Section7 1

TECH TIP #1
Which Boiler is Right For Me?
282 www.federalcorp.com
TECH TIP #1 (Cont.)
OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 283

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #1 (Cont.)
TECH TIP #1 (Cont.)
For more information concerning boilers and boiler

applications, please contact a sales representative at
Federal.
7

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #2
BOILER TYPE AFFECTS SCALING & EFFICIENCY
TECH TIP #2 (Cont.)
BOILER TYPE AFFECTS SCALING & EFFICIENCY

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
288
7
TECH TIP #3
HIGH PRESSURE STEAM BOILER ROOM SCHEMATIC
Q: How can I optimize my steam boiler plant?
Waste Heat Recovery

Economizer
Electrical Power Optimization

Feedwater Pump VFD Combustion Optimization
Metered Fuel/Air Ratio
Oxygen Trim
Electrical Power Optimization
Waste Heat Recovery Combustion Air Fan VFD
www.federalcorp.com
Copywrite David
Farthing 1998

TECH TIP #3
STEAM PLANT OPTIMIZATION--$$ SAVINGS
(800) 289-3331
OKLAHOMA CITY
Steam Plant Optimization

WHAT ARE THE OPPORTUNITIES?
FAX: (405) 232-5438

(405) 239-7301
Waste Heat Recovery (Thermal)
] Economizers = 2-6%
] Blow-Down Heat Recovery = 1-2%
] Flash Steam Recovery = 1-5%
TULSA
c h Tips
. Te 10
(800) 955-1918
See rough e-
] Metered Fuel/Air Ratio Control = 2-7% 4 th ore d t

m n
] Oxygen Trim Control = 1-3% for on Pla
s tion
tail iza
Electrical Power Optimization im
Opt
(918) 249-1918
] Combustion Fan VFD Control = 5-50%!!
FAX: (918) 249-9014

] Feedwater Pump VFD Control = 5-50%!!
Copywrite David
OKC 800-289-3331
Farthing 1998 Tulsa 800-955-1918
289
TECH TIP #4
BOILER WATER TREATMENT
Here are the three most important rules of taking care of boilers, chillers, and heat exchangers in fact, any equipment:
1. Water treatment
2. Consistent water treatment
3. Monitored consistent water treatment
Get the picture? Nothing is more important to the efficiency, longevity and maintainability of your hydronic system than water
treatment. Show us a system that is not treated and we know you will be spending a lot more on your energy bills and replacing
the equipment long before its useful life should be over.
Did you realize that scale on a boiler tube the thickness of an eggshell will cost the owner about 10% more in fuel? But the
thicker the scale becomes the quicker you lose efficiency, the loss is not linear. At a mere .20 of an inch your energy efficiency
drops off 50%. In other words, scale about a thick will force your boiler to burn 50% more fuel to provide the same heating
capacity as when it was brand new and clean. QUICKcall the water treatment experts!!!!!! It will cost you big bucks if you
dont treat your system.
In addition to the heat transfer surfaces, untreated systems will experience premature failures with pump seals, valve packing and
7 piping corrosion. We can not stress it strongly enough, water treatment is an investment not an expense.
ADVANCED TECHTIPSPlease contact us for further information on how to protect your investment and reduce your
energy bills.
TECH TIP #5
IS A DEAERATOR REALLY
NECESSARY?
The following is an excerpt from an article
that first appeared in an Industrial News-
letter sometime ago. The full title for the
article was Is a Deaerator Really Necessary
or- How to Return Your Piping System to
the Boiler.
From time to time we hear the question,

Why do we need a deaerator, weve been
operating for twenty years without one? Or,
How can you justify the extra expense of a
deaerator over a standard inexpensive boiler
feed system?
It is difficult to argue with this type of rea-

soning because a deaerator is a long-term
investment with variable pay off. But pay
off there is!
Now we are going to tell you something that

