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Form 2143
Date: 4/3/03
Repl: 2/1/99
BRYAN STEAM LLC
Installation and Operating Service Manual
BOILER FEED
SYSTEM
0
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INSTALLATION AND OPERATION SERVICE MANUAL BOILER FEED SYSTEM Bryan Steam LLC 783 North Chili Avenue * Peru, IN 46970 Phone 765.473.6651 • Fax 765.473.3074 E-mail: bryanboilers@iquest.net Internet: www.bryanboilers.com
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MODEL IDENTIFICATION & DESIGNATION Boiler Feed System A – H - FS – 15 – 12 – 50 – D A = LINING BLANK – NO LINING A – APEXIOR LINING B – GALVANIZED LINING H = TANK POSITION H – HORIZONTAL TANK POSITION V – VERTICAL TANK POSITION C - COMPACT FS = FEED SYSTEM (TS – TRANSFER SYSTEM) “15” = BOILER RELIEF VALVE SETTING “12” = MAX. BOILER HP “50” = TANK SIZE (GALLONS) “D” = NO. OF PUMPS S – SIMPLEX PUMPS D – DUPLEX (2) PUMPS T – TRIPLEX (3) PUMPS Q – QUADRAPLEX (4)
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T able of Contents SECTION 1 – INSTALLATION INSTRUCTIONS 1.1 FOUNDATION......................................................................................................... 1 1.2 CLEARANCE........................................................................................................... 1 1.3 UNCRATING THE FEED SYSTEM ........................................................................... 2 1.4 BOILER FEED SYSTEM CONNECTIONS...............................................
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 Section 1 Installation Instructions – Boiler Feed System Note: Please read the entire instruction manual before attempting installation. Insurance and local or state regulatory codes may contain additional or more stringent requirements than those contained in this manual. Installation must conform to these codes and any other authority having jurisdiction. Appropriate sections of the National Electric Code and ASME Code should be co
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 feed system near its permanent location. Before installation, take inventory of items that were shipped loose so they will not be misplaced. 1.4 BOILER FEED SYSTEM CONNECTIONS 1.4.1 GENERAL Maintain clearances as shown on the dimensional drawing for servicing and as referenced in N.E.C. All piping should be designed and installed to avoid any loadings on the feed system connections or piping. Install pump discharge piping so that accessibil
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 1.4.5 OVERFLOW CONNECTION The overflow connection should be piped to an approved drain for gravity flow of any water that may reach that level in the tank. The purpose of the overflow connection is to keep the tank from being flooded in case a high level condition occurs in the unit. If a feed system is used in proper operation, the overflow should not need a trap or any valve for proper discharge of the water into an atmospheric drain. 1.4
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 1.5.2 MAKE UP FILL VALVE A self-contained mechanical float type make up water control is proved to accept incoming water up to a differential pressure of 70 psi (see manufacturer’s date for exact pressures). The make up valve assembly mounts directly into the tank to eliminate unnecessary external piping and can be removed from the outside of the vessel for easy maintenance and inspection. The valve is made of brass or bronze with a copper f
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 1.6 PROCEDURE TO BE FOLLOWED BEFORE PLACING BOILER FEED SYSTEM IN OPERATION 1.6.1 CLEANING THE FEED SYSTEM After installation is complete, the feed system should be checked for debris. Any debris found in the tank, pump, or strainers should be removed before start-up. Mechanical floats should be checked to make sure no debris is keeping the float from operating correctly. If a steam pre- heater assembly as supplied, the pressure/temperature
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 Section 2 START-UP AND OPERATION – BOILER FEED SYSTEM 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 FEED SYSTEM ITEMS OR ACCESSORIES, OR BEFORE CLEANING OR REPLACING PARTS OF ANY KIND TAKE THE FOLLOWING P
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 2.1.2 ATMOSPHERIC TANK DESIGN This tank was designed to be used only in atmospheric conditions. To avoid potential hazards, this tank should never be pressurized. Safety precautions should be taken to make sure the tank is never pressurized. 2.1.3 LOW WATER CONDITION (A low water cutout is not supplied as standard on the boiler feed system, although it may have been supplied as an optional item.) Under normal operating conditions, the ta
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 2.2 OPERATING INSTRUCTIONS CAUTION: Check all electrical terminals and piping connections for tightness before start-up. 2.2.1 FAMILIARIZATION WITH MANUAL(S) The user of the feed system and boiler system must familiarize himself with this manual to be sure he is prepared to operate and maintain the system properly. The operating instructions should be kept in a safe place and available to all who may be working or operating the feed system.
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 Section 3 CARE AND MAINTENANCE BOILER FEED SYSTEMS 3.1 REQUIRED PRECAUTIONS DURING TEMPORARY USE 3.1.1 GENERAL A boiler system is often utilized in new construction to assist in curing of building components or to provide temporary heat or for other purposes. If precautions are not taken during this time to protect the boiler system, a great deal of damage can occur before the ultima
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 6. Considerations of warranty should the boiler system 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 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 he
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 FILTRATION 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
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 3.6 SUGGESTED MAINTENANCE SCHEDULE DAILY Make visual inspection of gauges, monitors, and indicators and record readings in boiler system log. Make visual check of instrument and equipment settings against factory recommended specifications. Check operation of float controls to ensure proper functioning. The lower piping connections of float type level controls (if external float supplied) should have a suitable blowdown valve piped into
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BOI L ER FEED SYSTEM DATE: 4/3/03 REP:2/1/99 Idle boilers are vulnerable to attack when air contacts untreated wet metal surfaces. To prevent corrosion, the metal must be protected by either keeping the surfaces completely dry or by excluding air from the system. PRE-OPERATIONAL CLEANING AND LAY-UP Proper lay-up techniques must be used on an idle system even if it has never been in operation. Before pre-operational lay-up, the boiler system must be chemically cleaned as outlined in Se
