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.. FOREWORD

This manual is designed to give detailed service and maintenance information for York Power Steam-PaksPackaged Steam Generators manufactured by York-Shipley, Inc. The York Power Steam -Pak is a precision piece of machinery and has been manufactured and designed with great care. The entire product is manufactured according to the most rigid specifications and by the most precise methods, and all component parts have been carefully engineered and mounted. The entire unit is carefully inspected and tested before it leaves the factory.

The same type of intelligent care should be taken in the application, the installation, the starting, the operation and the maintenance of the Steam-Pak unit. The function of this manual is to furnish detailed instructions to the service engineer in order to allow him to take this type of intel

ligent care. Properly applied, installed, started, operated and main

tained the Steam-Pak Generator will serve its user long and efficiently and will give complete satisfaction.

TABLE OF CONTENTS

Operation Test Pre-Start Up Inspection How To Find Part Numbers And Order Parts General Description

LOCATION OF BASIC ASSEMBLIES Light Oil . Gas . Combination Light Oil - Gas # 5 Heavy Oil # 6 Heavy Oil Combination Gas - #5 Heavy Oil Combination Gas - #6 Heavy Oil

BASIC BOILER ASSEMBLIES Boiler Tube Sizes Series 582 Low Pressure Series 588 Low Pressure Series 596 Low Pressure Series 582 Hot Water Series 588 Hot Water Series 582 High Pressure Series 588 High Pressure Series 596 High Pressure Series 5112 High Pressure

COMBUSTION CHAMBER

REFRACTORY ARRANGEMENTS Series 582 & 588 400 & 500 H.P. (157284) Series 588

Series 582 & 588 Series 588 Series 582 & 588 Series 588

Series 596

Series 596 Series 596

Series 5112

Series 5112 Series 5112

REAR COVER ASSEMBLY Series 582 Series 588 Series 596 Series 5112

600 H.P. (158609) Light Oil & Gas-Light Oil 400 & 500 H.P. (158606) 600 H.P. ( 158607) Gas 400 & 600 H.P. (158605) 600 H.P. ( 157757) Heavy Oil & Gas-Heavy 700 H.P. (157922) Light Oil & Gas-Light 700 H.P. (157923) Gas 700 H.P. (157811) Heavy Oil & Gas Heavy 850 H.P. (158405) Light Oil & Gas Light 850 H.P. (173222) Gas 850 H.P. (156144) Heavy Oil & Gas-Heavy

All ( l 7 4008) All (174023) All (173651) All (154781)

Oil

Oil

Oil

Oil

Oil

Combination

Combination

Combination

Combination

Combination

Combination

PAGE NO.

l 2 3 4

5 6 7 8 9

10 ll

13 14 16 18 20 22 24 26 28 30

32

35

35

35

36

36 37

37

38 38

39

41 42 43 44

FRONT COVER ASSEMBLY Series 582 Series 582 Series 588 Series 588 Series 596 Series 596 Series 5112 Series 5ll2

TABLE OF CONTENTS CONT 1 D

All Left Side (173997) All Right Side (173999) All Left Side (174028) All Right Side (174031) All Left Side (173673) All Right Side (173678) All Left Side (154480) All Right Side (154486)

CROSS SECTIONAL VIEW OF PUFF DOOR . GASKET - HANDHOLE MANHOLE . BOILER MAINTENANCE . . . CARE AND REPAIR OF WATER SIDE BOILER BOILER WATER, rt•s Treatment and Cautions

PAGE NO.

46 46 47 47 48 48 49 49

50 51 51 53 66

-

OPERATION TEST

A purchaser has the opportunity to either purchase a boiler as a fire-tested unit or a non-fire tested unit, depending on the intended use and the personnel available.

lolhen a unit is fire tested at York-Ship 1 ey' s factory, an operation test data sheet is permanently fastened to the inside of the control panel door, with the information as shown in the example below.