may shock you. Under the proper conditions,
it is theoretically possible for one pound of
oxygen to combine with four pounds of iron
(iron oxideRust!) This is not to say it is a promised fact but merely a probability. Along with Carbon Dioxide in the steam,
the chances become four (4) times greater of achieving this theoretical balance. This means it is possible for the oxygen
in 16 GPM of water to remove, oxidize and/or dissolve nearly 50 pounds of iron per week. Where does the iron pipe go?
It comes back to the return line, to the feed system, pumped into the boiler and then blown down to the sewer. There
goes your piping system, boiler, expensive heat exchangers and other system componentsDown the sewer!
If you, or the contractor, or the customer, or the engineer, think you can short cut an over-budgeted job by ignoring the
laws of nature, you are fooling yourselvesbut dont try to fool Mother NatureShe will get you eventually!
What you end up doing is making your boiler and piping system a deaerator because the oxygen and carbon dioxide are
going to react someplacethe laws of nature demand it.
YOU ARE NOT DOING ANYONE A FAVOR WHEN YOU LEAVE OUT THE DEAERATORSPECIFY A QUALITY DEAERATION
SYSTEM AND SLEEP AT NIGHT. 7
ADVANCED TECHTIPSWe have several articles that go into deaerator selection, sizing and operation in great detail.
Contact our office for further information.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #6
ENERGY SAVINGS WITH STACK ECONOMIZERS
Courtesy Heatmizer, inc.-- www.heatmizer.com
HEATING PROCESS OR DOMESTIC HOT WATER
The most effective use of recovered heat from natural gas combustion is in heating hot water for
process or domestic use. The reason is that the lower the entering water temperature becomes, the
higher will be the temperature difference from the entering flue gas temperature, and the greater will
be the heat extracted. Water temperatures below about 120F will usually cause condensation of the
water vapor formed by the combustion of hydrogen in the natural gas. The HEATMIZER is designed
with corrosion resistant materials and a condensate separation and drainage system to remove con-
densate. Collected condensate has given up its latent heat to the water circulated through the HEAT-
MIZER, increasing the recovered heat.
Hospitals usually have standby #2 oil to fire in emergencies. We recommend bypassing the products
of combustion around the surfaces of the heat exchanger in such cases of limited oil firing due to pos-
sible corrosion from the sulphur content of the oil. We offer a built-in bypass as a standard equipment
option.
The hot water circulation rate is usually sized at 7 GPM per 100 Boiler HP and should be installed to
pull water off the bottom of the tank and also from the cold water supply (CWS) for the coolest enter-
ing water to produce maximum HEATMIZER savings.
An aquastat is located near the top of the storage tank to limit the tank temperature. If the heat recov-
ered exceeds the heat required by the tank, the HEATMIZER is switched to bypass the fluegas until the
tank is cooled.
Note the flue gas recirculation (FGR) duct in the illustration. This duct connects from a flange on the
cold side of the HEATMIZER to the burner inlet air louver chamber on a low NOx burner. As low NOx is
obtained by lowering combustion flame temperatures, the cooler FGR will reduce the NOx by several
PPM.
HEATING BOILER FEEDWATER
7 The most common use of recovered heat from flue gas is in heating boiler feedwater. This is mainly
because the heat sink is the boiler and the flue gas flow from the boiler is proportional to the steam
generated and in turn to the feedwater flow.
The temperature of the tank will vary depending on the amounts of cold water makeup to the boiler
and the condensate return temperature from the system. For example, with 20% cold water makeup
and 180F condensate return, one would expect an average tank temperature of 156F (without any
additional steam or waste heat added). The colder the tank temperature, the greater the heat recov-
ery, as this creates a greater difference between the water to the HEATMIZER and the entering flue
gas temperature, enabling a further lowering of the exit gas temperature with consequently greater
savings.
The HEATMIZER requires a continuous water flow through the unit whenever the burner is operat-
ing to prevent boiling in the heat exchanger as well as to efficiently utilize the additional investment.
This involves operating the feedwater pump whenever the burner operates. This also requires proper
sizing of the feedwater pump to avoid inefficient operation at low loads. For example, with on-off FW
pump operation, it is normal to size the pump at 2 times the boiler evaporation rate so it can catch
up quickly on a call for water. On a continuous flow HEATMIZER installation, this practice would result
in an oversized pump, particularly at low firing rates. Most FW pumps must have a minimum flow of
approximately 10% (of max flow) for proper cooling. Good practice is to use a back pressure regulating
valve to bypass water back to the tank when the boiler feed water valve is closed, thus assuring the
required minimum cooling flow at pump and HEATMIZER.
A fluegas bypass option is normally provided as standard with the HEATMIZER. A high limit aquastat,
mounted at the tank that receives flow from the backpressure regulator, will automatically switch the
HEATMIZER to bypass fluegas until the tank temperature drops to normal.
Fluegas condensation will occur when HEATMIZER entering water temperatures are 120F or lower.
Condensate lines should be terminated slightly above the drain so that flow may be easily observed. The
condensate from the combustion of hydrogen in natural gas is slightly acidic (Ph about 4 or 5). This will
not damage the drain. Boiler room drains also usually receive boiler blow down water, which is alkaline
and which tends to neutralize the condensate.
Good operation of the HEATMIZER is based on the premise of continuous operation and steady state
conditions. To obtain these conditions, it is necessary to have modulating control of firing rates and water
levels on both the boiler and the DA. This type of control is common for larger boilers, especially the wa-
tertube types which, having low water volumes, require continuous feedwater flows. Modulating controls
are not as common on fire tube boilers, even larger ones. Higher turndown burners help reduce the low fire 7
rate, which aids in keeping the burners on and helps reduce the on-off cycle with its accompanying
high loss of efficiency during burner pre- and post-purge.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #7
CONTINUOUS TOP BLOWDOWN HEAT RECOVERY
Courtesy Madden Mfg.-- www.maddenmfg.com
How Does it Work?
Hot, High pressure continuous blowdown water drained from the

boiler, contains valuable heat energy. The continuous blowdown
process helps control boiler water quality and operating efficiency
by removing suspended and dissolved solids from the water in the
boiler drum.
Recovery of up to 50% of the BTUs available may be accomplished

by generating low pressure flash stream in a flash tank. This supply
of stream can be used in boiler D/A tank or other low pressure
steam applications. As the flash steam is generated, the blowdown
condensate that remains is used to preheat the boiler feed water
using a low pressure liquid heat exchanger. For smaller, lower pres-
sure blowdown requirements, the HX Series heat recovery system
utilize a higher pressure liquid to liquid heat exchanger without a
flash tank to do the heat recovery job. Contact a Federal sales rep-
resentative will recommend the model you need to maximize your
fuel savings potential.
kRecover 90% of the heat energy in continuous top blowdown that would be lost
down the drain.
7 kReduce temperature of blowdown discharge to drain to meet statute limits.

