BOILERS  
WARNING:  
IMPROPER SERVICING AND START-UP OF THIS EQUIPMENT MAY CREATE A  
POTENTIAL HAZARD TO EQUIPMENT AND TO OPERATORS OR PERSONS IN THE  
BUILDING.  
SERVICING AND START-UP MUST BE DONE ONLY BY FULLY TRAINED AND  
QUALIFIED PERSONNEL.  
CAUTION:  
BEFORE DISCONNECTING OR OPENING ANY FUEL LINE, OR BEFORE CLEANING OR REPLACING  
PARTS OF ANY KIND, TAKE THE FOLLOWING PRECAUTIONS:  
Turn OFF the main fuel shutoff valves, including the pilot gas cock if applicable. If the burner is a multiple  
fuel type, shut OFF all fuel supplies.  
Turn OFF all electrical disconnects to the burner, boiler and any other equipment or systems electrically  
interlocked with the burner or boiler.  
All cover plates, enclosures, and guards must be in place at all times except during maintenance and  
servicing.  
2.1 FIRING RATE ADJUSTMENT - ATMOSPHERIC GAS UNITS  
2.1.1 The following procedures must be followed  
carefully before putting the boiler in operation.  
Failure to do so will present severe hazards to  
equipment, operating personnel and building  
occupants.  
which firing rate system is used, see the boiler  
Equipment List and Wiring Diagram.  
2.1.4 ADJUST BOILER MINIMUM INPUT  
After setting the correct Maximum input as  
described in the Lighting Instructions, proceed to  
adjust the minimum input as outlined below. This  
applies only to those boilers which are designed  
and equipped for two-stage (High/Low/Off) firing  
or Modulation. On those boilers which are  
equipped for ON/OFF firing only, no minimum  
input adjustment is required. NOTE: the low firing  
rate input is adjustable only on boilers equipped  
with two-stage or modulating motorized gas  
valves (V4055, V9055, or AH4 actuators) or with  
motor-operated modulating butterfly gas valves.  
The other two-stage firing systems (VR850 or  
VR852 combination valves or dual diaphragm  
valve type bypass systems) have a non-  
adjustable minimum input rate.  
2.1.2 ADJUST PILOT BURNER  
Carefully follow the Lighting Instructions in the  
boiler manual for the proper adjustment of the  
pilot burner. This is absolutely essential before  
attempting to adjust the main burner.  
2.1.3 ADJUST BOILER INPUT(S)  
The boiler input must be adjusted for both  
maximum and minimum input values which are  
listed on the boiler nameplate. First adjust the  
maximum input rating using the method  
described in Lighting Instructions in the Boiler  
Manual. Refer to the following information for the  
adjustment of the minimum input. To determine  
the adjustment  
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NOTE  
2.1.6 MINIMUM INPUT ADJUSTMENT - DUAL  
DIAPHRAGM GAS VALVE HIGH/LOW BY-PASS  
SYSTEM  
THE LOW FIRE ADJUSTMENT SHOULD  
RESULT IN A GAS PRESSURE ON THE  
BURNER MANIFOLD EQUAL TO 1" WATER  
COLUMN FOR NATURAL GAS AND 3" FOR  
PROPANE GAS.  
The minimum input on this control system is NOT  
adjustable. The maximum input must be properly  
set as outlined in Lighting Instructions. This  
system consists of two V48A (120 volt coil) or two  
V88A (24 volts coil) diaphragm gas valves which  
are piped in parallel. The minimum input is  
controlled by an orifice plug installed in a coupling  
in the by-pass piping (low fire valve piping), sized  
for approximately 1" w.c. manifold pressure at low  
fire natural gas (2" w.c. if propane gas). When the  
high fire gas valve is not activated, gas flows only  
through the bypass piping. When the high fire gas  
valve is activated, gas will flow though both  
valves achieving full input.  
2.1.5 MINIMUM INPUT ADJUSTMENT  
COMBINATION GAS VALVES (VR850 OR  
VR852)  
The minimum input on these gas valves is NOT  
adjustable. The maximum input must be properly  
set as outlined in Lighting Instructions. See the  
manufacturer's instructions on the VR850 or  
VR852 included in the Boiler Manual for further  
information.  
-
2.2 FIRING RATE ADJUSTMENT - GAS METER READINGS  
2.2.1 CHECKING BURNER INPUT  
calculated from this timing. The method is  
The burner input rate can be checked by taking  
readings from the gas meter. Please note  
checking the rate with a meter is the only way to  
be sure of input. Manifold readings are only an  
approximate value and may vary from unit to unit.  
described in Lighting Instructions. If the meter is  
not calibrated for gas temperature and pressure,  
correction factors must be applied to determine  
correct rate in SCFH (standard cubic feet per  
hour). Consult the National Fuel Gas Code (ANSI  
Z223.1, NFPA 54) or the local gas utility for  
further information. Refer to Table 2.2A for  
correction factors for the gas pressure at the  
meter. Refer to Table 2.2B for the gas  
temperature correction factors.  
In order to obtain accurate data, there must be no  
other appliances using gas from the same meter  
while the burner input rate is being checked. The  
test hand on the meter should be timed for  
several revolutions. The input rate in cubic feet  
per hour is  
Table 2.2A - Pressure Correction  
Table 2.2B - Temperature Correction  
Gas Pressure at Meter  
7" w.c.  
Correction Factor  
Gas Temp. at Meter  
Correction Factor  
0.920  
1.017  
1.034  
1.051  
1.061  
1.136  
1.340  
40  
50  
60  
70  
80  
90  
F
F
F
F
F
F
14" w.c.  
