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Form 2055 

12 

Revision Date 5/1/2015 

 
 

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. 

3 . 3 . 1   S Y S T E M   C L E A N I N G   P R O C E D U R E  

For steam systems, the boiler will need to be connected to the header utilizing steam to purge the 
piping and thus push the debris out of the system. However, at this time all condensate must be 
wasted until it runs clear and water analysis of the condensate indicates that it is free of 
contaminants. Steam trap strainers must be periodically opened and cleaned of any debris which 
accumulates.  During this system clean out, the boiler make-up water must be properly softened 
and treated. At the conclusion of the system clean out, the condensate must be reconnected. 

For old or existing steam systems, the installation process may have jarred debris loose. 
Following the boil out of the new boiler, the condensate should be wasted until it is within proper 
guidelines. Check all steam trap strainers to assure their cleanliness. Refer to the succeeding 
section on replacement boiler installations. 

3.4 REPLACEMENT BOILER INSTALLATIONS: PROTECTION 
AGAINST CORROSION & SEDIMENT

 

3 . 4 . 1   C L E A N   O R   R E P L A C E   A L L   S Y S T E M   P I P I N G  
A N D   H E A T I N G   U N I T S  

Arrange for chemical or mechanical cleaning of the entire system. A chemical treatment company 
should be consulted for the proper means of any chemical cleaning. 

  Replace any piping considered to be deteriorated beyond safe or cleanable condition. 

  Flush the system clean, being certain to isolate the boiler. 

  Inspect, repair as necessary, or replace system air control devices. 

 

  Install gauge glasses on air expansion tanks and install a tank fitting in the system connection 

to the tank. 

 

  Install a strainer in boiler return piping. 

 

DO NOT FLUSH THE SYSTEM THROUGH THE BOILER. 

 

 

 

Содержание BE Series

Страница 1: ...orm 2055 Revision Date 5 1 2015 Installation and Operating Service Manual ELECTRIC STEAM BOILERS Bryan Steam LLC 783 N Chili Avenue Peru IN 46970 Phone 765 473 6651 Fax 765 473 3074 www bryanboilers com ...

Страница 2: ... Control Circuit Wiring 1 6 5 Safety Relief Valves 1 6 6 Low Water Cut Off 1 7 Procedures to be Followed Before Placing Boiler in Operation 5 1 7 1 Hydrostatic Test of Boilers and System S E C T I O N 2 S T A R T U P A N D O P E R A T I O N 2 1 Limit Circuit Cut Out Test 6 7 2 1 1 Protective Devises 2 1 2 Steam Pressure Operating Control 2 1 3 High Limit Control 2 1 4 Low Water Cut Off s 2 1 5 Com...

Страница 3: ...14 3 5 1 Purpose Of Water Treatment 3 5 2 Objectives 3 5 3 Water Softener 3 5 4 Continuous Monitoring Required 3 6 Suggested Maintenance Schedule 12 13 3 6 1 Daily 3 6 2 Weekly 3 6 3 Monthly 3 6 4 Annually 3 7 Float Actuated Water Level Controls 15 3 8 Water Gauge Glasses 15 16 3 8 1 Installation 3 8 2 Maintenance 3 8 3 Inspection 3 8 4 Replacement of Glass 3 9 Idle Boiler Care and Lay Up 16 20 3 ...

Страница 4: ...s The element end of the boiler should not have any obstruction to allow for the same length as the boiler supplied for removal and servicing of elements The back of the boiler as long as panels are not supplied in the rear can be mounted next to an obstruction Local codes must be applied to specific installations and the minimum clearances established accordingly Provisions must also be made for ...

Страница 5: ...capacity to better control the boiler feed rate 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 by a feed pump control which is mounted on the boiler T...

Страница 6: ... CONNECTION IMPORTANT All electrical connections must conform to the NEC and to all other applicable State and Local Codes The heating elements supplied with Bryan electric boilers are of the resistance type with an incoloy sheath and a watt density not exceeding 75 watts square inch These elements are typically delta wired unless otherwise specified Power supply voltage must be as shown on the wi...

Страница 7: ...ts supplied with this boiler A description of the major components follows however detailed information can be found in each manufacturer s literature data 1 6 3 P O W E R P A N E L W I R I N G These circuits are broken down into branch circuits of no more than 50 amps per circuit A distribution lug in the BE Series and a copper bus bar in the BH Series is used to branch the power to individual fu...

Страница 8: ...t pressure of the relief valve 1 6 6 L O W W A T E R C U T O F F The function of the low water cut off is to shut down the boiler if for any reason the water level should drop below the normal operating range 1 7 PROCEDURES TO BE FOLLOWED BEFORE PLACING BOILER IN OPERATION 1 7 1 H Y D R O S T A T I C T E S T O F B O I L E R S A N D S Y S T E M After completing the boiler installation the boiler co...