kFast investment payback from fuel, cooling water and makeup water savings, Mad-
den systems usually pay for themselves in less than 12 months.
kDurable, time proven designs, built to take the punishment of continuous, 24 hour
a day service for years.
TECH TIP #8
VFD APPLICATIONS IN THE BOILER ROOM
Just as our industry is discovering electrical power savings through the application of variable frequency drives
controlling motors on air handlers, circulating pumps, cooling tower fans and many others pieces of equipment, the
boiler room is no exception. Two motors to better control are the fan motor on the burner and the boiler feed pump
(on a steam boiler). Although small motors can be controlled by drives, the larger the motor, the more potential for
savings. Steam boilers larger than 200 Boiler HP can be considered candidates. Special boiler control systems
are necessary to generate signals which can be used by VFDs. (See Tech Tip #9) This is most easily added if a new
boiler is being ordered or an existing boiler is being re-controlled.
Electrical savings from 5-50% can be expected! Savings depend on the application, but the more the boiler runs
at part-load, the more the savings. If the combustion air and feed water can be controlled with a VFD rather than
primarily a fan damper or water valve, there are savings.
Following are two examples of calculations of savings on larger boilers. TechStuff software (on the Federal website)
is used in these examples. Example 1 shows the calculations on a 30 HP blower motor on a burner. Example 2
shows savings on a continuously run boiler feed pump. Let a sales professional at Federal help you survey your
boiler room for possible savings.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #9
METERED FUEL/AIR RATIO CONTROL PLUS O2 TRIM
by David Farthing
from Federal Corp. Technical Library--www.federalcorp.com
Today's economic and environmental de- Fixed Position Parallel Controls. The sim- rate placement of fuel and air positioners
mands dictate that we get the greatest plest form of combustion control for power for specific firing rates. These signals make
practical efficiencies from our plant. To do burners is the fixed position parallel control PPC system much improved over FPC sys-
this, we must have a basic understanding (FPC) (Figure 1) also known a direct or jack- tems.
of what those efficiencies are and how to shaft control. This strategy incorporates a
implement them. single positioning motor, which drives both The new systems are gaining acceptance
the fuel and air positioning devices via an over FPC systems because they offer an
NEW TECHNOLOGY IMPROVES OVERALL interconnected single mechanical link, the economical means to improve overall
COMBUSTION EFFICIENCY AND BURNER jack-shaft. combustion efficiency. PPC systems are
STABILITY WHEN LOADS AND DEMANDS suitable for 100 to 900 boiler horsepower
ARE VARIABLE. The simplicity of the FPC control strategy (Bhp) boilers that operate with relatively
makes it a very economical choice for small stable loads. Larger systems are also be-
Advanced automatic systems for combus- burners with modest firing rate changes. coming more prevalent.
tion control are excellent methods for im- However, because fuel and air are fixed,
proving systems and process automation the fuel/air ratio is also fixed. The burner PPC systems can hold excess oxygen levels
success. New technology available today cannot compensate for environmental to within 3% to 4% in many applications,
helps improve overall combustion effi- changes such as combustion air tempera- but because they lack true process vari-
ciency and burner stability when load and ture or fuel pressure. Additionally, the FPC able feedback in the fuel/air systems, they
demands are variable. The most sophisti- strategy lacks feedback to the control ele- should be used cautiously in applications
cated systems can eliminate the need for ment, which can cause fuel to cross over with extremely fast load swings. Like FPC
operator input during load changes while the airflow and cause a fuel-rich furnace or systems, PPC systems cannot compensate
maintaining safe and reliable fuel/air ra- other burner efficiency losses. for changes in fuel or combustion air char-
tios. acteristics.
To help prevent a fuel-rich furnace, FPC sys-
This discussion describes several systems, tems are set to allow 4% to 8% excess oxy- Series Metered Control Systems. Boilers
from the simplest to the most elegant, and gen to the furnace. In practice, the excess larger than 750 Bhp commonly incorpo-
focuses on the features, benefits and appli- oxygen is normally set at 6% to 7%, allow- rate series metered control (SMC) systems,
cations of several system applied to single- ing for seasonal air temperature changes. where load changes are neither large nor
burner packaged boiler. frequent. In this application, both fuel and
Parallel Positioning Control Systems. air are metered. The boiler master control-
A Look at Combustion Strategies These systems function similarly to FPC ler regulates combustion airflow with a set
systems, except that fuel and air end-devic- point. The airflow controller cascades the
Here are some control strategies to con- es are separated and driven by individual airflow signal to the fuel controller as its
sider for improving burner efficiency. The positioners. Modern electronic parallel po- remote set point. A ratio algorithm signal
right strategy depends on boiler loads, sitioning control (PPC) incorporates end- sent to the fuel controller adjusts the fuel/
demands-and economics. device positioning signals to ensure accu- air ratio.
Metered Parallel Positioning Control Sys-

tems. Boilers operating at 1,000 Bhp or
higher may incorporate metered parallel
positioning control (MPPC) systems. These
operate the fuel and air control loops in
parallel from a single setpoint generated by
the boiler master controller. A combustion
air set point ratio establishes the fuel/air
proportions.
This fuel/air customization feature means

excess oxygen in the exhaust gases may be
reduced to 3% to 4%. To maintain an air-
rich furnace on transition, MPPC systems
are normally set with additional excess air
to compensate for fuel flow during setpoint
excursions. In practice, the excess air is set
at 4.5% to 5% to compensate for barometric
changes in air density. During steady-state
operation, this can be adjusted to 2.5% to
3% using an oxygen trim system.
7 Cross-limited Parallel Metered Control

Systems. This strategy improves on MPPC
Figure 1. Fixed position parallel jackshaft combustion system with fuel/air ratio estab-
lished through fixed mechanical linkages.
TECH TIP #9 (Cont.)
METERED FUEL/AIR RATIO CONTROL PLUS O2 TRIM
by interlocking fuel/air ratio control to pre-

vent a fuel-rich furnace. The cross-limited
control (CLC), or lead-lag control (Figure 2),
is dynamic and easily adjusts to different
response times of the fuel and air end de-
vices. This flexibility allows its use in sys-
tems with sudden and large load swings
and provides precise combustion control at
steady-state operation.
CLC systems easily maintain excess oxygen

levels at 3% to 4% in gas burners and 2.5%
to 3% in #2 oil systems. Additionally, the
cross-limiting feature prevents fuel from
overshooting airflow.
Because of its capability for close tolerance

control, CLC systems are suited for all sizes
of boilers that can support the systems
installation cost. Additionally, the CLC sys-
tem can be readily adapted to oxygen trim
control and is suitable for most low-NOx
burner applications.
Selecting a Strategy
The economic balance between fuel cost,

safely, boiler load, and control system cost
will eventually determine which of these
systems best suits your process.
Figure 2. Cross limiting, or lead-lag fuel/air ratio control, is the most dynamic of all
combustion control strategies.
Calculated savings on a sample 600 HP steam boiler comparing manual Jack-Shaft Control 7
to Cross Limited Control with O2 trim.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #10
BOILER FEED PUMP SIZING AND SELECTION
Courtesy Industrial Steam--www.industrialsteam.com
TECH TIP #10 (Cont.)

