Bryan Boilers BE Series Service manual

Form 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

Form 2055 i Revision Date 5/1/2015
Table of Contents
SECTION 1 –
INSTALLATION INSTRUCTIONS
1.1 Boiler Foundation ......................................................................................1
1.2 Clearances ................................................................................................1
1.3 Uncrating the Boiler...................................................................................1
1.4 Boiler Connections .................................................................................2-3
1.4.1 General
1.4.2 Steam Supply Connection
1.4.3 Feedwater Connection
1.4.4 Safety Relief Valve(s)
1.4.5 Blowdown Connection
1.5 Electrical Connection.................................................................................3
1.6 Boiler Accessory Equipment...................................................................4-5
1.6.1 Elements
1.6.2 Boiler Components – General
1.6.3 Power Panel Wiring
1.6.4 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
SECTION 2 –
START-UP AND OPERATION
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 Combination Low Water Cut-Off & Feeder
2.1.6 Other Controls
2.1.7 Boiler Feed System
2.1.8 Chemical Feed System & Softener
2.2 Operating Controller..................................................................................8
2.2.1 PLC Step Control
2.3 Operating Instructions ...............................................................................8
2.3.1 Familiarization with Manual(s)
2.4 Maintenance Schedule..............................................................................8
2.4.1 Posting Schedule

Form 2055 ii Revision Date 5/1/2015
Table of Contents – cont.
SECTION 3 –
CARE AND MAINTENANCE
3.1 Required Precautions During Temporary Use......................................9-10
3.1.1 General
3.1.2 Operator Skills/Responsibilities
3.2 Cleaning the Boiler and System – New Systems ...............................10-11
3.2.1 Boil Out Procedure
3.3 System Clean Out...................................................................................12
3.3.1 System Cleaning Procedure
3.4 Replacement Boiler Installations -
Protection Against Corrosion & Sediment..........................................12-13
3.4.1 Clean or Replace All System Piping and Heating Units
3.5 Boiler Water Treatment......................................................................13-14
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
3.9.1 General
3.9.2 Pre-Operational Cleaning and Lay-Up
3.9.3 Taking Boilers Off Line
3.9.4 Pre-Shutdown Precautions
3.9.5 Washdown
3.9.6 Lay-Up Considerations
3.9.7 Wet Lay-Up of Steam Boilers – Short Term
3.9.8 Wet Lay-Up – Alternate Method
3.9.9 Dry Lay-Up of Steam Boilers – Long Term
3.9.10 Returning Idle Boiler to Service

Form 2055 1 Revision Date 5/1/2015
INSTALLATIOIN INSTRUCTIONS
ELECTRIC STEAM BOILERS
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 NEC should be consulted and
followed.
1.1 BOILER FOUNDATION
Before uncrating, the boiler location should be prepared. The boiler should set upon a good level
concrete floor. If the boiler is not level or the floor is not in good condition, a concrete foundation
should be built, the dimensions being larger than the outside dimensions of the boiler base.
1.2 CLEARANCES
The front of the boiler should not be any closer than 36" from any obstruction for servicing the
electrical panels. 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 service, accessibility, and clearance for piping
and electrical connections.
NOTE
ADHERE TO ALL APPLICABLE LOCAL CODES REGARDING BOILER INSTALLATION AND
CLEARANCES.
1.3 UNCRATING THE BOILER
Uncrate the boiler near its permanent location. Leave it on the bottom crating until ready to place it
permanently. Leave the plastic shroud on the boiler until all piping work is complete, cutting holes
in the plastic for access to connections.
Remove the bolts attaching the boiler to the crate at the underside of the bottom crating. Lift or
slide the boiler off of the bottom crating into position. Be careful not to tip the boiler up on one
corner or side, which could cause damage to jacket.
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Form 2055 2 Revision Date 5/1/2015
1.4 BOILER CONNECTIONS
1.4.1 GENERAL
Do not run any pipes along the element access and power panel side of the boiler. Maintain
clearances as shown on the dimensional drawing for servicing and as referenced in NEC. All
piping should be designed and installed to avoid any loadings on the boiler connections or piping.
1.4.2 STEAM SUPPLY CONNECTION
A steam shut-off valve must be installed between each boiler and the steam main. This valve
must be of the outside screw and yoke design to allow indication from a distance whether the
valve is open or closed.
1.4.3 FEEDWATER CONNECTION
Install a check valve and a globe valve between the feed pump and the boiler. It is also
recommended to install a globe valve between the feed pump and the receiver tank. This valve
can then be adjusted to bypass excess pump 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. This control is to activate the
feed pump on a boiler feed system. It will be necessary to supply such a system if not
already installed
by an automatic water feeder mounted on the boiler. This is used only on systems
requiring 100% make-up, such as humidification, steam process, etc.
NOTE
It is not recommended to provide the make-up for a closed steam heating system to the boiler by
means of a water feeder. It is preferred that system make-up be connected to the condensate
return tank of a boiler feed system. A boiler feed system may be used in conjunction with an
existing condensate receiver system by allowing the receiver system to pump condensate into the
boiler feed system tank.