0.902  
21" w.c.  
0.885  
1 psig  
0.868  
2 psig  
0.852  
5 psig  
0.836  
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2.3 SAFETY SHUT-OFF DEVICES (FLAME SUPERVISION)  
2.3.1 FLAME SUPERVISORY SYSTEM  
flame loss. In addition to the information given in  
The boiler is equipped with a flame supervisory  
system, either the Thermocouple type (such as a  
combination gas valve or a pilotstat) or electronic  
type (such as the RA890, or RM7895). The  
purpose of this device is to detect the main or  
pilot flame, depending on the type of device, and  
control the gas valves accordingly. The device  
must be checked for proper operation. See  
Lighting Instructions in the Boiler Manual for the  
correct procedure. The flame supervisory system  
must be tested to assure that it will shut off the  
main gas valves in case of a  
Lighting Instructions, operating sequence and  
troubleshooting information may be found in the  
manufacturer's instructions in the Boiler Manual.  
2.3.2 AUTOMATIC (ELECTRIC) IGNITION  
SYSTEMS  
On boilers equipped with automatic electrically  
ignited pilots, follow the procedures described in  
Lighting Instructions and test the controls for  
proper operation.  
2.4 LIMIT CIRCUIT CUT-OUT TEST  
2.4.1 PROTECTIVE DEVICES  
All operating and limit controls and low water  
cutoffs must be tested for proper operation.  
water feeder combination) or electric probe type  
auxiliary control. These water level controls are  
intended to sense (and control) the level of the  
water in the boiler. They operate to shut off the  
boiler if the water level drops below their sensing  
level. The low water cut-off and water level  
controls must be operationally tested by manually  
lowering the boiler water level (by opening the  
boiler blowdown valve for probe controls, and by  
opening the control blowdown valve for float type  
controls). The boiler should cycle off when the  
water level drops below the control point of the  
low water cut-off. When the water level is  
restored, the boiler should cycle back on.  
Depress the manual reset button of devices  
which require manual reset in order to restore the  
boiler to operation. Carefully read the enclosed  
literature on the low water cut-off controls,  
particularly installaing, operating and servicing.  
2.4.2  
STEAM  
PRESSURE  
OPERATING  
CONTROL  
The steam pressure in the boiler is regulated by  
the Boiler Operator. This is a pressure control  
which senses the steam pressure and turns the  
boiler on and off accordingly. This control must be  
operationally tested. Adjust the pressure setting  
on the control to a pressure less than the boiler  
pressure (as shown on the boiler pressure  
gauge). The control should turn the boiler off.  
Restore the control setting to normal. The boiler  
should cycle on.  
2.4.3 HIGH LIMIT CONTROL  
At least one additional pressure control is  
provided as the high limit control. It is set at a  
pressure above the operator to act as a back-up  
should the operator fail. The high limit control  
must be operationally tested. With the boiler  
operating, decrease the pressure setting of the  
limit control below the current pressure of the  
boiler. The boiler should cycle off. Restore the  
high limit control setting to normal (pushing rest  
button if it is a manual reset type). The boiler  
should now cycle on.  
2.4.5 COMBINATION LOW WATER CUT-OFF &  
FEEDER  
The low water cut-off/feeder supplied with some  
boiler serves as a low water cut-off (see above)  
and also causes make-up water to be added to  
the boiler should the water level drop below its  
control point.  
This type of control must be operationally tested  
as for low water cut-offs and also to assure that  
the make-up water is introduced as needed.  
Carefully read the enclosed literature on the Low  
2.4.4 LOW WATER CUT-OFF(S)  
Most boilers are supplied with a float-operated  
primary low water cut-off (and pump control or  
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Water Cut-off controls, particularly installing,  
operating and servicing.  
2.4.7 BOILER FEED SYSTEM  
The boiler feed pump must be operationally  
tested to assure that it can provide boiler  
feedwater at the pressure and in the amount  
needed for safe and reliable boiler operation.  
2.4.6 OTHER CONTROLS  
Additional controls as required for the particular  
installation may also be provided. Refer to the  
literature on these devices included in the Boiler  
Manual. All such devices must be operationally  
tested to assure reliable operation of the boiler  
and system.  
2.4.8 CHEMICAL FEED SYSTEM & SOFTENER  
Check the performance of the boiler water  
softener and chemical treatment system.  
Chemically test the feedwater to be certain it  
complies with the recommendations of the  
chemical treatment consultant.  
2.5 RECOMMENDED DRAFT AND COMBUSTION READINGS  
ATMOSPHERIC GAS-FIRED BOILERS  
BOILER SERIES  
DRAFT AT BOILER CO2 @ HIGH  
O2 @  
HIGH FIRE  
CO  
(ppm)  
SMOKE  
NO.  
OUTLET  
(i.w.c.)  
FIRE  
F
CL  
K
-0.01 TO -0.04  
-0.02 TO -0.04  
-0.02 TO -0.06  
7.5 TO 8.5 % 5.0 TO 7.5 %  
7.5 TO 9.0 % 4.8 TO 7.5 %  
8.0 TO 9.5 % 4.0 TO 6.7 %  
< 400  
< 400  
< 400  
0
0
0
FORCED DRAFT GAS FIRED BOILERS  
BOILER SERIES  
DRAFT AT  
BOILER  
CO2 @  
HIGH FIRE  
O2 @  
HIGH FIRE  
CO  
(ppm)  
SMOKE  
NO.  
OUTLET (i.w.c.)  