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #11
STEAM BOILER RATINGS & FEED PUMP CAPACITY REQUIRED (ON-OFF OPERATION)
ON-OFF pump operation is used on smaller boilers. Modulating feed water should normally be considered on
boilers larger than 100 boiler HP. (See Tech Tip 10)
TECH TIP #12
BOILER CODE EXPLANATIONS
Many different codes are adhered to in Oklahoma; heres a listing of the main approval bodies that we run across.
Oklahoma State Boiler Code: Obviously the number one agency for approving a new boiler installation in the state of Oklahoma. We find that
the inspectors are a very knowledgeable and conscientious bunch. Anytime there is an interpretation to be made they should be consulted. The
Oklahoma City office telephone number for the Chief Boiler Inspector is (405) 528-1500, extension 242, or the statewide number is 1-888-269-
5353, extension 242.
Controls and Safety Devices (CSD-1): CSD-1 code is a term that you will hear in Oklahoma quite a bit. The Ok State Boiler Code adopted this
back in July 1994. CSD-1 is an amendment to the ASME code that gives a level of safety that adopts most of the UL code and some of the IRI
and FM requirements. CSD-1 is a state requirement on any combustion equipment above 400,000 btuh input.
GE Capitol (formerly Industrial Risk Insurance-IRI): GE Capitol has long been recognized as a level of safety above the standards that UL rec-
ognize. On any piece of gas fired equipment above 2,500,000 btuh input it is prudent to strongly consider requiring the GE Capitol approval.
Factory Mutual Insurance (FM): FM is another insurance industry standard that will require additional safety controls. Again, on the larger boil-
ers, if you are serious about safety insist on one of the agency approvals such as FM.
Underwriters Laboratories (UL): UL has been one of the most basic approval bodies in North America for many years. Insist that your equip-
ment carry the UL label.
American Society of Mechanical Engineers (ASME): ASME has set up a code that should be followed in the construction of the boiler. No
manufacturer would consider building a boiler without ASME approval.
National Board (NB): NB has the unenviable job of keeping track of all the pressure vessels built. The NB registers all manufactured boilers and
pressure vessels, trains inspectors and provides accident investigation services.
ADVANCED TECHTIPSThe above listing is by no means exhaustive or meant to cover all the nuances of each code. Please contact us
for a thorough explanation of the code requirements as needed. Tech Tip #13 is published by Gordon-Piatt and details many of the different
requirements of each of the typical gas controls used in conjunction with the above agencies.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #13
GAS TRAIN BASICS
GAS TRAIN COMPONENTS..To Vent or Not To Vent

Do I need to vent the gas pressure switches?
The gas regulator?
What about my V88 diaphragm gas valve?
What about the normally open vent valve?
Can I combine these vents so I dont have to run several lines?
A. According to UL 795, the normally open vent valve line must be run to a safe location
outside by itself, no other vent line can be combined with it. (See below for an alternative to
using normally open vent valves.)
B. According to UL 795, the vent off of a gas regulator must be run to a safe location outside by
itself, no other vent line can be combined with it.
C. In order to use a vent limiter on a gas regulator, the following guidelines are suggested:
1. Maximum inlet pressure to regulator 5#.
2. Maximum regulator size is 1.
3. Regulator must be mounted in upright, horizontal position.
4. Can only be used if boiler/appliance is within 6 of regulator.
5. Vent limiter must be manufactured by the regulator mfg.
D Vent outlets from gas pressure switches & diaphragm gas valves (V88) can be ganged
together into a single vent line, provided the cross-sectional area is a least the size of the
largest vent opening plus 50% of the area of all additional vent lines. See the following
photo for details.

NOTICE: Always terminate vents away from air intakes or sources of ignition. Be sure that moisture
and insects cannot enter the pipe(s) as well. Always utilize a drip leg to keep incidental moisture
from traveling back down vent tubing and damaging the diaphragm.
How to Avoid the Need for a NORMALLY OPEN VENT VALVE

Honeywell (and possibly others) now manufacture combustion flame safeguard control systems
7 called VPS (Valve Proving Systems) which prove the double block valves. We recommend this
system instead of the double block and bleed system which has traditionally been used. This new
system eliminated possible fuel leaks to the atmosphere, saves expense in installation and also
increases safety.
GAS TRAINS--WHAT DO THE CODES REQUIRE?

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
GAS SYSTEM SCHEMATICS
UL, FM & CSD-1 (which requires a plugged leak test cock downstream of
each safety gas valve) Systems
TECH TIP #14
What codes apply to relief valves? What do all those
funny letters mean?

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #15
BOTTOM BLOWDOWN VALVE OPERATION FOR STEAM BOILERS

Everlasting Valve Company, the premier boiler bottom blowdown valve manufacturer, recommends the following
operating procedure when performing a bottom blowdown on your boiler.
1. Before cutting boiler into line, blowdown to reduce the alkalinity. This prevents carryover. Test the water
and give blowdowns until the water is just right. Consult with your water treatment specialist to determine
frequency and duration of blowdowns.
2. Blow out sediment, mud or scale while boiler is steaming.

