Columbia MPH 100 Installation, Operation And Maintenance Manual Download Page 6

MPH COLUMBIA BOILER COMPANY

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INTRODUCTION

Series MPH Modified Scotch Boiler

The Columbia Multi-Pass Horizontal (MPH) boiler is a modified scotch boiler
designed for hot water, and/or low pressure steam applications. The pressure vessel
is available as a welded pipe  boiler or a rolled tube boiler. These units are manufac-
tured to the specifications set forth by Section IV of the ASME Boiler and Pressure
Vessel Code. Boilers are inspected and stamped for conformity to requirements of
the National Board of Boiler and Pressure Vessel Inspectors.  All boilers are designed
to be fired using No. 2 fuel oil, and/or natural, manufactured, or liquid propane (LP)
gas, and are powered by standard AC electrical service. 

Columbia MPH hot water and low pressure steam boilers are typically shipped
knocked down (unassembled), but are also available factory packaged. All boilers are
furnished with a burner and boiler trim (the jacket is factory installed). Boiler trim con-
sists of the operating and limit controls, pump control and/or low water cut off
(LWCO) controls, and a safety valve.  Factory packaged boilers are fully assembled
and test fired.

Summary of Contents for MPH 100

Page 1: ...COLUMBIA MULTI PASS HORIZONTAL BOILER MPH SERIES INSTALLATION OPERATION and MAINTENANCE MANUAL COLUMBIA BOILER COMPANY POTTSTOWN PENNSYLVANIA ...

Page 2: ......

Page 3: ...LLING A NEW STEAM BOILER 14 OPERATING THE BOILER 16 STARTING THE BOILER 17 STOPPING THE BOILER 17 BURNER START UP AND TEST INFORMATION 18 CONTROL DESCRIPTIONS 19 MAINTENANCE 22 Daily Boiler Check Maintenance List 22 Weekly Boiler Check Maintenance List 22 Monthly Boiler Check Maintenance List 23 Semiannual Boiler Check Maintenance List 23 Annual Boiler Check Maintenance List 23 WATER TREATMENT 25 ...

Page 4: ...r performed testing on the MPH boiler line using specific makes and models of burners Should you choose to supply your own burn er please contact the burner manufacturer to confirm compatibility with the MPH boiler design 6 A barometric damper or draft regulator may be required on MPH installa tions A draft regulating device is required on all multiple boiler installations where the boilers utiliz...

Page 5: ...rned after receiving authorization from your dealer freight prepaid to the Columbia Boiler Co 390 Old Reading Pike Pottstown PA 19464 The use of the Columbia returned goods form is mandatory when returning defective material c Columbia is not responsible for any labor cost for the removal and replacement of equipment d Equipment which is repaired or replaced will carry a warranty equal to the unex...

Page 6: ...ity to requirements of the National Board of Boiler and Pressure Vessel Inspectors All boilers are designed to be fired using No 2 fuel oil and or natural manufactured or liquid propane LP gas and are powered by standard AC electrical service Columbia MPH hot water and low pressure steam boilers are typically shipped knocked down unassembled but are also available factory packaged All boilers are ...

Page 7: ...t is essential that this information be avail able to assure prompt service Boiler Model and Size HP _____________________________________________ Boiler Serial Number __________________________________________________ Boiler National Board Number ___________________________________________ Date Installed _______________________________________________________ Burner Type and Model _______________...

Page 8: ... and service on burner boiler pip ing controls or combustion vent DO NOT install exhaust fans in or near the boiler room Exhaust fans consume available make up air during burner operation More importantly when the boiler cycles off exhaust fans pull hot flue gases back through the burner causing burner parts to deteriorate and possibly fail Maintain a positive pressure in the boiler room at all ti...

Page 9: ... apply a gasketing material between the burner flange and the burner mounting plate to seal the burner Use a non asbestos fiber rope or a wet insu lating material for a gasket as shown in Figure 2 Wet insulation is the preferred gasketing material because it compresses into a flat gasket which conforms to and fills any and all voids Secure the burner in the boiler using the four bolts supplied wit...