D
HED  
-0.01 TO -0.04  
-0.01 TO -0.04  
0.0 TO -0.04  
7.5 TO 9.5 %  
7.5 TO 9.5 %  
4.0 TO 7.5 %  
4.0 TO 7.5 %  
< 400  
< 400  
< 400  
< 400  
< 400  
< 400  
0
0
0
0
0
0
CL  
8.5 TO 10.0 % 3.2 TO 5.0 %  
8.5 TO 10.0 % 3.2 TO 5.0 %  
9.0 TO 10.0 % 3.2 TO 5.0 %  
9.0 TO 10.0 % 3.2 TO 5.0 %  
HECL  
RV & RW  
AB  
0.0 TO -0.06  
+0.50 TO -0.10  
+0.25 TO -0.06  
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FORCED DRAFT OIL FIRED BOILERS  
BOILER SERIES  
DRAFT AT  
BOILER  
CO2 @  
HIGH FIRE  
O2 @  
HIGH FIRE  
CO  
(ppm)  
SMOKE  
NO.  
OUTLET (i.w.c.)  
D
CL  
-0.01 TO -0.04  
0.0 TO -0.04  
10.0 TO 12.0 % 4.0 TO 7.2 %  
10.0 TO 12.0 % 4.0 TO 7.2 %  
11.5 TO 12.5 % 3.7 TO 5.0 %  
11.5 TO 12.5 % 3.7 TO 5.0 %  
< 400  
< 400  
< 400  
< 400  
0
0
0
0
RV & RW  
AB  
+0.50 TO -0.10  
+0.25 TO -0.06  
NOTE: THE VALUES FOR CO2 AND O2 ARE SHOWN FOR HIGH FIRE ONLY. THE VALUES FOR LOW  
FIRE OR MID RANGE WILL GENERALLY BE LOWER, PARTICULARLY FOR ATMOSPHERIC GAS-  
FIRED BOILERS. DRAFT SHOULD BE MEASURED APPROXIMATELY 24" FROM TOP OF BOILER,  
BEFORE ANY DRAFT CONTROL.  
2.5.1 DRAFT ADJUSTMENT - ATMOSPHERIC  
GAS BOILERS  
ARE MADE TO ASSURE ADEQUATE DRAFT  
THROUGH THE VENTING SYSTEM.  
2.5.2 DRAFT ADJUSTMENT -FORCED DRAFT  
BOILERS  
Draft adjustments are generally not necessary on  
forced draft boilers. The draft must be measured  
as part of the start-up procedure. The measured  
draft at the boiler flue should fall within the  
recommended range specified in the appropriate  
table.  
Refer to Section 1.8.6 for the adjustment method  
for barometric dampers. Adjust the damper so as  
to yield a draft which results in values of CO2 and  
CO within the allowable limits listed above in the  
appropriate table.  
Draft adjustments are generally not required for  
boilers equipped with draft diverters. The diverter  
must  
be  
installed  
without  
modification.  
Combustion readings are required, however, to  
assure that the boiler operation is both safe and  
efficient.  
On some installations the draft may be excessive  
due to a high chimney. In these cases, the draft  
should be adjusted within the recommended  
range specified in the above appropriate table.  
This may be done using a barometric damper, a  
restrictor, or a locking quadrant damper. Such  
devices must be installed and adjusted by a  
qualified technician.  
Draft measurement should preferably be made  
with an inclined tube manometer. If a draft gauge  
is not available, check to be sure the flue gases  
are being carried up the venting system by  
passing a lighted taper or match around the edge  
of the draft hood relief opening (or barometric). If  
the venting system is operating correctly, the  
match flame will be drawn toward the draft hood  
relief opening. Otherwise the products of  
combustion will tend to push the flame and  
extinguish it.  
2.5.3  
COMBUSTION  
ADJUSTMENTS  
-
FORCED DRAFT  
Refer to the separate burner manual for the  
procedures for burner adjustments. The burner  
must be adjusted for smooth lightoff. Combustion  
parameters should be within the range specified  
in the above appropriate table. In no case should  
the level of CO be allowed to exceed the limit  
given, and the smoke spot reading must also not  
exceed the value shown.  
CAUTION  
IF THE PRODUCTS OF COMBUSTION ARE  
BEING EMITTED INTO THE ROOM (VENTING  
SYSTEM NOT OPERATING CORRECTLY),  
THE BOILER MUST NOT BE OPERATED  
UNTIL PROPER ADJUSTMENTS OR REPAIRS  
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2.6 OPERATING INSTRUCTIONS  
2.6.1 FAMILIARIZATION WITH MANUAL(S)  
The user of the boiler must familiarize himself  
with this manual and the burner manual for forced  
draft boilers to be sure he is prepared to operate  
and maintain the boiler properly.  
The operating instructions should be kept in the  
pocket in the boiler for F Series boilers, or  
adjacent to the boiler for all others.  
READ THE MANUAL BEFORE ATTEMPTING A  
START UP.  
2.7 MAINTENANCE SCHEDULE  
2.7.1 POSTING SCHEDULE  
Post a maintenance schedule in accordance with  
the recommendations in this manual. A copy of a  
typical schedule is included in this manual.  
Section 3  
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CARE AND MAINTENANCE  
STEAM BOILERS  
CAUTION:  
The boiler area should be kept free of combustible materials, gasoline and other flammable liquids.  
The boiler and venting system must be kept free of obstructions of the air louvers and draft hood  
relief openings.  
The following procedures must be conducted as outlined to assure safe operation of the boiler.  
All cover plates, enclosures, and guards must be in place at all times except during maintenance  
and servicing.  
