Gerry 2015 MacBook

Color of Steam

DOs AND DON’Ts OF SIZING REPLACEMENT BOILERS

For Steam

�� Do size according to the installed radiation load. Be sure to make appropriate allowance for additional piping and pick-up.

�� Don’t size based on a heat loss.

� Use the existing boiler size and firing rate as a guide and/or cross-reference only.

For Hot Water

�� Do size based on a heat loss if the system is copper baseboard. OK to size a copper baseboard system based on the lineal footage of installed radiation.

�� Do size according to the installed radiation load if the system is cast iron radiation. Be sure to make appropriate allowances for additional piping and pick-up.

�� Use the existing boiler size and firing rate as a guide and/or cross-reference only.

TECHNICAL TIDBITS

�� Piping and pick-up factors for I = B = R Rated Boilers: � � �� Hot Water = 1.15 � � �� Steam = 1.33

�� 1 Boiler Horsepower =� 33,475 BTUH

�� 1 Lb. Steam (212°F) =� 970.3 BTU

�� 1 Sq. Ft. of Steam =� 240 BTUH

�� 1 Sq. Ft. of Water =� See Table Below

HEAT EMISSION BASED ON ROOM TEMPERATURE OF 70°F

Avg water temp in radiation… 150 160 170 180 190 200 210 215 Heat emission BTUH/sq. ft… 110 130 150 170 190 210 230 240

29 Cubic Inches

Relative Volume of Water vs Steam

1 Cubic Foot = 1728 Cubic Inches

2 Pipe

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Room Name§ Feet of Copper

Baseboard ElementNumber of

CI Radiators# of Tubes or Columns

Number of Sections

Cast Iron Height

Cast Iron Width

Feet of CI Baseboard

EDR*/Section or /Foot from Chart Total

12345678910111213141516171819202122232425

= Total Feet of Copper BB Element TOTAL EDR == Element x 600 BTUH§ (@180˚) EDR x 150 BTUH† (@170˚) =

§Water temperature other than 170˚ see capacity chart † For water temperature other than 170˚, see EDR Output Chart

*EDR = Square feet of Equivalent Direct Radiation

(Enter #T for Tubes or #C for Columns)

RadiationMeasuringSheet

Room Name§ Feet of Copper

Baseboard ElementNumber of

CI Radiators# of Tubes or Columns

Number of Sections

Cast Iron Height

Cast Iron Width

Feet of CI Baseboard

EDR*/Section or /Foot from Chart Total

1 Den 2 5T 5 4 402 1/2 Bath 1 5T 4 2.67 10.683 Dining Room 2 5T 6 4 484 Living Room 3 5T 6 4 725 Kitchen 2 5T 5 4 4067 Bath 1 5T 4 2.67 10.688 Master Bath 1 5T 5 2.67 13.359 Master Bed 2 5T 5 4 4010 Stairs/Hall 1 5T 4 4 1611 Bedroom 1 2 5T 5 4 4012 Bedroom 2 2 5T 5 4 4013141516171819202122232425

= Total Feet of Copper BB Element TOTAL EDR = 370.71= Element x 600 BTUH§ (@180˚) EDR x 170 BTUH† (@180˚) = 63020.7

§Water temperature other than 180˚ see capacity chart † For water temperature other than 180˚, see EDR Output Chart

*EDR = Square feet of Equivalent Direct Radiation

(Enter #T for Tubes or #C for Columns)

RadiationMeasuringSheet

Domestic Hot Water:ECT with Tankless Coil

63/64 with Indirect Tank

Hot Water Zone on a Steam Boiler*

*From heatinghelp.com. Used with permission.

Hot Water Zone on a Steam Boiler*

*From heatinghelp.com. Used with permission.

handout

Skimming a Steam Boiler Skimming a newly installed steam boiler is a crucial step to ensure the proper operation of the system. A dirty boiler will produce wet steam, which could cause the following symptoms:

• Surging water line

• Water dropping from the top of the boiler sight glass

• Uneven heating in the building or lack of heat in certain areas

• Short cycling of the boiler

• Boiler continually calling for additional makeup water

• Short cycling of the boiler feed pump if one is incorporated in the system

• Flooding of the boiler when it shuts down

• Water hammer in the pipes as they heat up

Before you re-pipe or alter the installation, eliminate the possibility of dirt by properly skimming the boiler; however, a dirty boiler is not the only possible cause of the symptoms listed above.