Teat IMfMdor - ----··---·------

You wi 11 notice in the upper right-hand corner, the boiler data information is shown, such as serial number, boiler number, etc. This data should always be used to identify a particular unit when requesting assistance and/or information from the Factory Service Department at York, PA . or other authorized service agencies.

Sene~ No.-----

STEA#MtAK Mod.! No. ··-----

loler Mf9-No.-----H. NO.------o ... - OPERAnON TEST FAINo. _______ __

1. o,_.hoft.l Sq. Ft. ---------A. low W•t.r c..toff ___ fto.d P-.. St..t ___ Stop ___ Wct.r Ructu.tloot .t HU1re --------

1. Loc.tion of l'rinwtry LW.C.O.--{¢ loll.r Couplift9 to¢ of low.r .,..,... ..tJ. -------C. Loc.tion of ~ry LW .C.O.--{¢ lloa.r Coup/'"'9 to w•t.rliM .....tOft ustlolg). ------

2. Type Combvmoft Coomol Do.. Coomol et..cl: Out----------Comp-wtor "A" V.M. __ T- 0peo1 fr-. dot.d po&ltioft • ....._ H..d ..ttlftt fNM tu.h --.- -'---

l . limit s.ttin91: On ___ Off ___ Type Noul.

G.t lutt.rtly- Notdt.o Of*l: Lo __ HI--·~ Air lutt...fly- NotcM. Open: Lo __ -·Hl __

5. S.f V 1v tt. 1TU U... 6. C.R- Checl: oty • e ting -Low Fl,. High Fire I~P· Oil GAS

St...., Pr .. ..,.. HI __ "-""" WWI.oo .._......, w-........

Fvel Pump P-..... co, -- - co, -- ,_. LO_ 4r.ft . .,.

Air Comp. P.....,..

Fvel R.te Cu. ft. fM" hr. Hi-fire Fv.l R•te G•ls. ,_ hr.

U..fire Oil T.mp. To NODI. G., P......,..e ot s.,.,.... 1•1 low Rre - - - -Pilot G .. p,....,... Ty~

(b) Mid fire R.-St.d. T.m,_otvr.-Got (c) Hi9h Rre

St.d. T em,...ot.,._oa

Noz:do O;f Prenuro

HIGH FIRE lOW FIRE IATW •· B.ctnc.l R .. d~

Fuel Water Ill ower Fuel Woter Blower ,_, Wofflr Blower

A Maton:-AMPS. 8

Blower c Fv.l AB

Compreuor VOLTS. BC W.t., PumF' CA

AMPS. H .. ton:- VOLTS

WATTS

7. Neme Pl.to Voltoqe Rotinq& on on Moton, Control& ond Tron&f«mer - -- - ------··---

8. Poroco;f Heoto< Aqueatot S.ttinq . .. ..... - · ---· ... .. - - - --·---- - ----- ------- ---

9. If on SPH Boilo~oin Food Wetor System & Poroco;f Hooter ond odd Anti..freozo .. - -- -----·

10. Time Unit wu~CTUALLY firinq ......... ______ .... , Time unit ••• on Teat Sto~ - ---- -

11. Food W•tor P-p Pipinq a..cl - - ·---·- , Food Wotor Pump ond Volt•«Je a..d. - ··--------12. Rom.orb __

- ----- ----

.. .................. --· ·-- ·-·--·--·----··------

·· ···-·- -·-· ·- -----·- -------------- -

--- ------ ... --·------·-- - - - - ----------,.. •no., .._ U«

- 1 -

PRE START UP INSPECTION

A St3rt-Up Form shown is supplied to each respective representative for his Pre-Start-Up Inspection as requ 1red by terms of existing contracts. The representative wi 11 forward the Form to the service agency, who in turn starts the equipment up and comp letes this Form.