3.1 REQUIRED PRECAUTIONS DURING TEMPORARY USE  
GENERAL  
1. Knowledge of burner/boiler operation.  
A boiler is often utilized in new construction to  
assist in curing of building components or to  
provide temporary heat for the construction crew  
or for other purposes during the time the building  
is under construction. If precautions are not taken  
during this time to protect the boiler, a great deal  
of damage can occur before the ultimate owner  
takes over the building.  
2. Possession and understanding of boiler/burner  
operating instruction manual.  
3. Assurance that the boiler is fed with only  
treated water at all times and that chemical  
treatment and blowdown procedures are always  
followed.  
It is the mutual responsibility of the installing  
contractor and the boiler owner to consider the  
effect of temporary usage on the boiler warranty.  
The following should be observed so as to assure  
the longevity of the boiler.  
4. Notification to the manufacturer (or  
manufacturer's agent) to provide start-up services  
if the boiler was purchased with start-up by a  
factory representative.  
5. Adherence to all of the start-up procedures  
noted in the boiler/burner manual.  
OPERATOR SKILLS/RESPONSIBILITIES  
During the temporary use period, a single  
individual must be assigned responsibility for the  
care and operation of the boiler. This person's  
responsibility must include, but not be limited to,  
the following:  
6. Considerations of warranty should the boiler be  
used for temporary heat without adherence to the  
recommended start-up and operating procedures  
outlined in the instruction manuals.  
3.2 CLEANING THE BOILER AND SYSTEM - NEW SYSTEMS  
BOIL OUT PROCEDURE  
In combination with system contamination,  
The internal surfaces of a newly installed boiler  
will have oil, grease or other protective coatings  
used in manufacturing. Such coatings must be  
removed since these coatings lower the heat  
transfer rate and could lead to overheating of a  
tube and reduce operating efficiency. Before  
boiling out procedures may begin, the burner  
must be ready for firing. The operator must be  
familiar with the procedure outlined in the  
boiler/burner operating instruction manuals.  
bacteria may cause objectionable odors,  
sometimes resembling natural gas. It is important  
to keep these fumes from air intakes which would  
distribute them throughout the building. On steam  
humidification systems this is especially critical.  
Consult your local water treatment chemist for  
further information.  
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CAUTION  
6. Fill the boiler with clean softened water until the  
water level reaches the upper header. Then add  
the cleaning solution into the upper header. Add  
more clean water until the boiler is completely  
filled. The water used for this initial fill should be  
at room temperature, and must be softened as  
noted.  
The boil out procedure outlined must be  
performed by, or under the direct supervision of,  
a qualified technician. The chemicals used  
present a hazard of burns and physical injury if  
mishandled. Always use suitable face mask,  
goggles, protective gloves and garments when  
handling caustic chemicals. Do not permit the  
chemical to come into contact with skin or  
clothing. Always follow the safety precautions on  
the container's label. Add chemicals slowly and in  
small amounts to prevent excessive heat and  
agitation. Do not add water to acid. Do not add  
water to dry chemical. This will cause splattering  
and/or explosion and severe risk of personal  
injury.  
7. After filling, fire the boiler intermittently (at low  
fire) at a frequency as necessary to hold the  
boiler solution at boiling point temperature. DO  
NOT PRODUCE STEAM PRESSURE. Boil the  
water, supervised at all times, for at least five  
hours.  
8. After the five hour boil out, begin to add a small  
amount of fresh softened water so as to create a  
slight overflow of the overflow pipe. This will carry  
out impurities which have accumulated at the  
water surface. Continue to apply heat and  
overflow until the water emitted from the overflow  
pipe clears. Then shut off burner.  
Boiling out under pressure is not recommended.  
If boil out under pressure is required, competent  
assistance must be provided.  
Your water consultant or water treatment  
company will be able to recommend a cleaning or  
boil out procedure. In the event that such service  
is unavailable or as yet not selected, the following  
may be used.  
9. Let the boiler cool to 120 F or less. Then drain  
the boiler. Use caution that the water is  
discharged with safety.  
10. Remove the inspection/cleanout openings in  
the boiler upper and lower headers and wash the  
waterside surfaces thoroughly using high  
pressure water stream.  
1. The boil out of the boiler and system is neither  
difficult nor expensive. The chemicals needed for  
cleaning are readily available. Trisodium  
phosphate, and sodium hydroxide (lye) are the  
most commonly used chemicals. Use only one  
type of solution in the system. The amount of  
chemical required will vary according to  
conditions, but an amount of one pound of  
chemical per fifty gallons of water is suggested.  
11.  
Inspect the boiler's internal (waterside)  
surfaces thoroughly after the procedure. If the  
surfaces are not clean, repeat the boil out.  
12. After boil out, close all openings. Install relief  
valves, gauge glasses and other components as  
necessary. Completely fill the boiler with fresh,  
softened, ambient temperature water. Fire the  
boiler at low fire until water temperature of at least  
180 F is reached. This will drive off dissolved  
gases.  
2. Before introducing the solution into the boiler,  
an overflow pipe should be attached to the top of  
the boiler and routed to a safe point of discharge.  
3. Remove all safety valves to ensure that none  
of the solution will come into contact with the  
valve seats. Use care in removing and reinstalling  
valves.  
13. The boiler is now ready to operate.  
4. All valves in the piping to and from the system  
must be closed to prevent the chemical solution  
from getting into the system.  
IMPORTANT  
If boiler is not to be operated within 24 hours, a  
lay-up procedure is required. Refer to instruction  
for lay-up.  
5. Gauge glasses must be protected from contact  
with the boil out chemicals.  
