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Kevin C. Maguire – Industry Consultant
September 29, 2016
WEBINAR
How to Prevent and Control The Big 5 Boiler and
Pressure Vessel Recommendations
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Why are we here?
1. Better understand the basics of boiler maintenance
2. Understand jurisdictional requirements
3. Operate boilers reliably, and efficiently
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Big 5 Recommendations
3
The top five recommendations our inspector are finding during
their inspections are:
1. Log sheets
2. Leaks
3. Faulty controls/Gauges
4. Scale/Corrosion
5. Insulation
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Components
1. Log Sheets
2. Steam Traps
3. Safety valves/Safety Relief Valves
4. Low Water Cutoffs
5. Controls
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Boiler Logs
Why use them
What to include
How to use them
5© 2012 The Hartford Steam Boiler Inspection and Insurance Company. All rights reserved.
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6
Manufacturer: Boiler Number: Location: Week Beginning:
Day and
Time
Weather Conditions Pressure Temperature
Water
Safe
ty R
eli
ef
Valv
e T
este
d
Bu
rner
Op
era
tio
n
Op
era
tor
on
du
ty
Ou
tsid
e T
em
pera
ture
Ou
tsid
e C
on
dit
ion
Bo
iler
Feed
Wate
r
Su
pp
ly
Retu
rn
Feed
wate
r
Flu
Gas
Lo
w W
ate
r C
uto
ff
Bo
iler
Blo
w D
ow
n
Wate
r T
reatm
en
t
Exp
an
sio
n tan
k
Monday
A.M.
P.M.
Tuesday
A.M.
P.M.
Wednesday
A.M.
P.M.
Thurs
day
A.M.
P.M.
Fri
day
A.M.
P.M.
Satu
rday
A.M.
P.M.
Sunday
A.M.
P.M.
NOTE: Should any checks or test indicate that the device being tested or observed is not in good operating condition, it should be repaired immediately. Record repairs under the comment section so that a complete
r
record will be available for review at any time.
Hot water heating boiler log
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10 October 2016 7
Comments:
Procedure Date Procedure Date
Safety Relief Valve: Pull try-lever to full open position with the normal operating
pressure on the boiler. Release try-lever to allow the valve to snap closed. Caution
- All discharges must be piped to a safe area. SRV need to be tested four times
per year and recorded on the Boiler Operating Log.
Pump and System: At least once a week check pump for proper operation and
leaking packing. Examine check valves, makeup float valves, expansion tanks and
other parts of the system. The results of the visual inspection should be recorded
on the Boiler Operating Log.
Low Water Fuel Cutoff: Probe type low water cutoffs are tested quarterly with the
burner in-operation. Hold down the test button (approximately 45 seconds) until the
burner starts shutting down and then release. The burner will continue to shutdown
the boiler and remain shut down until the reset button is pressed. Boiler will re-start
in about 45 seconds. The results of the test should be recorded on the Boiler
Operating Log.
Burner Operation: All flame failure and fuel supply devices should be properly
tested in accordance with the manufacturer's instructions. Always have a factory
trained service mechanic check, adjust and repair gas and oil burners and their
controls prior to the start of the heating season. Make daily checks on flame
condition, fuel leaks and operating condition of the burner. Any problems noted, call
your service personnel at once.
Emergency Cutoff switch: With the boilers firing, shutdown the boilers using the
manually operated remote shutdown switch at the boiler room door. If more than
one entrance to the boiler room, this test should be completed for each remote
shutdown switch. The testing of the remote shutdown switch should be performed
at the beginning of each heating season.
Repairs: Mark any joint or fittings which have shown signs of leakage. Make a
record of any repairs needed to the boiler, to the system or to attachments. Have
proper repairs made as promptly as possible after the end of the heating season so
that the heating plant will be ready for service when needed. Never make repairs
while the boiler is in operation.
Hot water heating boiler log flip side
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General
Leaks
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STEAM TRAPS
1. Steam traps hold back steam and allow condensate to pass.
2. Steam traps remove condensate that causes “water hammer” which
damages valves, piping & equipment.
3. Types:
Inverted bucket Float thermostatic Thermostatic
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Signs of Steam Trap Failures
1.Warm boiler room
2.Condensate receiver venting steam
3.Condensate pump water seal failing regularly
4.Overheating/Underheating in different rooms
5.Boiler operating pressure difficult to maintain
6.Water hammer
7.Steam in condensate return lines
8.High Energy Bills
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Solids in boiler water come from:
System makeup water (well or city water).
Water treatment chemicals which are added to remove scale producing
elements from the boiler water.
System return water that contains system deterioration and/or processing
contaminates.
Air (oxygen and carbon dioxide) that enters the system via:
Pump seals
Valve packing
Air bleeders & vents
Sources of Boiler Contamination
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Fireside Soot
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Scale/Sediment
1. Most common cause of overheating
2. Interferes with heat transfer
3. Dissolved minerals in boiler water
Scale/Sediment
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Corrosion
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1. Prevent contaminates from forming scale on the internal
water surfaces of the boiler.
2. Neutralize oxygen that causes corrosion in the boiler as well
as the system.