The Form is then forwarded by the service agency to our Offices in York, PA for proper distribution and payment of start-up and service reserve monies. Accardi ng to our policy, this Form must be completed in its entirety, with signatures of the service personnel, customer and/or custodian affixed.

fOIM NO. 1404-1 PRE START UP INSPECTION

Addreo..d To _________________ Date ____________ _______ _

The installation of __________ installed at _______________ and identified by "H"

No. _ ______ hos Men inspected by me end the following points checked for completeness :

1. Voltage of _____ is connected to bailer 0 5. 8reeching connected to 1fack . .... ......•... ... 0 0 6.

0 7.

0 The fOfegoing has been checked by me this dote of ___________ and for this reason tho! startup should be perform..:!.

~gned ____________________ _

START UP FORM FOR INDUSTRIAL EQUIPMENT

Zone Number __________ Oate ___________ Unit Model No.

Serial Number _________ Type Fuel Uoed ______ ___ Voltage, Freq, Phase-----------

Install..:! at _______________ Addreii ____ _______ Oty _________ _

Type Pilot, El..:tric __________ Gao & Btu/cu. ft. _________ light Oil _____ ___ _

Installation Appearance, Dirty 0. Completed 0. Incomplete 0. Temporary Heat 0. REMARKS, _ _________________________________________ __

OPERATION CHECK DATA

High fire Octo Check Poinh

low Fire Data

Gas Oil Goo Oil =========9~~~~===· ~ •·o-~-·-~-~==~==~·==·=Fo----·-~. ==~=~

I. Stod. Temperature- Net f .

2. Breechino COr - •;.

3. Trans. Oil Pres.- lbo.

4 . Nonie Air Pres. - lbs.

5 . Noule Oil Temp.- °F.

6 . Pilot Goo Prell.- ln. H,O

7. Main Gas Preu.- ln . H,O

8. Goo Rate - cu./ft ./hr.

9 . Pump Suction Vacuum

10. Safety Shut Of! Time

Fireye D.C. II Type Combustion Control ___ Control Test Voltage __ Ignition Timing __ Main Flame Cut Off Time _ _

I 2 Has Custodian Been lnstrvcted? 0 Yes, 0 No, Custodian's Signuture _ ___ _

13 . Customer Remarks : ____________________________________ =

1~ . Signature ____ _________ , Dote __________ __

Cw•to•..-

15. ~gnature ____________ =, Dote _____ ___ _

RETURN AU. COPIES TO YORK-SHIPLEY, INC., YORK, PA. FOR START UP PAYMENT

- 2 -

-

HOW TO FIND PART NUMBERS

Since this manual consists of several sections, each section has a Table of Contents.

If a part of the Basic Boiler is needed:

1. Locate the size of Unit and Page No. where basic boiler is shown. 2. Locate part from Parts List shown on basic boiler. 3. If parts for refractory arrangement, front cover, rear cover, peep sight,

handhole or manhole or manhole gaskets are needed, see proper sheet.

If a part of the burner and blower arrangement is needed. (See Service Manual Burner Section ID-65-452).

l. Locate the page where the burner and blower arrangement for the boiler in question is shown.

2. Locate part from Parts List. 3. Nozzle & Electrode Assembly or Ignitor Assembly are located in this section

and individual parts are shown on those sheets. 4. Compressor arrangement, fuel oil pump set arrangements, steam oil pre

heater arrangement, hot water oil pre-heater arrangement and electric heater arrangement and parts are shown in heavy oil burner section only.

If a part of the Aqua-temp arrangement is needed.

l. Section of Aqua-temp shows parts and arrangement numbers.

Parts that are not called for on any arrangements, such as, blower motor and fuel pump etc . order as per assembly number which is shown on burner and blower arrangement. Specify motor nameplate information and fuel pump number.

HOW TO ORDER PARTS

l. Specify serial number and model number. 2. For individual parts such as Electrical Components, specify electrical

characteristics, along with Serial Number and Model Number.

MODEL EXPLANATION

York-Shipley boilers are designated by letters and numbers to explain their Models - 582 Series & 588 Series. The "5" stands for 5 sq. ft. per developed H.P. The 82 & 88 stands for the diameter of the boiler shell in inches.