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3.3 SYSTEM CLEAN OUT  
Many boilers have been ruined with system  
contaminants such as pipe dope, cutting oil,  
metal shavings or chips and other debris which  
are left in the piping. If these contaminants are  
not removed, they will end up in the boiler.  
During this system clean out, the boiler make-up  
water must be properly softened and treated. At  
the conclusion of the system clean out, the  
condensate must be reconnected.  
For old or existing steam systems, the installation  
process may have jarred debris loose. Following  
the boil out of the new boiler, the condensate  
should be wasted until it is within proper  
guidelines. Check all steam trap strainers to  
assure their cleanliness. Refer to the succeeding  
section on replacement boiler installations.  
SYSTEM CLEANING PROCEDURE  
For steam systems, the boiler will need to be  
connected to the header utilizing steam to purge  
the piping and thus push the debris out of the  
system. However, at this time all condensate  
must be wasted until it runs clear and water  
analysis of the condensate indicates that it is free  
of contaminants. Steam trap strainers must be  
periodically opened and cleaned of any debris  
which accumulates.  
3.4 REPLACEMENT BOILER INSTALLATIONS:  
PROTECTION AGAINST CORROSION & SEDIMENT  
BOILER MUST CONTROL FEED WATER  
The water feed to the boiler must be controlled by  
the boiler-mounted water level control. It is  
unacceptable to use gravity return or to let the  
water feed be controlled by a condensate/  
receiver/ condensate pump system. The water  
feed to the boiler must be controlled:  
the entire system. A chemical treatment company  
should be consulted for the proper means of this  
chemical cleaning.  
Replace any piping considered to be deteriorated  
beyond safe or cleanable condition. Flush the  
system clean, being certain to isolate the boiler.  
by a feed pump control which is mounted on  
the boiler. This control is to activate the feed  
pump on a boiler feed system. It will be  
necessary to supply such a system if not already  
installed. - OR -  
by an automatic water feeder mounted on the  
boiler. This is used only on systems requiring  
100% make-up, such as humidification, steam  
process, etc.  
DO NOT FLUSH THE SYSTEM THROUGH THE  
BOILER  
NOTE: For some old systems, there is a  
reluctance to clean the piping because of the  
possibility of leaks occurring in badly corroded  
lines. Should the customer refuse cleaning, it is  
necessary to install filtration equipment. Install  
either a fibrous filter or a centrifugal filter in the  
boiler return piping. This will collect and remove  
sediment from the system. A booster pump may  
have to be installed as well to overcome the  
additional pressure drop introduced in the line by  
the filter. When filling the system, provide  
chemical treatment as outlined in Section 3.5.  
NOTE  
It is not recommended to provide the make-up for  
a closed steam heating system to the boiler by  
means of a water feeder. It is preferred that  
system make-up be connected to the condensate  
return tank of a boiler feed system.  
A boiler feed system may be used in conjunction  
with an existing condensate receiver system by  
allowing the receiver system to pump condensate  
into the boiler feed system tank.  
CAUTION  
Failure to properly clean the system or to install  
mechanical sediment removal equipment can  
result in tube blockage and severe corrosion plus  
damage to pumps, controls, and air removal  
device.  
CLEAN OR REPLACE ALL SYSTEM PIPING  
AND HEATING UNITS  
Arrange for chemical and mechanical cleaning of  
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3.5 BOILER WATER TREATMENT  
PURPOSE OF WATER TREATMENT  
WATER SOFTENER  
Water treatment is required for satisfactory  
operation of the boiler. It must be devised to  
prevent depositing of scale and to prevent  
corrosion from acids, oxygen and other such  
harmful elements that may be in the water supply.  
A qualified water treatment chemist should be  
consulted and the water systematically treated.  
It is highly recommended that a zeolite water  
softener be used for all make-up to the boiler. It is  
intended that this be used in addition to the  
chemical treatment of the boiler. Water softening  
removes calcium and magnesium, the primary  
causes of hard boiler scale.  
CONTINUOUS MONITORING REQUIRED  
Water treatment should be checked and  
maintained whenever the boiler is operating. The  
boiler operator should be sure that the boiler is  
not operating for long periods without proper  
water treatment. Water treatment may vary from  
season to season or over a period of time.  
Therefore, the water treatment procedure should  
be checked not less than four times a year, and  
possibly more frequently as the local water  
conditions may indicate.  
OBJECTIVES  
The basic objectives of water treatment are:  
1. Prevent the accumulation of scale and  
deposits in the boiler.  
2. Remove dissolved gases from the  
water.  
3. Protect the boiler against corrosion.  
4. Maintain the highest possible boiler  
fuel efficiency.  
5. Decrease the amount of boiler down  
time from cleaning.  
3.6 EXTERNAL "FIRE-SIDE" CLEANING  
PURPOSE  
If the buildup of soot is appreciable, the flue gas  
venting system must be thoroughly inspected  
internally as well, and cleaned as necessary.  
Carbon (soot) is an insulator and is corrosive.  
The heating surface of a boiler must be kept free  
from soot accumulation to keep the boiler  
operating at its highest efficiency and to avoid  
damage from corrosion.  
IMPORTANT  
If either soot or condensation is apparent, a boiler  
service technician should be consulted. The  
presence of soot indicates poor combustion and  
possibly hazardous boiler operation. Failure to do  
so may result in fire, explosion potential, or  
asphyxiation. A combustion test and burner  
adjustments should be undertaken at once.  
SOOT REMOVAL  
If the yearly inspection of the boiler tube surfaces  
reveals a build-up of either soot or rust (usually  
due to condensation), the tubes should be  
thoroughly brushed. (Tube cleaning brushes are  
available from Bryan Steam) To inspect and, if  
necessary, clean the tube surfaces and flue  
collector, first remove the tube access panels.  