Important: make certain blowdown valves are closed on idle boilers or scalding water will blow into
them.
3. Blow down when boiler has a low load. Sediment settles more under these conditions. Watch gauge glass;
dont leave an open valve.
4. Be careful when blowing down boilers. First, open quick-opening valve slowly; then open slow-opening valve
slow enough to prevent shock, but fast enough so valve seat wont wire draw. To stop blowing down, close
slow-opening valve quickly; then close fast-opening valve.
5. Never jam a blowdown valve if it wont close. Open a few turns fast to clear, then close again slowly. Try
this several times to dislodge any scale or sediment. Jamming on scale will wire-draw or score the seats
and disc of valve.
6. For cleaning, inspection or repairs, empty cold boiler through blowdown line. Never empty until the boiler
is quite cool, or boiler seams and joints may warp and cause leakage.
ADVANCED TECHTIPS..The next page is reprinted by permission of Everlasting Valve Company. It details the
service and selection of blowdown valves as detailed by ASME/ANSI. For further information contact our office
or consult the latest ASME Boiler & Pressure Vessel Code, Section I.
Everlasting Valve Co. - Boiler Blow Down Page 1 of 1
Boiler Blow Down Back to Main Page
7
Back to Main Page
Selector Guide (pg 1) Selector Guide (pg 2) Selector Guide (pg 3) Selector Guide (pg 4)
(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #16
BOILER/BURNER SURVEY FORM FOR CSD-1

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #17
By state law, the contractor must submit this form to the State Boiler Inspection Office and re-
quest a boiler inspection for every boiler installation. This form is also available on-line by going
to the Oklahoma Department of Labor Safety Standards Division page on the State of Oklahoma
web site www.ok.gov/odol
Lloyd L. Fields Print Form Tom Monroe
COMMISSIONER Chief Boiler Inspector
MANUFACTURER'S/INSTALLING CONTRACTOR'S REPORT

FOR MEETING THE REQUIREMENTS FOR ASME CSD-1 (CG500)
UNIT MANUFACTURER
Name
Address City/State Zip
Telephone Fax
UNIT IDENTIFICATION (Boiler)

Manufacturer's Model # Year Built
ASME # Nat. Bd. #
UL # AGA #
OK #
STEAM HOT WATER

Max. W.P. psig Max. W.P. psig
Min. Safety Valve Cap. PPH Max. temp. deg. F
Min. Safety Relief Valve Cap.
PPH or Btu
BOILER UNIT DESCRIPTION (TYPE)

If Modular (No. of Modules)
BOILER UNIT CAPACITY (OUTPUT)
Burner - Manufacturer Model

UL or AGA # Serial
FUELS (as shipped)
INSTALLATION LOCATION (if known)

Customer Name
Address
City State Zip
Telephone Fax
Operational
Test
Performed,
Control/Device Manufacturer Model # Date
OPERATIONAL CONTROLS
Low-Water Fuel Cutoff
CW-120(a), CW-140
Forced Circulation
CW-210(a)
Steam Pressure
CW-310(b)
7
Water Temperature
CW-410(b)
4001 N. LINCOLN BLVD, OKLAHOMA CITY, OKLAHOMA 73105-5212 - PHONE (405)528-1500 FAX (405) 525-0252
Operational
Test
Performed,
Control/Device Manufacturer Model # Date
SAFETY CONTROLS
Low-Water Fuel Cutoff
CW-120(a), CW-120(b),
CW-130, CW-140
Forced Circulation
CW-210(b)
High-Steam Pressure Limit
CW-310(c)
High Water Temperature Limit
CW-400(c)
Fuel Safety Shutoff Valve, 1
CF-180
Fuel Safety Shutoff Valve, 2
CF-180
Pilot Safety Shutoff Valve, 1
CF-180(c)
Atomizing Medium Switch
CF-450(b)
Combustion Air Switch
CF-220
High Gas Pressure
CF-162
Low Gas Pressure
CF-162
Low Oil Pressure
CF-450(a)
High Oil Temperature
CF-450(c)
Low Oil Temperature
CF-450(d)
Purge Air Flow
CF-210
Flame Safeguard (primary)
CF-310. CF-320
Flame Detector
CF-310, CF-320
LOW FIRE START
Low Fire Start Switch
CF-610
SAFETY OR SAFETY RELIEF VALVE(S) OPERATION TEST PERFORMED, DATE

CW-510, CW-520
Manufacturer
Model
Size
Capacity PPH/Btu/hr
Representing Equipment Manufacturer, Name

Signature
Date
Representing Installing Contractor, Name
7
Signature
Date License #
Revised 11-9-07

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
TECH TIP #18
WATER LEVEL CONTROLS FOR STEAM BOILERS
Steam Boilers
Theyve been with us for over two hundred years, and most of
the time theyre so reliable most folks dont give them much
thought. They sit in buildings all over the world, transferring
heat from fuel to water, allowing us to warm our buildings or
complete our processes.
Steam boilers are simple, efficient and reliable. No machine

does a better job of moving BTUs from one place to another.
Weve used them for space heating since before the United
States Civil War in 1861.
Even before the Civil War, we used steam boilers for industrial
processes. Today we use them to run factories, press clothes,
wash dishes, pasteurize milk, sterilize medical equipment,
and to heat entire cities! Their capabilities seem endless.
But despite its simplicity, any steam boiler can run into trouble
if its control system doesnt act properly. If the energy you put
into the boiler exceeds what the boiler can absorb, the boiler
can rupture. So you must always be on guard.
A simple safety relief valve of the right capacity and reliefpres-

sure setting protects the boiler from over pressure. But over
pressure isnt the only thing that can threaten a steam boiler.
There are also the dangers of dry firing.
Should the internal water level drop too low, the boiler can
burn out. So here too, you must always be on guard. You
see, a steam boiler needs its water to move the heat away
from its metal surfaces. Without the right internal level of
water, heat quickly accumulates. Too much heat creates a
very dangerous operating condition.
Boiler manufacturers have always set up minimum safe water
level requirements for their equipment. Our controls help
enforce those requirements in two ways:
By maintaining a minimum safe water level in