Series 582 - 400 H.P. Series 588 - 500 H.P. & 600 H.P. Series 596 - 700 H.P. Series 5112 850 H.P.

582 SPLC 400 I I

Basic Unit Design I

Horsepower

SPLC - Low Pressure 15 P.S.I. 400- 850 SPHC - High Pressure 150 P.S.I. SPWC -Hot Water 30 P.S.I.

- 3 -

N6 1

Fuel

2 #2 Light Oil 5 #5 Heavy Oil 6 #6 Heavy Oil N - Gas N2 -Gas -Light Oil N5 -Gas - #5 Heavy Oil N6 -Gas - #6 Heavy Oil

0 .l N es1gn o.

GENERAL DESCRIPTION

The general information in this Manual is directtly applicable to YorkShipley's 582, 588, 596 & 5112 Series Boilers in sizes from 400 to 850 H.P., and Burner Assemblies for gas, oil and combination gas/oil to operate on one fuel and change to another fuel, either manually or automatically by the use of switches.

The boiler is manufactured by York-Shipley, Inc. under the Steam-Pak Trade Name. It is a three-pass construction, with two tube passes and one firing tube pass. The combustion is completed in the center firing tube. Air is furnished by a Forced-Draft Blower to complete combustion and force the gas to the vent on the rear of the boiler. With modulation, or equivalent, the rate of combustion varies as to the load on the boiler. This modulating motor is connected to a damper on the air blower and fuel valve to accomplish variation. The blower is direct-connected to the fan wheel.

The Burner and Controls are varied and can be arranged to meet all owner/ engineer and Code requirements. The Burner assemblies cover standard control systems and parts. Gas-electric ignition is standard on all models.

One Manual is supplied with each unit shipped from York, PA. Replacements are available for a nominal fee. Requisition same from Advertising & Sales Promotion Manager, York-Shipley, Inc., P. 0. Box 349, York PA, 17405.

All oil burners are low pressure air atomized with a separate driven air compressor and fuel oil pump. The oil pump on #6 on units is manually controlled to maintain heated oil in the system. The panels are located for ease of maintenance and adjustment and are away from all heat of the boiler.

All burners are equipped with flame failure devices, to provide shutdown of the flame when necessary. Pre-purge and post-purge are used, to purge boiler of vapor and other gases. Controls to operate steam pressure, water temperature and water line are placed on the boiler as needed.

- 4 -

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mounting

Nozzle Assembly

Ignition System

l inkage

BURNER ASSEMBLY

LOCATION OF BASIC ASSEMBLIES

location of Basic Assemblies are shown on this photo

graph to enable a person to quickly locate the Part, Service

or Maintenance information he requires .

BOILER ASSEMBLY

Main Parts

Boiler-Tubes

Front Cover

Rear Covers

Jacket

Insulation

Manhole-Handholes

Combustion Chamber-

Target

Rear Refractory-Baffle

Base

BLOWER ASSEMBLY

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gauges

COMPRESSOR ARRANGEMENT

Motor

Compressor

Lubrication System

Drives

FUEL OIL PUMP

Pump

Motor

Drives

Gauges

Valves

liGHT Oil-All SIZES

OPTIONAL AQUA-TEMP ASSEMBLY

!Hot Water Only)

Valve Assemby

Diffuser

Anti-Shock Control

Wiring

BASIC BOILER ASSEMBLY

L

- 5 -

FUEL OIL PUMP ARRANGEMENT

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-¥otor

Wiring

Mounting

Ignitor Assembly

Ignition System

linkage

BURNER ASSEMBLY




or Maintenance information he requires.