Examine the exterior of the tubes for evidence of  
soot or rust. Using a flashlight, carefully look  
between the tubes. There should be an  
unobstructed opening between all tubes, and the  
top surfaces of the tube must be free from soot  
accumulation. Also inspect the interior of the flue  
collector. Brush or vacuum the soot from all  
surfaces. Be sure to cover atmospheric burners  
with a protective cover during cleaning to prevent  
soot from falling into them.  
Rust on the tubes indicates that boiler-operating  
temperatures are too low. The set point of the  
boiler operating control must be no less than  
130 F for natural gas or propane firing, and  
170 F for oil fired boilers. Boilers equipped with  
outdoor reset control must also follow these  
limits.  
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3.7 SUGGESTED MAINTENANCE SCHEDULE  
DAILY  
MONTHLY  
1. Make visual inspection of gauges, monitors, and  
indicators and record readings in boiler log.  
1. Make visual inspection of linkage and proper  
operation of flue, vent, stack, or outlet dampers. Check  
draft as specified in Section 2 of this manual.  
2. Make visual check of instrument and equipment  
settings against factory recommended specifications.  
2. Check float low water cutoff as described above.  
3. Check operation of float type low water cutoffs to  
ensure control is functioning. The lower piping  
connections of float type level controls should have a  
suitable blowdown valve piped into a proper drain. This  
valve should be opened periodically to allow any sludge  
accumulated in the control to be flushed out. On closed  
loop water heating systems this should not be often  
required. Consult manufacturer's instructions.  
3. For those units equipped with a power burner, check  
low draft, fan, air pressure and damper position  
interlocks as specified in burner manual.  
4. Check high and low gas pressure interlocks. Refer to  
manufacturers instructions for correct procedure.  
5. Check high and low oil pressure interlocks. Refer to  
manufacturers instructions for correct procedure.  
WEEKLY  
1. On units equipped with firing rate control, verify that it  
is functioning correctly by adjusting control and  
observing if input changes accordingly.  
ANNUALLY  
1. Perform leakage tests on pilot and main gas or main  
oil fuel valves as specified in manufacturers instructions.  
2. Make visual inspection of igniter and pilot flame. For  
an atmospheric unit, confirm pilot flame is as shown in  
this manual (Section 1.9) and that the main burners light  
off correctly (smoothly) and that the flame is clean and  
normal. For units with a power burner, check pilot flame  
signal strength as specified in burner manual.  
2. Check operating control, high limit, low fire start  
control, and low water cutoff as specified in  
manufacturers instructions.  
3. For units equipped with power burners, check air  
atomizing interlock, fuel valve interlock switch, purge  
switch, burner position interlock, and fuel changeover  
control, as specified in burner manual.  
3. Check pilot and main fuel valves for correct operation.  
Open limit switch - make audible and visual check -  
check valve position indicators and check fuel meters, if  
supplied.  
4. The boiler should be checked at least yearly by the  
local gas utility company. Particular attention should be  
paid to the pilot burner safety devices. The pilot burner  
should be checked to ensure that prompt ignition of all  
burners occurs as the gas valve opens. Refer to Section  
1.9.  
4. Confirm boiler area is free of combustible materials  
and that there is nothing obstructing air openings, draft  
hood relief openings, etc.  
5. Check combustion safety controls for flame failure  
and flame signal strength as specified in manufacturer's  
instructions located at the back of this manual for  
atmospheric units or in the burner manual for units  
equipped with a power burner.  
5. The flue gas passages and the exterior surfaces of  
the boiler tubes should be inspected at least annually.  
Any accumulation of soot or debris should be thoroughly  
cleaned out.  
6. If the yearly inspection of the boiler tube surfaces  
reveals a build-up of soot (carbon) or rust, the tubes  
surfaces should be thoroughly brushed. Failure to do so  
may result in fire or asphyxiation hazards.  
6. Check all limit controls as specified in manufacturer's  
manual.  
7. Check float low water cutoff as described above.  
7. The boiler pressure vessel and piping should be  
checked annually.  
8. Check combustion safety control for pilot turndown  
and refractory hold-in as specified in manufacturer's  
instructions.  
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3.8 FLOAT-ACTUATED WATER LEVEL CONTROLS  
Inspect float type water level controls for proper  
operation. Visually inspect sight glasses for  
evidence of scale forming residues. Refer to  
section 3.9 for gauge glass maintenance.  
On humidification or process systems, the  
blowdown schedule should be based on  
recommendation from a water treatment and  
maintenance program specifically designed for  
the boiler.  
On closed steam heating systems, the float low  
water cutoff should be blown down by means of  
At the annual inspection, all float type level  
controls should be disassembled, cleaned and  
inspected thoroughly. When re-installed these  
controls must be given an operational test.  
opening  
a
blowdown valve on the lower  
connection of the cutoff once per day.  
3.9 WATER GAUGE GLASSES  
INSTALLATION  
INSPECTION  
Check with the maintenance supervisor and  
engineering for the proper glass to be used.  
Compare the box and the glass label or marking  
to ascertain that the gauge glass ratings or  
temperature and pressure are suitable for use on  
the boiler. Use new gaskets when replacing  
glass. The gaskets used should be the same type  
as those originally supplied with the boiler. Make  
certain that the gauge glass valves are properly  
aligned.  
To examine for scratches, shine a bright  
concentrated light at about a 45 angle. Anything  
that glistens brightly should be inspected closely.  