Water Treatment
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0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0%
1/32
1/25
1/20
1/16
1/8
1/4
3/8
1/2
Increase Fuel Consumption
Sc
ale
Th
ick
ness
Sca
le T
hic
kne
ss
The Cost of Scale in Boilers
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Safety Valves/Safety Relief Valves
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Testing of Safety and Safety Relief Valves
Safety Valve Safety Relief Valve
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Safety and Relief Valves
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Safety and Relief Valves
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Vertical vs. Horizontal
Installation
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Safety Relief Valve Review
1. Installed with stem vertically
2.Nameplate
3.Pipe to a safe area
4.Discharge pipe is properly secured
5.Discharge is visible to Operator
6.Pulleys and Chains
7.No shut off valves between boiler and safety valve.
8.No painting
9.Quarterly testing
10.Document results
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Low Water Cutoffs
Probe type low water cutoff Float type low water cutoff
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STEAM LOW WATER CUTOFFS
Steam Boilers
1. Need 2 LWCOs
2. Common connection on steam side
3. Separate connections on water side
4. Secondary LWCO needs to be a manual reset
5. Drains need to be piped to a safe area
Drain pipe minimum ¾”
6. No shut off valves between LWCO and boiler
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1.Blow down daily during heating season – Steam2.Pipe discharge to a safe area3.Visible to the operator.
DO NOT REDUCE SIZE OF DISCHARGE PIPEMinimum = ¾”
1.Open annually for inspection. Remove plugs in cross tees Remove float Check mercury switches Check electric wiring
Steam Low Water Fuel Cutoffs
Preventive Maintenance
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HWH LOW WATER CUTOFFS
Hot Water Heating Boilers
Need 1 LWCO
Installed above the lowest safe permissible water level established by the boiler manufacturer
LWCO tested without draining the entire system
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Monitoring Temperature
Thermometer
installed at or near
the boiler outlet
and easily
readable
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EMERGENCY CUTOFF SWITCH
Location
Every entrance
Tested
Annually
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General
Housekeeping
Storage, Lighting, clearances
Fire prevention
Emergency Egress
Combustibles
Oil, and cleaners products
Flammables
wood, paper and cardboard
keep at least 8 to 10 feet from the boiler
Paint and Gas
Ventilation
Leaks
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INVESTIGATION INTO THE CAUSALITY
OF HOT WATER BOILER FAILURES
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Background
Claims
2009-2013
NYSIR receives 40 Cast Iron Boiler claims
January – June 2014
10 Cast Iron boilers
2 Cast Aluminum boilers
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Boiler Claims
Type Number Developed
of Claims AGL1
Hot Water Boilers 20 110,140
Steam Boilers 20 375,125
TOTAL 40 485,265
AGL = Adjusted Gross Loss
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Potential Opportunity
2,555 Cast Iron boilers owned by NYSIR
Subscribers
Monetary Savings
Reducing cast iron boiler losses
Non-monetary Savings
Downtime 1 to 4 weeks
Extra expense for rental equipment
Shutdown of schools for extended periods
Relocate students
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2015 Efforts to Address Losses
Completed 40 Focus Loss Prevention
inspections
January – April 2015
Focused questions NYSIR Subscribers
Care and maintenance of boilers
Energy Management Control System (EMCS)
Thermal Cracking
Short Cycling
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Pilot Objective
1. What can be done to reduce the boiler claims?
2. Does one brand or model of boiler account for more losses than others?
3. With respect to the boilers, is NYSIR better or worse than their peers or HSB
experience as a whole?
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Results and Analysis
According to HSB data, country-wide there is no difference in
claim rates between HB Smith and non-HB Smith boilers
NYSIR has an overall average boiler claim experience (all
occupancies)
Schools tend to have better boiler experience than non schools
NYSIR boiler experience is worse than average for schools
NYSIR has worse claim experience with HB Smith boilers than
non HB Smith boilers
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Pilot Results and Analysis
The return water to the boiler should not be lower
than 140° F
The return water to the boiler should not be more
than 40° F below the boiler temperature or supply
water temperature.
Rapid drops in return water temperature are known
to produce thermally induced shock. There are no
known guidelines around this measure.
Firing rate
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Findings
1.Thirty (30) Locations had boilers operating below 140° F
2.Eleven (11) had a temperature difference of more than 40° F
between the supply water and return water temperature
3.Twenty (20) of the boilers were short cycling (i.e., seven or more
firings in an hour)
4.Four (4) locations were operating within general manufacturers
recommendations for all three parameters.
5.None of the boilers reached or exceeded the American Society of
Mechanical Engineers (ASME) high temperature limit of 250° F
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Conclusions
1. Reduce fuel costs;
2. Boiler technician vs. EMCS technician;
3. Too many heating zones actuating at same time;
4. Improper mixing valve operation
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Recommendations
1. The boiler should be tuned up and inspected by a qualified mechanic to the
manufacturer’s specifications. For boilers that are running at 140° F or less, the
sections should be examined for fireside corrosion. If corrosion is noted, the
return temperature set points should be adjusted.
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Recommendations
1. Once the boiler has been tuned up, the system that controls the boiler needs to
be set to the boiler manufacturers specifications. If there is a separate boiler
technician and a separate control (energy management control system)
technician, they need to work together to meet the boiler manufacturers
specifications. This may result in adjustments to one or more of the following.
Number of zones that are actuated at one time
The sequence of zones that are actuated
The temperature set points of the system
The turn down rate of the boiler
The use and maintenance of temperature mixing valves
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Jurisdictional Rules
1.Inspections
External and Internal
Every 24 months for low pressure boilers
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Jurisdictional Rules continued
2. Installation requirements
3. Rules for repairs
4. Rules for alterations
5. Inspector’s role
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QUESTIONS
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THANK YOU VERY MUCH
FOR YOUR ATTENTION