the boiler.
By signaling the burner to stop should the water
level drop below that point.
In this brief Systems Guide we will explain how we do these

two very important jobs.
Whats a Normal Water Level?
The proper steam boiler water level varies from manufacturer

to manufacturer, but generally we can say that its normal to
start by manually filling the boiler to the twothirdsfull point on
the gauge glass. As the boiler operates, the water will quickly
turn to steam and head out toward the system.
Steaming takes place at a constant rate of about onehalf

gpm per 240,000 BTU/HR (D.O.E. heating capacity rating).
This is a law of physics, so it doesnt vary from manufacturer
to manufacturer. If youre working with a boiler with a rating
of say 1,000,000 BTU/HR, you can be assured the water is
turning to steam and leaving that boiler at the rate of about
two gpm. And its leaving at speeds measured in miles per
hour (sometimes exceeding 60 mph!). So its very important
for your near-boiler piping to be correct. If its not, the fast
moving steam will pull water out of the boiler and create
problems for you in the system and the boiler.
As the water (in the form of steam) heads out toward the
system, the water level in the boiler will, of course, drop.
How far it drops depends a lot on the size and condition of
your piping system. You see, ideally, the water should begin
to return to the boiler before the boilers internal water line
drops to a critical point. Thats the point at which the low
water cutoff will cut power to the burner, or an automatic
water feeder will open.
Because the water is in the system piping and radiating during

operation, the normal water level becomes a point thats
somewhere in the lowerthird of the gauge glass.
Remember that youre working with a range of operation here,

not a fixed point. If the water were to stay at the top of the
gauge glass all the while the burner was firing, you probably
wouldnt be making steam! So dont get too caught up with
the word normal because the only thing thats normal is
that the water level will rise and fall.
Boiler manufacturers, as we said before, do establish a mini-

7
mum safe water level for their boilers, however. That point

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
is usually just out of sight of the bottom of the gauge glass. and 9.
Should the water level drop to this point, the boiler may be Check the condition of the water. Dirty water will prime
in danger of overheating. We have to find a way to protect and foam.
the boiler from itself. Check the burners firing rate. Overfiring can cause
priming.
All leading authorities and insurance companies recognize
this need. The ASME Code for Low Pressure Heating Boil- The pipes may not be properly pitched.
ers, for instance, specifies, Each automatically fired steam
or vapor steam boiler shall be equipped with an automatic The automatic feeder may not be working properly.
low water fuel cutoff. The device the code refers to is what Its chamber may be filled with sediment.
most people in the field commonly call a low water cutoff. Its feed line may be clogged.
Its job is to stop the burner and protect the boiler.
All of the condensate may not be returning from the system
(a common problem with process applications).
What Causes a Low Water Condition?
The boiler metal may be corroded and leaking at the
Because its an open system, some evaporative water loss water line.
is normal for a steam system. How much depends on the Flood the boiler to its header to check for leaks.
size and condition of the system. If youre losing too much
water, however, its time to begin troubleshooting. There are Good troubleshooters take the time to look over the entire
many places to look system before deciding whats wrong. Take the time to do it
right, and youll be the person with the answers
Here are a few good places to start:
Watching the Water Level
The air vents are dirty, not seating properly, and passing
steam to the atmosphere.
The best way to prevent overheating damage to a boiler is to
Someone left the boiler blowdown valve partially open. stop the burner if the water level falls too low. This is the low
water cutoffs job. There are several types of low water
Someone, for whatever reason, has been drawing hot water
from the boiler.
The relief valve has discharged.
The condensate pump isnt working as it should.

The float may have come loose.
The condensate may be too hot to pump. (Check those
steam traps!)
Improper nearboiler piping may be throwing water up into

the system, or causing the waterline to tilt during operation.
The wet returns may be leaking. (Always suspect any buried

pipe).
A check valve may be stuck closed or partially closed.
The boiler may be foaming and priming.

Check the pH of the water. It should be between 7
cutoffs you can use. Lets look at them. probe) back to a ground (the threaded portion of the probe).
As long as water covers the probe, an electronic go signal
will travel to the burner. When water drops off the probe for
Float Operated Low Water CutOffs a continuous ten seconds, an electronic stop signal goes
to the burner, shutting it down and protecting the boiler from
Float operated low water cutoffs have been around since the a low water condition.
1920s and have earned a reputation worldwide for reliability.
Usually youll mount this type of low water cutoff directly in At ITT McDonnell & Miller, we manufacture several different
the boilers gauge glass tappings. We make quick hookup types of probe low water cutoffs to meet any of your job
fittings for these units to simplify installation. applications.
The water level in the low water cutoffs chamber will mimic One of those applications might involve the boilers water
the water level in the boiler. As the water level drops in the level. The water capacity of todays boilers is considerably
boiler during steaming, the level in the chamber, and the less than that of boilers from decades ago. Along with this,
cutoffs float drops with it. Should the float drop to the boilers the water level operating range of todays boilers is smaller.
critical low water cutoff point, the float will trip an electrical Further, the amplitude of surging water levels is increasing.
switch thats wired in series with the burner. The burner As a result, the low water cutoff must be smart enough
instantly stops firing. It will stay off until the water level rises to recognize these variations and react appropriately. We
to a safe operating point. have done this by incorporating delay features in the probes
operating logic. These include a delay on break feature (DOB)
This happens when the condensate returns from the system which keeps the burner lit for 10 seconds after water leaves
or when an automatic water feeder or a boiler attendant adds the probe. This minimizes the effects of a surging water line.
water to the boiler. When the level reaches a safe position, Another addition the delay on make feature (DOM) allows
the low water cutoff will make its electrical connection and an additional feed time of 15 seconds once water comes
the burner will restart. in contact with the probe. This minimizes rapid burner and
feeder cycling by slightly elevating the water level so that
When a steam system is well balanced, the low water cutoffs water lost to steaming will return (in the form of condensate)
job is to stand by and wait. The situation we just described before the water level drops below the probe.
suggests that theres something out of balance in that system.
Well look at this again in a few minutes. Float Type in operation, these are similar to the external,
float operated low water cutoffs we looked at before. The
difference is that instead of sensing a duplicated water level
Probe and Float Type BuiltIn Low Water CutOffs outside the boiler, these units sense the level directly inside
There are some jacketed boilers that dont easily accept quick
hookup fittings. These boilers will often have a tapping for
a builtin low water cutoff. These builtin units do the same
thing as the external units we just looked at, but instead of
being in a chamber, the builtins are right inside the boiler
where they can sense the water level directly.
We make two types of builtin low water cutoffs:
Probes The boiler manufacturer will specify the point where