Страница 9: ... PARTS OF ANY KIND TAKE THE FOLLOWING PRECAUTIONS 1 TURN OFF AND LOCKOUT ALL ELECTRICAL DISCONNECTS TO THE BOILER AND ANY OTHER EQUIPMENT OR SYSTEMS ELECTRICALLY INTERLOCKED WITH THE BOILER 2 ALL COVER PLATES ENCLOSURES AND GUARDS MUST BE IN PLACE AT ALL TIMES EXCEPT DURING MAINTENANCE AND SERVICING 2 1 LIMIT CIRCUIT CUT OUT TEST 2 1 1 P R O T E C T I V E D E V I C E S All operating and limit cont...

Страница 10: ... off controls must be operationally tested by manually lowering the boiler water level by opening the drain valve The boiler should cycle off when the water level drops below the control point of the low water cut off When the water level is restored the boiler should cycle back on Depress the manual reset button of devices which require manual reset in order to restore the boiler to operation Car...

Страница 11: ...ll begin to cycle off therefore turning off elements and reducing the heat output Each step control is supplied with a dead band area When the desired pressure is reached the step control will stay constant until a larger degree of drop is recognized This will keep the step controller from oscillating between steps during operation The operating control pressure needs to be set and maintained by t...

Страница 12: ... 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 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...

Страница 13: ... especially critical Consult your local water treatment chemist for further information CAUTION The boil out procedure outlined must be performed by or under the direct supervision of a qualified technician The chemicals used present a hazard of burns and physical injury if mishandled Always use suitable facemask goggles protective gloves and garments when handling caustic chemicals Do not permit ...

Страница 14: ...E STEAM PRESSURE Boil the water supervised at all times for at least five hours After the five hour boil out begin to add a small amount of fresh softened water so as to create a slight overflow of the overflow pipe This will carry out impurities which have accumulated at the water surface Continue to apply heat and overflow until the water emitted from the overflow pipe clears Then shut off the b...

Страница 15: ...ust be reconnected For old or existing steam systems the installation process may have jarred debris loose Following the boil out of the new boiler the condensate should be wasted until it is within proper guidelines Check all steam trap strainers to assure their cleanliness Refer to the succeeding section on replacement boiler installations 3 4 REPLACEMENT BOILER INSTALLATIONS PROTECTION AGAINST ...

Страница 16: ... WATER TREATMENT 3 5 1 P U R P O S E O F W A T E R T R E A T M E N T Water treatment is required for satisfactory operation of the boiler It must be devised to prevent depositing of scale and corrosion from acids oxygen and other such harmful elements that may be in the water supply A qualified water treatment chemist should be consulted and the water systematically treated 3 5 2 O B J E C T I V E...

Страница 17: ...quipment settings against factory recommended specifications Check operation of float type low water cutoffs to ensure control is functioning The lower piping connections of float type level controls should have a suitable blowdown valve piped into a proper drain This valve should be opened periodically to allow any sludge accumulated in the control to be flushed out Consult manufacturer s instruc...

Страница 18: ...eans of opening a blowdown valve on the lower connection of the cutoff once per day 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 At the annual inspection all float type level controls should be disassembled cleaned and inspected thoroughly When re0installed these cont...

Страница 19: ...may contain hidden damage and represent a safety hazard Be sure that the replacement glass is suitable for service conditions Protective shields to keep cold air water or falling objects from glass must be replaced 3 9 IDLE BOILER CARE AND LAY UP 3 9 1 G E N E R A L Corrosion damage to boilers is often the result of improper lay up during non operating periods Substantial damage can occur in only ...

Страница 20: ...od the lover conductivity limit should be below 3 500 micro ohms per centimeters The feed of internal treatment must be increased to maintain a specific residual concentration Continuous blowdown when used should be kept to a minimum so the reduction of solids is achieved by the increased manual blowdown 3 9 5 W A S H D O W N As the boiler cannot be washed immediately the heat in the boiler may ca...

Страница 21: ...3 2 of this manual Add the concentrated lay up solution to the boiler during the time it is being filled After the boiler is filled and the lay up solution has been added the boiler is to be operated for thirty minutes at low fire to circulate and mix the chemicals After filling the boiler must be closed or blanketed tightly The power supply to the boiler must be cut off Vent all air from the top ...

Страница 22: ... recommended requires that the boiler be drained dried as completely as is possible all openings 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 ...

Страница 23: ...nded solids on boiler metal surfaces Refer to previous instructions for boiler washdown 3 9 1 0 R E T U R N I N G I D L E B O I L E R T O S E R V I C E After wet lay up To start an idle boiler after wet lay up use the following procedure If the boiler was pressurized with nitrogen disconnect the nitrogen supply source and vent the boiler Using the blowdown valve drain the boiler partially and make...

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