Page 10: ... side of the boiler Only two of the three 1 NPT will be used The 157 can be piped to either side of the boiler Secondary Low Water Cut Offs Secondary LWCO s may be required to meet local codes or CSD 1 requirements A Warrick 26C1D1C Probe Type Low Water Cut Off is used in steam applications to meet CSD 1 require ments and is also standard on steam units Thread the remote sensor into the 1 2 NPT fi...

Page 11: ... 1 2 NPT fittings on the front of the boil er Aquastat Controllers Aquastat Controllers are used to regulate boiler water temperature Columbia supplies an Operating Control and a Safety Limit Aquastat with all hot water boilers and water heaters An additional Operating Aquastat may also be supplied for burners that function with low high low operation and or steam boilers using an optional coil Aq...

Page 12: ...pe the outside coil openings together for cold water inlets and the inside coil openings for hot water outlets If necessary temper the hot water sup ply by using a mixing valve Connect the hot water outlet source and a cold water supply line to a mixing valve to temper the hot water supply to the proper temperature requirements for process equipment Whenever boilers are supplied with one or two co...

Page 13: ...lity shutoff valves in accessible locations on the oil supply line Locate one close to the tank and the other close to the burner ahead of the filter Some filters come with built in shutoff valves Install a generous capacity fil ter inside the building between the fuel tank shutoff and burner For additional information consult the burner section of this manual GAS SUPPLY PIPING Contact your local ...

Page 14: ...500 40 210 360 560 1200 2100 3200 6400 50 190 325 500 1100 1900 2850 5800 60 180 300 480 1000 1800 2300 4800 80 150 260 410 850 1550 2000 4200 100 135 230 370 750 1375 1680 3500 150 110 190 300 600 1100 1200 2750 200 75 165 260 540 950 1000 2000 Fitting Equivalent Lengths of Standard Pipe in Feet for Listed Fittings Std Tee 5 5 7 5 9 0 12 0 13 5 15 20 Std Elbow 2 7 3 7 4 5 5 5 6 1 8 11 Vent lines ...

Page 15: ... 21 sq in per boiler horsepower The result of the above calculation is expressed as free area meaning no restrictions of any kind If louvers or screens are used over combustion air openings calculate the percentage of free area to allow for these restrictions Do not have exhaust fans in the immediate proximity of the boiler room if at all possible as they will cause a reversal of draft through the...

Page 16: ...UARE HOLE ROUND PIPE INCHES APPROXIMATE APPROXIMATE MPH 30 1 260 000 630 26 X 26 30 MPH 40 1 680 000 840 30 x 30 34 MPH 50 2 100 000 1050 34 X 34 38 MPH 60 2 520 000 1260 36 X 36 40 MPH 70 2 940 000 1470 40 x 40 42 MPH 80 3 360 000 1680 42 X 42 46 MPH 90 3 780 000 1890 44 X 44 50 MPH 100 4 200 000 2100 46 X 46 52 ...

Page 17: ...e 3 With the boiler firing slowly open the ball valve installed at the skimmer port on the back of the boiler 4 Add water to the boiler at a rate that will allow the boiler to maintain a water temperature between 180 200 F Note do not add too much water so that the water level rises above the skimmer tapping 5 Continue to allow water to flow from the skim tapping until it appears to be oil free 6 ...

Page 18: ... TO CONTACT SKIN OR CLOTHING 4 Mix the chemicals with water and pour into the boiler through the safety valve opening 5 Replace the safety valve 6 Start the firing equipment 7 Boil the water for at least five hours 8 Stop the firing equipment 9 Drain the boiler to a location where hot water can be discharged safely 10 Wash the boiler thoroughly using a hose with sufficient pressure 11 Fill the boi...

Page 19: ... only be removed while performing maintenance and or service The fuel supply should not be turned on until the combustion chamber has been vented and the pilot light if gas ignited checked for proper operation All drain valves including blowdown valves for stream boilers water column drain valves gauge glass drain valves and gauge cocks should be closed The safety relief valves should be inspected...