Form 2055 3 Revision Date 5/1/2015
1.4.4 SAFETY RELIEF VALVE(S)
A connection is provided in the top of the boiler for the relief valve. The relief valve discharge
piping must be the same size as the relief valve discharge opening. Avoid over-tightening as this
can distort valve seats. All piping from relief valve must be independently supported with no
weight carried by the valve.
1.4.5 BLOWDOWN CONNECTION
Blowdown valve(s) must be full size of the connection on the boiler. Steam boilers 15 psig and
below require at least one blowdown valve. Higher pressure boilers require two blowdown valves
with one or both valves being slow opening type. Each water column and float type low water cut-
off must be equipped with a blowdown valve.
1.5 ELECTRICAL 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
wiring diagram enclosed. A fused main disconnect switch must be supplied per NEC
requirements. Wiring to the main power terminals in the power panel by the contractor must have
current carrying capacity equal to at least 125% of the amperage rating of the boiler. The lugs
supplied are at the top of the power panel and the entrance can be recognized on the
dimensional.
EQUIPMENT GROUNDING: The boiler must be grounded in accordance with the NEC,
ANSI/NFPA #70
CAUTION
ALL CONTROL PANELS AND CONTROLS ARE SUBJECT TO SOME INTERNAL HEAT.
ADEQUATE BOILER ROOM VENTILATION MUST BE PROVIDED.

Form 2055 4 Revision Date 5/1/2015
1.6 BOILER ACCESSORY EQUIPMENT
1.6.1 ELEMENTS
The immersion type electric resistance heating elements are mounted in a standard 150# flange
(300# flange if required). These elements are held into this flange with brass fittings. Each
element hairpin is rated at 5 KW or 10 KW at the rated volts. The incoloy sheath is a nickel,
chrome and iron alloy, which provides good resistance to oxidation and has good strength
characteristics at elevated temperatures. By virtue of its very high nickel content, the material
does not have a tendency to become embrittled after prolonged exposure to temperatures.
Corrosion resistance of the incoloy is attributed to the chrome and nickel content of the alloy. This
type of material was chosen as a sheath material because of its resistance to corrosion oxidizing
conditions and attacks from impurities in the various water conditions. Each element is easily
replaced by using ordinary hand tools. This eliminates the necessity of having a complete element
bundle as spare parts and also eliminates the necessity of returning the element bundle to the
manufacturer for repair, although this service is available.
1.6.2 BOILER COMPONENTS - GENERAL
The boiler equipment list in this manual lists the components 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 POWER PANEL WIRING
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 fuses and contactors in each branch circuit. Each leg in each circuit is
individually fused with fast acting fuses to interrupt power if required. The contactors are then
wired using high temperature wire to each element circuit and bundle located in the element
flange.
1.6.4 CONTROL CIRCUIT WIRING
The control circuit voltage is 120 V, single phase, and fed from a step down transformer (if
provided). The transformer’s primary side is connected to two fuses located in the power panel.
One side of the secondary is grounded and the other side feeds the control circuit through the
control circuit fuse. All of the safety controls are wired in series so that any one of the safety
controls will shut down the boiler if the limit is reached. Also, located in the control circuit a recycle
relay (in some cases the relay is built into the sequencer). In case of power failure, the function of
this relay is to eliminate a sudden power load on the distribution system. If a power failure occurs,
the recycle relay interrupts the control circuit power causing the magnetic contactors to drop out.