Any scratch which glistens and will catch a  
fingernail, or crescent-shaped or star-shaped  
mark is cause for replacement. This is because  
scratches, corrosion, chips and surface damage  
weaken the glass. If inner surface appears cloudy  
or roughened, and will not respond to cleaning  
procedures, this is evidence of chemical attack. If  
severe, this is cause for replacement.  
All bolts and nuts must be free running and well  
lubricated, preferably with  
a
graphite type  
REPLACEMENT OF GLASS  
lubricant. Washers under nuts and bolt heads are  
desirable. DO NOT tighten while equipment is in  
operation.  
Any glass that has been removed from its  
mounting in process boilers, regardless of the  
reason for removal, should be discarded and  
replaced with a new glass and gaskets. Used  
glasses may contain hidden damage and  
represent a safety hazard.  
MAINTENANCE  
Inspect the gauge glass regularly for any signs of  
clouding or scratching. In new processes, the  
gauge glass should be inspected daily until the  
need for replacement becomes apparent. This  
will help establish the routine inspection cycle.  
Be sure that the replacement glass is suitable for  
service conditions.  
Protective shields to keep cold air, water, or  
falling objects from glass must be replaced.  
The gauge glass should be blown down daily so  
as to remove accumulated sediment from the  
valves.  
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4.0 IDLE BOILER CARE AND LAY-UP  
GENERAL  
(when used) should be kept to a minimum so the  
reduction of solids is achieved by the increased  
manual blowdown.  
Corrosion damage to boilers is often the result of  
improper lay-up during non-operating periods.  
Substantial damage can occur in only a few days  
in proper precautions are not taken. This damage  
is irreversible and will reduce boiler reliability,  
increase maintenance costs and eventually  
shorten the useful life of the boiler tubes.  
WASHDOWN  
As the boiler cannot be washed immediately, the  
heat in the boiler may cause baking of residual  
sludge. The boiler should not be drained until  
cooled enough to prevent this. However, never  
leave the boiler filled with water for any extended  
period of time without taking measures to prevent  
corrosion.  
Idle boilers are vulnerable to attack when air  
contacts untreated wet metal surfaces. To prevent  
corrosion, the boiler metal must be protected by  
either keeping the surfaces completely dry or  
excluding air from the boiler. Air exclusion is  
accomplished either by keeping the boiler  
completely full of water (short term lay-up) or filling  
the boiler with nitrogen gas (long-term lay-up).  
The nitrogen gas prevents air infiltration and does  
not react with the metal.  
LAY-UP CONSIDERATIONS  
There are two basic methods of steam boiler lay-  
up: Wet lay up or Dry lay-up. The choice of which  
method should be used depends on:  
The possibility that the boiler may need to be  
placed in operation on short notice.  
Disposal of lay-up solutions  
In addition to the corrosion damage that occurs,  
the metal particles that are released will form an  
insulating scale on the tubes when the boiler is  
returned to service. These corrosion products will  
accumulate on critical heat transfer areas of the  
boiler, increasing the potential for localized  
corrosion and over heating.  
Freezing potential  
Wet Lay-up is recommended for relatively short  
outages, such as seasonal lay-up. This method  
has the advantage of allowing the boiler to be  
brought on line with short notice. But it can pose  
problems if there is any likelihood of freezing.  
PRE-OPERATIONAL CLEANING AND LAY-UP  
Proper lay-up techniques must be used on an idle  
boiler even if it has never been in operation.  
Before pre-operational lay-up, the boiler must be  
chemically cleaned as outlined in Section 3.2 of  
this manual. This is required, as noted in this  
section, to remove preservatives, oil and grease  
from the tube surfaces. Follow the short term or  
long term lay-up procedure as appropriate.  
Dry Lay-up is recommended for longer periods of  
boiler shut-down or storage. But it is practical only  
if boiler can be drained hot (120 F to 170 F) or if  
external drying can be provided.  
WET LAY-UP OF STEAM BOILERS - SHORT  
TERM  
In the wet lay-up procedure, the boiler is to be  
filled with chemically treated water and sealed to  
prevent air in-leakage. Nitrogen gas under slight  
pressure can also be used to displace air and  
protect the boiler surfaces from corrosion. The  
following steps should be taken for wet lay-up of a  
boiler:  
TAKING BOILERS OFF LINE  
In operation, boiler water contains suspended  
solids which are held in suspension due to water  
circulation and the action of treatment chemicals.  
Unless care is exercised when draining the boiler,  
these suspended solids settle on the tube  
surfaces and will air dry to an adherent deposit,  
sometimes requiring chemical cleaning to remove.  
In addition, these deposits may be misleading  
regarding the effectiveness of the chemical  
treatment program.  
1a. Procedure for operational boiler:  
At least thirty minutes before the boiler comes off  
line, add the following chemicals:  
Sodium Sulfite - 0.5 lbs. per 100 gallons water  
Polymeric Sludge Dispersant - 0.1 lbs. per 100  
gallons water  
Caustic Soda - 0.3 lbs. per 100 gallons water  
PRE-SHUTDOWN PRECAUTIONS  
For a period of three to seven days prior to  
shutdown, manual blowdown frequency should be  
increased. During this period, the lower  
conductivity limit should be below 3500 micro-  
mohs per centimeter. The feed of internal  
treatment must be increased to maintain a specific  
residual concentration. Continuous blowdown  
1b. Procedure for idle boiler:  
If the boiler has never been on line or has been  
out of service for cleaning - Select the highest  
quality water available to fill the boiler. Steam  
condensate, softened water, filtered fresh water,  
and boiler feedwater are generally acceptable for  
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lay-up. Raw city water is not recommended and  
should not be used.  
chemical. Then repeat Step. 2. Pay attention to  
the maintenance of the valves being used to  
isolate the boiler to prevent leakage and resultant  
dilution of the lay-up solution.  