BOILER ASSEMBLY

Main Parts

Boiler-Tubes

Front Cover

Rear Cover

Jacket

Insulation

Manhole-Hand holes

Combustion Chamber-

Target


Base

ASSEMBLY

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gauges

TRIM ASSEMBLY

GAS--ALL SIZES


!Hot Water Only)

Valve Assembly

Diffuser

Anti-Shock Control

Wiring


j

- 6 -

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mounting

Nozzle Assembly

Ignition System

linkage

BURNER--+ ASSEMBLY

COMBINATJON LIGHT OIL-GAS-All SIZES





BOILER ASSEMBLY

Main Parts

Boiler-Tubes

Front Cover

Rear Cover

Jacket

Insulation

Manhole-Handholes

Combustion Chamber-

Target


Base

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gauges


Motor

Compressor

lubrication System

Drives

FUEL OIL PUMP

Pump

Motor

Drives

Gauges


(Hot Water Only)

Valve Assembly

Diffuser

Anti-Shock Control

Wiring

BASIC ASSEMBLY

NOTE: Vent Valve for 300 H.P. & larger

COMPRESSOR ARRANGEMENT---t

- 7 -

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mounting

Nozzle Assembly

Ignition System

Linkage

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gouges

ASSEMBLY


location of Basic Assemblies ore shown on this photo

graph to enable a person to quickly locate the Port, Service


BOILER ASSEMBLY

Main Parts

Boiler-Tubes

Front Cover

Rear Cover

Jacket

Insulation

Monhole-Hondholes

Combustion Chamber-

Target


Bose

BLOWER ASSEMBLY

/ TRIM


Motor

Compressor

Lubrication System

Drives

ELECTRIC HEATER

Heater

Switches

FUEL OIL PUMP

Pump

Motor

Drives

Gouges

#5 HEAVY Oll-#5


!Hot Water Only)

Valve Assembly

Diffuser

Anti -Shock Control

Wiring

BURNER FUEL OIL PIPING

Strainer

Valves

Gauges

BASIC ASSEMBLY

ElECTRIC HEATER APPLIES ONLY TO

~ 6 FUEL OIL

COMPRESSOR ARRANGEMENT----4

- 8 -

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mounting

Nozzle Assembly

Ignition System

Linkage

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gauges

BURNER ASSEMBLY


Location of Basic Assemblies are shown on this photo


or Maintenance information he requires .

BOILER ASSEMBLY COMPRESSOR

Main Parts ARRANGEMENT

Boiler-Tubes Motor

Front Cover Compressor

Rear Cover Lubrication System

Jacket Drives

Insulation ELECTRIC HEATER Manhole-Handholes

Heater Combustion Chamber-

Switches Target

Rear Refractory-Baffle FUEL OIL PUMP Base Pump

Motor

Drives

Gauges

Valves BLOWER ASSEMBLY

/ TRIM

ELECTRIC HEATER

- 9 -

#6 HEAVY OIL-#6


!Hot Water Only)

Valve Assembly

Diffuser

Anti -Shock Control

Wiring


Strainer

Valves

Gauges

FUEL OIL HEATER

Heater

Mounting of Controls

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mount ing

Nozzle Assembly

Ignition System

Lin kage

TRIM ASSEMBLY

Safety Va lves

Safety Controls

Water Gouges

BURNER

ASSEMBLY~

CO MBINATIO N GAS-# 5 HEAVY OIL

LOCATION OF BASIC ASSEMBLIES AND ARRANGEMENTS

Th e location of the Basic Assemb lies are shown on this

ph o tograph to enable a person to quickly locate the part,

service or maintenance informa t ion he requires.

BO ILER ASSEMBLY

Main Parts

Bo il er-Tubes

Fron t Cover

Rear Cover

Jacket

Insu lation

M a nhole-Handholes

Combustion Chamber-

Target


Ba se


Motor

Compressor

Lubrication System

Drives

ELECTRIC HEATER

Heater

Switches

FUEl OIL PUMP

Pump

Motor

Drives

Gauges

Valves

BLOWER A SSEMBLY

~ TRIM ASSEMBLY

BASIC BOILER

J

APPLIES ONLY TO

" 6 FUEL OIL

OPTIONAL AQUA-TEMP ASSEMBLY !Hot Water Only)

Valve Assembly

Diffuser

Anti-Shock Control

Wiring

ASSEM BLY

COMPRESSOR ARRANGEMENT--?