theyd like to have this type of low water cutoff inserted. It
will usually sit just below the water line, at a point above the
boilers crown. A probe uses the boilers water to complete
an electrical circuit past an insulator (the center portion of the

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
relief valve will open. If you run them with too little water,
the boiler. We make them for you in five mountingbarrel sizes theyll overheat and suffer damage.
(Series 69) to accommodate different boiler insulation thick-
nesses. When you select a builtin float type control, make A low water cutoff is the only sure way of protecting a hot
sure it fits as far as possible into the boiler without the float water boiler from sudden loss of water. The ASME boiler
shield coming in contact with the boiler. code recognizes this by requiring all hot water boilers of
400,000 BTU/HR or more input to have low water fuel cut
When a low water cutoff stops a burner, it also stops the off devices.
entire heating system. Nothing will happen until the water
in the boiler returns to a safe operating level. ASME doesnt call for low water cutoffs on smaller, residen-
tial boilers, but we think all hot water boilers, regardless of
While this is very good for the boiler, it may not be the best their size, must have protection. However, the International
thing for the system. If the heat in the building is off for too Mechanical Code requires low water cutoffs on ALL hot water
long a time, water pipes may begin to freeze. and steam boilers. ITT McDonnell & Miller make several
devices, both float and probe type, that protect and meet
This is where automatic water feeders come in. An automatic
feeder will maintain a safe minimum water level in the boiler
and keep it operating, even if the system is leaking. It keeps
the system operating automatically until you can make the
repairs.
Hot Water Boilers
Low water protection isnt just for steam boilers. Hot water
boilers face the same perils of overheating damage if the
water line drops too low. Many people dont think of this as
often as they should because hot water boilers serve closed
systems. They have pressure-reducing valves that are sup-
posed to feed water automatically should a leak develop.
The truth, however, is that a pressure reducing valve is no

substitute for a low water cutoff. Pressure reducing, or feed
valves, often clog with sediment and wind up not feeding at
all. A buried pipe can corrode and spring a leak that flows
faster than a feed valve can satisfy. Relief valves can pop
and, while dumping water at a great rate, actually prevent the
feed valve from operating.
Lets take a closer look at how we can protect these boil-

ers.
Hot Water Systems
As we said, the things that affect steam boilers also affect

hot water boilers. If you run them with too much water, the
the needs of any boiler whether its cast iron, steel, or cop-
per construction.
Hot water systems regularly lose water through faulty air

vents, loose valve stem packing, cracked boiler sections,
loose nipples, corroded pipes, broken or loose pump seals,
leaking gaskets, or dripping relief valves, to name just a few
places. Most installers depend on their pressure reducing or
feed valve to replace the lost water automatically. But feed
valves often clog with sediment, especially in hard water
areas. And its very easy to close the supply valve to a feed
valve and forget to open it again.
On systems with buried pipes (say a radiant heating system)

a feed valve will open if a pipe breaks. It will feed fresh
water continuously until it either clogs (and stops feeding) or
destroys the ferrous components of the system with oxygen
corrosion. A simple feed valve can wind up costing a lot more
than its purchase price. This is why major suppliers of feed
valves, such as ITT Bell & Gossett, recommend you close the
feed valve once youve established your initial fill pressure.
This is also why we strongly recommend you use a low water
cutoff on every hot water boiler. Feed valves are not a sub-
stitute for low water cutoffs. They cant protect your boilers
from a low water condition. Feed valves are fine for filling the
system initially, and for helping you vent air from the radiators,
but once the system is up and running, you shouldnt look to
them for protection.
Over firing
There are times when hot water boilers dont lockout on

safety. Whether by control failure or human error, things go
wrong. And when they go wrong in a hot water heating system,
the water temperature can rise quickly to a point where the
compression tank cant take up the expansion of the water.
This causes the relief valve to discharge.
When the relief valve opens, theres a sudden drop in system

pressure. The water, which at this point is probably much
hotter than 212F (100C), will flash into steam. This is
why ASME insists that relief valves for hot water boilers
carry steamdischarge ratings. If a feed valve doesnt open
to replace this rapidly exiting water, a low water condition will
quickly result. The only thing that can protect the boiler at
this point is a low water cutoff. The feed valve cant protect
the boiler because its typical setting is 12 psig (.83 bar). In

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014
other words, the system pressure must drop below 12 psig

(.83 bar) before the feed valve will open.
The trouble is that while the relief valve is open and flashing
steam to atmosphere, the internal system pressure never
drops anywhere near 12 psig (.83 bar). A relief valve with a
30 psig (2.1 bar) setting, for instance, will open at 30 psig (2.1
bar) and close again when the pressure drops to about 26
psig (1.79 bar). The result is a loss of water with no makeup.
Repeat this cycle enough times and the boiler will be in a
dangerous low water condition. Keep in mind, steam exerts
pressure. It can easily fool a feed valve, and thats why feed
valves offer very little protection at all against low water.
Feeder/CutOff Combinations for Cast Iron and Steel