Form 2055 5 Revision Date 5/1/2015
Power is shut off to the elements until the modulating motor has driven the sequencer back to its
original starting position. The relay is then activated, and the sequencer will bring the steps back
on one at a time until the system is again balanced. There is also a limit supplied to be installed
with the shunt trip on the main circuit breaker in order to completely shut down all power to the
boiler. Refer to the electric wiring diagram supplied
1.6.5 SAFETY RELIEF VALVES
The safety relief valves are mounted on the top of the boiler. These are a final safety device in
case the operator and other safety devices fail. Such a failure will cause the pressure to rise in the
boiler to the set pressure of the relief valve. The relief valve will discharge, so that the boiler will
not be able to generate pressure beyond the set pressure of the relief valve.
1.6.6 LOW WATER CUT-OFF
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 HYDROSTATIC TEST OF BOILERS AND
SYSTEM
After completing the boiler installation, the boiler connections, fittings, attachments and adjacent
piping must be inspected for leaks by filling the unit with water. The pressure should be gradually
increased to a pressure just below the setting of boiler safety relief valve(s).
Remove the boiler access panels (see dimensional drawing in this manual). Inspect all openings
and fittings for any leaks. Although the boiler is hydrostatically tested at the factory, minor leaks in
fittings and attachments can develop from shipping vibrations or from installation procedures. It is
often necessary to re-tighten such fittings after installation and after the boiler has been in
operation for some time. Replace panels before starting boiler.

Form 2055 6 Revision Date 5/1/2015
START-UP AND OPERATION
ELECTRIC STEAM BOILERS
WARNING
SERVICING AND START-UP MUST BE DONE ONLY BY FULLY TRAINED AND QUALIFIED
PERSONNEL.
CAUTION
BEFORE DISCONNECTING OR OPENING ANY BOILER ITEMS OR ACCESSORIES,
BEFORE CLEANING OR REPLACING 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 PROTECTIVE DEVICES
All operating and limit controls, and low water cutoffs must be tested for proper operation.
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Form 2055 7 Revision Date 5/1/2015
2.1.2 STEAM PRESSURE OPERATING CONTROL
The steam pressure in the boiler is regulated by the Boiler Operator. This is a pressure control
which senses the steam pressure and turns the boiler on and off accordingly. This control must be
operationally tested. Adjust the pressure setting on the control to a pressure less than the boiler
pressure (as shown on the boiler pressure gauge). The control should turn the boiler off. Restore
the control setting to normal. The boiler should cycle on.
2.1.3 HIGH LIMIT CONTROL
At least two additional pressure controllers are provided as high limit controls. They are set at a
pressure above the operator to act as a back-up should the operator fail. The high limit control
must be operationally tested. With the boiler operating, decrease the pressure setting of the limit
control below the current pressure of the boiler. The boiler should cycle off. Restore the high limit
control setting to normal (pushing the reset button if it is a manual reset type). The boiler should
now cycle on.
2.1.4 LOW WATER CUT-OFF(S)
Most boilers are supplied with at least one float or electric probe type control, designed to sense
the level of the water in the boiler. It operates to shut off the boiler if the water level drops below its
sensing level. The low water cut-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. Carefully read the enclosed literature on the low water cut-
off controls, particularly installing, operating and servicing.
2.1.5 COMBINATION LOW WATER CUT-OFF &
FEEDER
The low water cut-off/feeder supplied with some boilers serves as a low water cut-off (see above)
and also causes make-up water to be added to the boiler, should the water level drop below its
control point. This type of control must be operationally tested as described in Section 2.1.1 and
also to assure that the make-up water is introduced as needed. Carefully read the enclosed
literature on the Low Water Cut-off controls, particularly installing, operating and servicing.
2.1.6 OTHER CONTROLS
Additional controls, as required for the particular installation, may also be provided. Refer to the
literature on these devices included in the Boiler Manual. All such devices must be operationally
tested to assure reliable operation of the boiler and system.
2.1.7 BOILER FEED SYSTEM
The boiler feed pump must be operationally tested to assure that it can provide boiler feedwater at
the pressure and in the amount needed for safe and reliable boiler operation.