1. When piping your steam boiler, add a full port ballvalve in the Hartford loop with a drain valve below it, as shown in the picture. The purpose of the ballvalve is to prevent condensate from going back into the boiler until the condensate in the return is free of dirt and oils.

2. Pipe an automatic/fresh-water feed bypass connection so that fresh water can enter the boiler even when the ballvalve on the return is closed in Step 1.

3. Install a short nipple, tee, and a ballvalve in the skim tapping of the steam boiler. This will be used to add Arm & Hammer Washing Soda and to skim the boiler. The top of the tee and valve will be capped when the boiler is in operation.

4. Start the skimming procedure by closing the ballvalve in the Hartford loop and remove the cap on the skimming ballvalve and open that valve. Turn on the boiler and run it until the boiler begins to steam. When the surging water begins to run out of the skimming valve and into the bucket, turn off the boiler.

5. Mix the Arm & Hammer Super Washing Soda in 4 gallons of hot water. Mix it thoroughly to make sure the soap dissolves completely in the water (don’t use your bare hand to mix the solution). Use ½ lb of soap per 100,000 BTU of boiler input rating.

6. Remove the cap on the steam skimming tee. Make sure the skimming ballvalve is closed and then add the cleaning solution. Be sure that no undissolved soap is poured into the boiler.

7. Reinstall the cap on top of the skimming tee and open the skimming ballvalve. Place or hang a bucket to catch water that will surge out of the boiler. Turn on the boiler, and when the boiler water begins to surge, be very careful to stay clear of the skim tapping so that the surging water doesn’t burn you. As soon as water starts to surge into the bucket, turn off the boiler. Be careful as it may overshoot the bucket. If the surging water comes out too fast, be ready to turn the ballvalve off. 8. When the surging water stops, remove the cap in the skim tee and crack open the fill bypass valve so that the cold water begins to enter the boiler. Allow the water to feed at the rate that will only allow the boiler water level to flow ½ way up the boiler skimming nipple. The skim tee allows you to watch the dirt float off and determine how fast the fresh water is flowing into the boiler so that it only goes ½ way up the nipple. When the water coming out of the skim tapping is cold, you can turn off the water. By carefully touching the skim piping with your hand you can tell if the water is cold.

9. Drain the water from the boiler through the drain valve at the bottom of the boiler. Also open the flush valve on the 67PE2 Low Water Cutoff, if one is installed, to help remove water from the boiler and flush out the LWCO. When the boiler is almost empty, open the fresh water fill valve and thoroughly flush out the bottom of the boiler with clean water.

10. When the water comes out clean from the bottom of the boiler, close the boiler drain valve and allow the boiler to fill. Close the skimming ballvalve and reinstall the cap on the skim tee. Keep the ballvalve in the Hartford Loop closed and open the drain valve below it. Allow water to rise up into the steam mains to flush out dirt and sediment. Do not let the water feed into the mains faster than the drain valve can drain it. Run it until the water from the mains is clear. Be careful if there are drip traps at the end of the steam mains, so as not to fill the traps with dirt. When the water is clear, shut off the fresh water feed and let any remaining water in the mains completely drain.

Drain the excess water out of the boiler until it is at the normal water line. Start the boiler and allow it to produce steam. If the same symptoms are still present, redo steps 5-10, but do not re-flush the mains. If the symptoms are not present, feed fresh water as required to maintain the water line and partially open the drain valve below the Hartford loop isolation valve. Allow the condensate to flow until it is clear and free of dirt and oils. Be sure to let the condensate out of the return slowly as to not completely empty the wet return and cause live steam to enter the wet return. 11. When you are satisfied that the return water is clean, close the drain valve and open the ballvalve in the Hartford loop. Remove the handle and hang it nearby. Allow the water level to reach its normal waterline and shut off the fresh water bypass valve. Reinstall the cap in the skimming ballvalve. 12. Watch to see that none of the dirty boiler symptoms return, if they do return, redo steps 5-11 with the exception of flushing the mains.

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