Hot Water Boilers
To protect a boiler from dry firing, the low water cutoff must be
located above the boilers crown. After the low water cutoff
shuts off the burner, you should have a way to add water to
the system to ensure the crown stays under water.
A combination water feeder and low water cutoff can do this

for you. If you position the feeder above the boilers crown,
it will mechanically feed water if the level should drop to that
point. This is an important consideration because even if
the electricity is cut off, its possible for the firing cycle to
continue if the fuel feed valve is mechanically locked open.
The combination units cutoff switch will act as a backup
to the primary low water cut-off, providing the boiler with ad-
ditional protection.
Protecting Copper Fin Tube Boilers
Copper fin tube boilers move heat from the flame to the water
almost instantly. This type of boiler depends on the proper
flow of water across its heat exchanger to move the heat
quickly out of the boiler and into the system. Should flow stop
while the burner is operating, heat will quickly build and cause
the water in the heat exchanger to flash into steam. This
condition is similar to a dry firing in a cast iron or steel boiler.
A McDonnell & Miller flow switch, installed on the copper fin
tube boilers hot water outlet, protects it from this danger.
The burner cannot fire unless water is moving across the flow
switch. When the flow stops for whatever reason, the McDon-
nell & Miller flow switch immediately cuts electrical power to
the burner and protects the boiler from overheating.
Pressure Relief Valves
7 Good engineering practice calls for every hot water boiler to

have a pressure relief valve. This springloaded valve must
be able to release the boilers entire load at the boilers

maximum operating pressure. Here are some things that can
cause a relief valve to open in a hot water heating system:

The automatic feed valve fails, allowing higher than normal
pressure to enter the system.
Someone leaves a hand bypass line open after

filling the system.
Someone hydrostatically tests the system at a pressure
greater than the relief valves setting.
The air cushion in the diaphragm type compression tank

doesnt match the systems static fill pressure. Keep in
mind most tanks come from the factory precharged at 12
psig (.83 bar). If the system needs more than 12 psig (.83
bar) pressure, you have to add more air to the tank, and you
have to do this while you have the tank disconnected from
the system.
The compression tank may be too small for the system.
The boilers aquastat is in a well without heat transfer

grease. When this happens, the boilers temperature will
quickly exceed the aquastats setting, causing rapid rise in
system pressure.
The circulator may be on the return side of the system with

the compression tank at its suction. If it is, the circulators
head pressure will appear inside the boiler as a net increase.
It may be enough to open the relief valve.
The burner limit may be jumpedout or stuck in a manual

position.
The main thing to keep in mind when youre troubleshooting

this one is that relief valves pop when any of these three
things happen:
The compression tank loses its air cushion

The system takes on more water.
The system temperature increases.
Think methodically, and keep your eyes wide open!
We hope this Basic System Operation Guide has given you

insight into the systems on which youre now working or will
face in the future. We welcome any questions or comments
you may have about the Guide, or about our products.
Thanks for your support, and for your continuing business.

(800) 289-3331 FAX: (405) 232-5438 (800) 955-1918 FAX: (918) 249-9014

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TECH TIP #1

Which Boiler is Right For Me?

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 283

For more information concerning boilers and boiler

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 285

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 287

Waste Heat Recovery

Electrical Power Optimization

Steam Plant Optimization

FAX: (405) 232-5438

] Metered Fuel/Air Ratio Control = 2-7% 4 th ore d t

FAX: (918) 249-9014

From time to time we hear the question,

It is difficult to argue with this type of rea-

Now we are going to tell you something that

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 291

HEATING PROCESS OR DOMESTIC HOT WATER

HEATING BOILER FEEDWATER

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 293

How Does it Work?

Hot, High pressure continuous blowdown water drained from the

Recovery of up to 50% of the BTUs available may be accomplished

7 kReduce temperature of blowdown discharge to drain to meet statute limits.

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 295

Metered Parallel Positioning Control Sys-

This fuel/air customization feature means

7 Cross-limited Parallel Metered Control

by interlocking fuel/air ratio control to pre-

CLC systems easily maintain excess oxygen

Because of its capability for close tolerance

The economic balance between fuel cost,

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 297

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 299

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 301

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 303

GAS TRAIN COMPONENTS..To Vent or Not To Vent

How to Avoid the Need for a NORMALLY OPEN VENT VALVE

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 305

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 307

BOTTOM BLOWDOWN VALVE OPERATION FOR STEAM BOILERS

2. Blow out sediment, mud or scale while boiler is steaming.

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 311

BOILER/BURNER SURVEY FORM FOR CSD-1

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 313

MANUFACTURER'S/INSTALLING CONTRACTOR'S REPORT

UNIT IDENTIFICATION (Boiler)

STEAM HOT WATER

BOILER UNIT DESCRIPTION (TYPE)

Burner - Manufacturer Model

FUELS (as shipped)

INSTALLATION LOCATION (if known)

SAFETY OR SAFETY RELIEF VALVE(S) OPERATION TEST PERFORMED, DATE

Representing Equipment Manufacturer, Name

Representing Installing Contractor, Name

OKLAHOMA CITY (405) 239-7301 TULSA (918) 249-1918 315

Steam boilers are simple, efficient and reliable. No machine

A simple safety relief valve of the right capacity and reliefpres-

By maintaining a minimum safe water level in

In this brief Systems Guide we will explain how we do these

Whats a Normal Water Level?

The proper steam boiler water level varies from manufacturer

Steaming takes place at a constant rate of about onehalf

Because the water is in the system piping and radiating during