- 10 -

BURNER ASSEMBLY

Main Parts

Controls

Burner Fan-Motor

Wiring

Mounting

Nozzle Assembly

Ignition System

linkage

TRIM ASSEMBLY

Safety Valves

Safety Controls

Water Gauges

BURNER

COMBINATION GAS-#6 HEAVY OIL

LOCATION OF BASIC ASSEMBLIES AND ARRANGEMENTS

The location of the basic assemblies are shown on this

drawing to enable a person to quickly locate the part,

service or maintenance information he requires.

BOILER ASSEMBLY

Main Parts

Boiler-Tubes

Front Cover

Rear Cover

Jacket

Insulation

Manhole-Handholes

Combustion Chamber-

Target


Base


Motor

Compressor

lubrication System

Drives

ELECTRIC HEATER

Heater

Switches

FUEL OIL PUMP

Pump

Motor

Drives

Gauges

Valves BLOWER ASSEMBLY

~ TRIM ASSEMBLY

ELECTRIC HEATER

COMPRESSOR

- 11 -


!Hot Water Only) Valve Assembly

Diffuser

Anti-Shock Control

Wiring


Strainer

Valves

Gauges

FUEL OIL HEATER

Heater

Mounting of Controls

ASSEMBLY

BASIC BOILER ASSEMBLIES

This section contains information on High Pressure, low

Pressure and Hot Water Basic Boiler assemblies. The Hot

Water Boiler has the addition of an Aqua-Temp Control

and Diffuser Tube Arrangement. Steam Boilers over 150

P.S.I ., and Hot Water Boilers over 160 P.S.I. or 250 " F, must

be built in accordance with the power boiler section (Sec

tion I) of the A.S.M.E. Boiler Code, which requires x-raying

of certain welded joints and be completely annealed.

The basic six boiler assemblies attached, and as listed

on the Parts list, include the following Assemblies which

will be described in detail. Refractory Arrangements

Rear Cover Assembly

Front Cover Peep Sight-Explosion Door

gaskets-Manhole

gaskets-Handhole

gaskets-Rear Cover

gaskets-Front Cover

- 12 -

-

PART NO.

114191

116696

129352

155179

BOILER TUBE SIZES

SIZE

2-l/2" O.D. x 207-9/16" (.105" Wall)

2-l/2" O.D. x 249-9/16" (.105" Wall)

2/l/2" O.D. x 247-9/16" (.105" Wall)

3" O.D. x 245-9/16" ( .105" Wall)

LENGTH SHOWN INCLUDES APPROXIMATELY 2" ALLOWABLE FOR CUTTING TO REQUIRED LENGTH AT ASSEMBLY.

- 13 -

_ LDO!Irl NJTf.IDS AS.~Nf/1-""t' ,_, IOU,.,..,. ,..,~r ,.,.,.,.


SERIES 582 LOW PRESSURE

llt'.~,lf.STI'N..,.,. ~.., ,., 7N.It!ID ,llllta.S.S ~Yilt A.ATC

When drawing or part number lists more than one item specify item desired.

- 14 -

BASIC BOILER ASSEMBLY PARTS LIST

Ref. No.

2 3 4 5 6 7 8 9

10 11

12 13 14 15 16 •17 '18 19 20 21 22 23 24 25 25A 26 27 28 29 30 31 32 33 34 35 36 37

38 39

40

41 42 43 44 45

46 47 48 49 50 51 52


No. Rqd.