Page 20: ...will not operate when the boiler has reached its normal water level until the reset button on the manually reset probe type low water cutoff is pushed NOTE Combustion efficiency must be checked at this time See the burner manufactur ers instructions for correct settings and more detailed information Follow the adjustment procedures outlined in the burner section of this manual to set up the burner...

Page 21: ...Fire__________________BTU HR Oil Firing High Fire Vacuum Reading At Oil CO2 Stack Outlet Test Point Draft Pump Inlet_______________ H G Low Fire___________________ _______ Low Fire__________________ W C High Fire_________________________ High Fire__________________ W C Oil Nozzle Supply Pressure Bachrach Scale Smoke Number Net Stack Temperature Low Fire__________________PSI Low Fire_______________...

Page 22: ...r normal operating conditions This setup allows the operating control to function properly and reduces the need to reset the control circuit constantly Set the safety limit value less than the error margin of the safety relief valve so the Pressure Control can safely control boiler pressure Make set point value adjust ments by turning the adjusting screws found on top of the Pressure Control casin...

Page 23: ...ntrol to resume operation For additional information on the appropriate Low Water Cut Off see the LWCO cut sheets fol lowing this booklet Safety Valve Safety valves shall be piped so that any discharge cannot cause injury to people or damage to property The discharge piping must be supported so that the weight of the piping is not trans mitted to the safety valve body The weight supported by the v...

Page 24: ...the operating Aquastat consists of an adjustable thermostatic control and separate temperature sensing immersion well This controller has a manual reset switch which must be depressed in the event that the operating circuit reached and shut off on safety For additional information on either controllers see the Publication following this booklet Low Water Cut off Hot water boilers utilize the McDon...

Page 25: ...aintained in the boiler room at all times Daily Boiler Check Maintenance List 1 Water Level Controls and Cut Offs are operating normally 2 Instrument and equipment settings are normal 3 Gauge glass is clean If leaks are detected replace glass gaskets and brass washers immediately When replacing gauge glass use only 5 8 O D Pyrex red line high pressure high temperature glass tubing with fire polish...

Page 26: ...ntroller 3 Test safety valves 4 Remove the Low Water Cut Off and clean inside casting 5 Oil fired clean replace oil filters or strainers if equipped 6 Oil fired replace ignition electrodes if equipped 7 Gas pilots conduct pilot turndown test 8 Gas fired replace ignition and flame rods 9 Gas fired check drip leg strainer 10 Oil fired check for refractory hold in 11 Check Automatic Change Over Contr...

Page 27: ...inoperative 11 Without pressure on boiler and with gauge valves closed snug up the bottom nut and then the top nut with a wrench after 1 day of operation Blowdown Perform blowdown procedures on boilers that require make up water such as steam boilers Hot water boiler are closed loop systems that recirculate the same water These boilers should require minimal make up water Blowing down the boiler i...

Page 28: ...nstructions for feedwater treatment prepared by a competent feedwater chemist Do not experiment with homemade treatment methods or compounds Representative samples of feedwater and boiler water must be analyzed frequently to ensure that they are in specification The following terms and guidelines are to be used in conjunction with the advice of a water treatment specialist Use proper water treatme...

Page 29: ...hould it exceed 0 007 mg l Sulfites Sodium sulfite is generally used for the chemical removal of dissolved oxygen within the boiler water To assure the rapid and complete removal of the oxygen entering the boiler feedwater system the concentration of sulfite in the boiler must be maintained at a minimum of 20 PPM parts per million Solids Solids can be broken up into two categories suspended solids...

Page 30: ...on of phosphates in the water to 30 50 PPM in order for complete reaction of the phosphates with the calcium hardness entering the boiler through the feedwater Hardness The hardness of water is caused by calcium and magnesium ions which will vary greatly throughout the country depending on the source of the water In boilers the hardness of the water can cause the formation of scale and sludge or m...

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