Form 2055 8 Revision Date 5/1/2015
2.1.8 CHEMICAL FEED SYSTEM & SOFTENER
Check the performance of the boiler water softener and chemical treatment system. Chemically
test the feedwater to be certain it complies with the recommendations of the chemical treatment
consultant.
2.2 OPERATING CONTROLLER
2.2.1 PLC STEP CONTROL
As previously discussed, electric boilers are broken down into branch circuits. Each circuit is
controlled by a step control (if two steps or less, then controlled by their own pressure control).
Step control operates by having a signal sent from the operating control that typically sends a
modulation signal depending on the pressure setting at the pressure operating control. The
pressure operating controller will send a signal to the step control to cycle on more steps until the
desired pressure is reached. Once the pressure control is satisfied, steps will 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 the
operator for the desired output.
2.3 OPERATING INSTRUCTIONS
2.3.1 FAMILIARIZATION WITH MANUAL(S)
The user of the boiler must familiarize himself with this manual to be sure he is prepared to
operate and maintain the boiler properly. The operating instructions should be kept in a safe
place and available to all who may be working or operating the boiler
CAUTION
CHECK ALL ELECTRICAL TERMINALS AND CONNECTIONS FOR TIGHTNESS BEFORE
START-UP.
READ THE MANUAL BEFORE ATTEMPTING A START UP.
2.4 MAINTENANCE SCHEDULE
2.4.1 POSTING SCHEDULE
Post a maintenance schedule in accordance with the recommendations in this manual. A copy of
a typical schedule is included in this manual.

Form 2055 9 Revision Date 5/1/2015
CARE AND MAINTENANCE
ELECTRIC STEAM BOILERS
CAUTION
The boiler area should be kept free of combustible materials, gasoline and other
flammable liquids.
The following procedures must be conducted as outlined to assure safe operation of
the boiler.
All cover plates, enclosures, and guards must be in place at all times, except during
maintenance and servicing.
3.1 REQUIRED PRECAUTIONS DURING TEMPORARY USE
3.1.1 GENERAL
A boiler is often utilized in new construction to assist in curing of building components or to
provide temporary heat for the construction crew or for other 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 assure the
longevity of the boiler.
3.1.2 OPERATOR SKILLS/RESPONSIBILITIES
During the temporary use period, a single individual must be assigned responsibility for the care
and operation of the boiler. This person’s responsibility must include, but not be limited to, the
following:
Knowledge of boiler operation.
Possession and understanding of boiler operating instruction manual.
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Form 2055 10 Revision Date 5/1/2015
Assurance that the boiler is fed with only treated water at all times and that chemical
treatment and blowdown procedures are always followed.
Notification to the manufacturer (or manufacturer’s agent) to provide start-up services if
the boiler was purchased with start-up by a factory representative.
Adherence to all of the start-up procedures noted in the boiler manual.
Considerations of warranty should the boiler 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
3.2.1 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 heat
transfer rate and reduce operating efficiency. The operator must be familiar with the procedure
outlined in the boiler operating instruction manuals.
In combination with system contamination, bacteria may cause objectionable odors, sometimes
resembling natural gas. It is important to keep these fumes from air intakes which would distribute
them throughout the building. On steam humidification systems this is 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 the chemical to come into contact with skin or clothing.
Always follow the safety precautions on the container's label. Add chemicals slowly and in small
amounts to prevent excessive heat and agitation. Do not add water to acid. Do not add water to
dry chemicals. This will cause splattering and/or explosion and severe risk of personal injury.
Boiling out under pressure is not recommended. If boil out under pressure is required, competent
assistance must be provided.
Your water consultant or water treatment company will be able to recommend a cleaning or boil
out procedure. In the event that such service is unavailable or as yet not selected, the following
may be used:
The boil out of the boiler and system is neither difficult nor expensive. The chemicals needed for
cleaning are readily available. Tri-sodium phosphate or sodium hydroxide (lye) are the most
commonly used chemicals. Use only one type of solution in the system. The amount of chemical
required will vary according to conditions, but an amount of one pound of chemical per fifty gallons
of water is suggested.