Prepare the chemical solution described in (1a) in  
a separate tank. Adhere to the safety precautions  
described in Section 3.2 of this manual. Add the  
concentrated lay-up solution to the boiler during  
the time it is being filled.  
ALTERNATE METHOD  
An alternate wet lay-up method is to pipe clean  
continuous blowdown water from a properly  
treated boiler into any convenient bottom  
connection on the idle boiler, allowing the water to  
flow through the boiler and out the top (through  
any convenient top opening) to the sewer. This  
method will insure a continuous, complete fill with  
warm, properly treated water. It also prevents in-  
leakage of air by keeping the boiler slightly  
pressurized. It may also provide enough heat to  
keep the fireside of the boiler dry and possibly  
produce adequate freeze protection.  
After the boiler is filled and the lay-up solution has  
been added, the boiler is to be operated for thirty  
minutes at low fire to circulate and mix the  
chemicals.  
2. After filling, the boiler must be closed or  
blanked tightly. The power supply to the boiler  
must be cut off. Vent all air from the top of the  
boiler to allow complete fill with the required  
solution. Nitrogen gas at 5 psig may be introduced  
though a suitable opening to prevent air in-  
leakage during the lay-up period. An alternative to  
the nitrogen gas (see safety precautions under dry  
lay-up) is to install a 55 gallon drum or auxiliary  
vessel as shown in Figure 3.11A. This is to be  
fitted with a cover and filled with properly treated  
water. This vessel or drum should be connected  
to an available opening in the top of the vessel. Its  
purpose is to create a hydrostatic head and to  
allow a ready visual check of water level loss or  
in-leakage during the lay-up period.  
DRY LAY-UP OF STEAM BOILERS - LONG  
TERM  
The dry lay-up method recommended requires  
that the boiler be drained, dried as completely as  
is possible, all opening and valves closed.  
Nitrogen gas at 5 psig is introduced to the boiler to  
pressurize it and prevent air in-leakage. The  
success of the procedure depends on the  
thorough drying of the boiler metal surfaces after  
draining and the exclusion of air during the lay-up.  
CAUTION  
The use of nitrogen for blanketing is  
recommended in both the wet and dry lay-up  
procedures. Even though nitrogen in dilute  
quantities is non-toxic, it will not support life.  
Precautions must be taken before entering  
equipment filled with nitrogen for inspections or  
any other purposes. These precautions shall be  
as follows:  
disconnection of nitrogen supply line  
complete purging and venting of the equipment  
with fresh air  
testing oxygen levels inside before any attempt  
to enter  
Figure 3.11A: WET LAY-UP STATIC HEAD  
DRUM  
all confined entry guidelines applicable to site  
must be followed  
3. During lay-up, test the boiler weekly to assure  
the proper levels of sulfite and alkalinity. To do  
this, take a sample of the boiler water from the  
surface blowdown line or other high point. The  
test results should be:  
Sodium Sulfite 200 ppm minimum  
Phenolphthalein Alkalinity (as CaCO3)  
400 ppm minimum  
Appropriate caution signs shall be posted around  
the equipment to alert personal that nitrogen  
blanketing is in use. A boiler laid up dry must be  
tagged with information that the unit is not to be  
operated until the boiler is properly refilled.  
If the tests indicate chemical concentration has  
decreased, chemical may be introduced to the  
boiler by putting it in the drum shown in Fig.  
3.11A. Then lower the boiler water level to  
introduced it into the boiler. Then operate the  
boiler at low fire to circulate the water and mix the  
1. Drain the boiler before the steam pressure falls  
to zero. Then pressurize with 5 psig nitrogen gas  
through a suitable top opening during draining.  
The nitrogen pressure is to be maintained through  
draining and subsequent storage.  
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An alternate method is to completely dry a clean  
boil (by blowing hot dry air though the boiler) and  
then purge the air from the boiler and pressurize  
with 5 psig nitrogen. Be aware that all metal  
surfaces which are not completely dry are  
vulnerable to corrosion, particularly if oxygen is  
present.  
1. If the boiler was pressurized with nitrogen,  
disconnect the nitrogen supply source and vent  
the boiler.  
2. Using the blowdown valve, drain the boiler  
partially and make up with feedwater so as to  
dilute the chemical residuals to operating  
concentration levels.  
2. If a boiler has been down for repairs and is to  
be laid up, it should be operated to pressurize with  
steam and then drained and pressurized with  
nitrogen as in step 1.  
3. After the boiler water concentrations and the  
water level are returned to proper operating  
conditions, the boiler can be started in the normal  
manner.  
3. All connections must be blanked or tightly  
closed.  
After Dry Lay-Up  
To start an idle boiler after dry lay-up, use the  
following procedure:  
Note: Operating boilers must be removed from  
service to minimize adherence of boiler water  
suspended solids on boiler metal surfaces. Refer  
to previous instructions for boiler washdown.  
1. Disconnect the nitrogen supply source and vent  
the boiler in a safe manner - external to the  
building and away from air intakes. Then  
thoroughly purge the boiler of nitrogen with dry air.  
RETURNING IDLE BOILER TO SERVICE  
After wet lay-up  
To start an idle boiler after wet lay-up, use the  
following procedure:  
2. The boiler was to have been cleaned before the  
lay up procedure. So it is necessary only to fill the  
boiler with properly treated water. Then proceed  
with start-up.  
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