Form 2055 11 Revision Date 5/1/2015
Before introducing the solution into the boiler, an overflow pipe should be attached to the top of
the boiler and routed to a safe point of discharge.
Remove all safety valves to ensure that none of the solution will come into contact with the valve
seats. Use care in removing and reinstalling valves.
All valves in the piping to and from the system must be closed to prevent the chemical solution
from getting into the system.
Gauge glasses must be protected from contact with the boil out chemicals.
Fill the boiler with clean softened water until the water level reaches the upper header. Then add
the cleaning solution into the upper header. Add more clean water until the boiler is completely
filled. The water used for this initial fill should be at room temperature, and must be softened as
noted.
After filling, turn the boiler on (at a low input) at a frequency as necessary to hold the boiler
solution at boiling point temperature. DO NOT PRODUCE 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 boiler.
Let the boiler cool to 120°F or less. Drain the boiler. Use caution that the water is discharged with
safety.
Remove the inspection/cleanout openings in the boiler and wash the waterside surfaces
thoroughly using a high pressure water stream.
Inspect the boiler’s internal (waterside) surfaces thoroughly after the procedure. If the surfaces are
not clean, repeat the boil out.
After boil out, close all openings. Install relief valves, gauge glasses and other components as
necessary. Completely fill the boiler with fresh, softened, ambient temperature water. Operate the
boiler until water temperature of at least 180°F is reached.
The boiler is now ready to operate.
IMPORTANT
IF BOILER IS NOT TO BE OPERATED WITHIN 24 HOURS, A LAY-UP PROCEDURE IS
REQUIRED. REFER TO INSTRUCTION FOR LAY-UP.

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 SYSTEM CLEANING PROCEDURE
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 CLEAN OR REPLACE ALL SYSTEM PIPING
AND HEATING UNITS
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.

Form 2055 13 Revision Date 5/1/2015
NOTE:
For some old systems, there is a reluctance to clean the piping because of possible 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 be required to overcome
the additional pressure drop introduced in the line by the filter. When filling the system, provide
chemical treatment as outlined in Section 3.3.
CAUTION
Failure to properly clean the system or to install mechanical sediment removal equipment can
result in tube blockage and severe corrosion plus damage to pumps, controls, and air removal
devices.
3.5 BOILER WATER TREATMENT
3.5.1 PURPOSE OF WATER TREATMENT
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 OBJECTIVES
The basic objectives of water treatment are:
Prevent the accumulation of scale and deposits in the boiler.
Remove dissolved gases from the water.
Protect the boiler against corrosion.
Maintain the highest possible boiler fuel efficiency.
Decrease the amount of boiler down time from cleaning.
3.5.3 WATER SOFTENER
It is highly recommended that a zeolite water softener be used for all make-up to the boiler. It is
intended that this be used in addition to the chemical treatment of the boiler. Water softening
removes calcium and magnesium, the primary causes of hard boiler scale.

Form 2055 14 Revision Date 5/1/2015
3.5.4 CONTINUOUS MONITORING REQUIRED
Water treatment should be checked and maintained whenever the boiler is operating. The boiler
operator should be sure that the boiler is not operating for long periods without proper water
treatment.
Water treatment may vary from season to season or over a period of time. Therefore, the water
treatment procedure should be checked not less than four times a year and possibly more
frequently as the local water conditions may indicate
3.6 SUGGESTED MAINTENANCE SCHEDULE
3.6.1 DAILY
Make visual inspection of gauges, monitors, and indicators and record readings in boiler
log.
Make visual check of instrument and equipment 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 instructions.
3.6.2 WEEKLY
On units equipped with operating control, verify it is functioning correctly by adjusting
control and observing if input changes accordingly.
Make visual inspection of all fuses and electrical components making sure they are in
good operating condition..
Confirm boiler area is free of combustible materials and that there is nothing hindering
proper operation of the boiler..
Check all limit controls as specified in Section 2.1 of this manual.
Check float low water cutoff as described above.

Form 2055 15 Revision Date 5/1/2015
3.6.3 MONTHLY
Make visual inspection of all wiring and components.
Check float low water cutoff as described above.
3.6.4 ANNUALLY
Check operating control, high limit and other electrical components for proper operating
procedures as specified in manufacturer’s instructions.
The elements in the boiler should be removed at least yearly for proper visual inspection. If
elements need to be replaced, they should be replaced or the element bundle sent to the
factory for service at this time.
The boiler pressure vessel and piping should be checked annually.
3.7 FLOAT-ACTUATED WATER LEVEL CONTROLS
Inspect float type water level controls for proper operation. Visually inspect sight glasses for
evidence of scale forming residues. Refer to section 3.8 for gauge glass maintenance.
On closed steam heating systems, the float low water cutoff should be blown down by means 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 controls must be give an operational test.
3.8 WATER GAUGE GLASSES
3.8.1 INSTALLATION
Check with the maintenance supervisor and engineer for the proper glass to be used. Compare
the box and the glass label or marking to ascertain that the gauge glass ratings or temperature
and pressure suitable for use on the boiler. Use new gaskets when replacing glass. The gaskets
used should be the same type as those originally supplied with the boiler. Make certain that the
gauge glass valves are properly aligned.
All bolts and nuts must be free running and well lubricated, preferably with a graphite type
lubricant. Washers under nuts and bolt heads are desirable. DO NOT tighten while equipment is
in operation.

Form 2055 16 Revision Date 5/1/2015
3.8.2 MAINTENANCE
Inspect the gauge glass regularly for any signs of clouding or scratching. In new processes, the
gauge glass should be inspected daily until the need for replacement becomes apparent. This will
help establish the routine inspection cycle.
The gauge glass should be blown down daily so as to remove accumulated sediment from the
valves.
3.8.3 INSPECTION
To examine for scratches, shine a bright concentrated light at about a 45 Deg angle. Anything
that glistens brightly should be inspected closely. Any scratch which glistens and will catch a
fingernail, or crescent-shaped or star-shaped mark is cause for replacement. This is because
scratches, corrosion, chips, and surface damage weaken the glass. If inner surface appears
cloudy or roughened, and will not respond to cleaning procedures, this is evidence of chemical
attack. If severe, this is cause for replacement.
3.8.4 REPLACEMENT OF GLASS
Any glass that has been removed from its mounting in process boilers, regardless of the reason
for removal, should be discarded and replaced with a new glass and gaskets. Used glasses 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 GENERAL
Corrosion damage to boilers is often the result of improper lay-up during non-operating periods.
Substantial damage can occur in only a few days if proper precautions are not taken. This
damage is irreversible and will reduce boiler reliability, increase maintenance costs and eventually
shorten the life of the boiler.
Idle boilers are vulnerable to attack when air contacts untreated wet metal surfaces. To prevent
corrosion, the boiler metal must be protected by either keeping the surfaces completely dry or
excluding air from the boiler. Air exclusion is accomplished by either keeping the boiler
completely full of water (short term lay-up) or filling the boiler with nitrogen gas (long-term lay-up).
The nitrogen gas prevents air infiltration and does not react with the metal.
In addition to the corrosion damage that occurs, the metal particles that are released will form an
insulating scale on the boiler when it is returned to service. These corrosion products will
accumulate on critical heat transfer areas of the boiler, increasing the potential for localized
corrosion and overheating.

Form 2055 17 Revision Date 5/1/2015
3.9.2 PRE-OPERATIONAL CLEANING AND LAY-UP
Proper lay-up techniques must be used on an idle boiler even if it has never been in operation.
Before pre-operational lay-up, the boiler must be chemically cleaned as outlined in Section 3.2
and 3.3 of this manual. This is required, as noted in this section, to remove preservatives, oil
and grease from the inner boiler. Follow the short term or long term lay-up procedure as
appropriate.
3.9.3 TAKING BOILERS OFF LINE
In operation, boiler water contains suspended solids that are held in suspension due to water
circulation and the action of treatment chemicals. Unless care is exercised when draining the
boiler, these suspended solids settle on the interior surfaces and will air dry to an adherent
deposit, sometimes requiring chemical cleaning to remove. In addition, these deposits may be
misleading regarding the effectiveness of the chemical treatment program.
3.9.4 PRE-SHUTDOWN PRECAUTIONS
For a period of three to seven days prior to shutdown, manual blowdown frequency should be
increased. During this period, 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 WASHDOWN
As the boiler cannot be washed immediately, the heat in the boiler may cause baking of residual
sludge. The boiler should not be drained until cooled enough to prevent this. However, never
leave the boiler filled with water for any extended period of time without taking measures to
prevent corrosion.
3.9.6 LAY-UP CONSIDERATIONS
There are two basic methods of steam boiler lay-up: Wet lay-up or Dry lay-up. The choice of
which method should be used depends on:
The possibility that the boiler may need to be placed operation on short notice.
Disposal of lay-up solution
Freezing potential
Wet Lay-Up is recommended for relatively short outages, such as seasonal lay-up. This method
has the advantage of allowing the boiler to be brought on line with short notice. But it can pose
problems if there is any likelihood of freezing.
Dry Lay-Up is recommended for longer periods of boiler shutdown or storage. But it is practical
only if boiler can be drained hot (120° F to 170° F) or if external drying can be provided.