1 1 1 1

175

45 21 21 2

252" 2

24 12

1

1 1

20 20

1 12 12 1 1 1 1 1 1 1 1 1 1

38 420"

6 1 2 2 1 3 3

29 12

2 2 2 3

205"·

1 1

950= 1 1 7 1

Part Name

Boiler Fabrication Assembly Front Tube Sheet Rear Tube Sheet Furnace Tube Boiler Tubes (Refer to page 13) for Boiler Tube Size)

Front & Rear Cover Studs Nut, Hex., Brass, 5/8" llNC-2 Washer, Plain, 3/4" Third Pass Cover Plate Rope, l/2" (Third Pass) Rear Cover Clamp Assembly Nut, Hex., Cad Plated, l/2" l3NC-2 Washer, Lock, Int-Ext, 1 /2" Rear Cover Assembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 380 Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Flat, 5/8" Nut, Hex ., Cad Plated, 5/8" llNC-2 Inspection Cover Nut, Hex., Cad Plated, 1/2" l3NC-2 Washer, Flat, l/2" Top Panel 1st Section Top Panel 2nd Section Top Panel 3rd Section Right lst Casing Panel Left lst Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 3rd Casing Panel Right 5th Casing Panel Left 5th Casing Panel Spacer Insulation 2" x 3" x 48" Rope, l"Diameter (Front Cover) Ring, Handhole Insulation Retaining Rope Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex., Cad Plated, 3/8" l6NC-2 Washer, Lock, I nt-Ext, 3/8" Strap (Signoid) 5/8" x .020 Thick x 120Ft . Lg., Galvanized & Waxed Clip (Signoid ) 5/ 8" Screw, i:lQ, Rd. Hd., Type "A", 1/2" Lg. Screw, Cap, Hex. Hd . , 1-1 /8 " 7NC x 5-1 / 2" Lg. Nut, Hex., 1-1/8" 7NC Washer, Plain, 1-1 /8 " 7NC Cover Clamps Left 3rd & Right & Left 4th Casing Rope, 1" Diameter Single Braided Fiberglass, #360-AAA Grade Glass, Peepsight Gasket, Peepsight Plicast 24 LWI-24 Washer, Peepsight Gas ket, Peepsight Insulating Block #EC-350 Hinge Assembly (Rear Cover)

- 15 -

400 (178625) Part No.

178622 178620 178621 158014 114191

91974 53691

105153 173996 53754

117901 53689

108170 174008 100774

173997 173999 105152 105146 21139 53689

105151 178623 178624 114304 174003 174004 174005 174006 174007 126429 126430 107690 53755

151353 151544 158668 117979 111278 53682 57432

102875

52348 105164

105145

105148 105154 137284 126427 107790

78522 78521

107823 121012 84330

106726 173987

·:~

1 +

I I

LO(ATf '2-4 5'!ur:'" A! ~._,Q~IN

~0~ fA~T t"41f'46 (~CA-l, (OVL~


SERIES 588

(A~I\G

ll.£n;~ACTO~

'!)'ECl'IOH

LOW PRESSURE

OPliONAL fA~1f."''I~4C.

AR" 'c.l fOR THI~O PA~!a (DVtl'\. PLJ..1 L

LOc..AH., ~i ... r~ A~ !> .. :.;·,..· •~

*~ LOCAlf 1'2. :STUD.) A~ ~HQV,.., fOtl "THIRO PA>> CCN!R PLATfS , (~11~N1 PDP! TO !NO 0' ~HI:.LL

().- - . "-t.L rJ. ~T( f'. <"- (·

ARP (.'- fOP ~ (.J.. A. C.Ovt. · •~

""CR. r.A ~":' ft-. ' t.JC. A[_ .l.~:; c::;-.•c.. a ,..~5"!


16 -

~f(T~N

Of P££P '16t4T 0



500 600 Ref. No. (178683) (178670) No. Rqd. Part Name Part No. Part No.

1 Boiler Fabrication Assembly 178682 178669 1 Front Tube Sheet 178664 178664 1 Rear Tube Sheet 178665 178665 1 Furnace Tube 158014 159333

223 Boiler Tubes (Refer to page 13 114191 116696 for Boiler Tube Size)

2 45 Front & Rear Cover Studs 91974 91974 3 21 Nut, Hex., Brass, 5/8" llNC-2 53691 53691 4 21 \lasher, Plain, 3/4" 105153 105153 5 2 Third Pass Cover Plate 174036 174036 6 275" Rope, 1/2" (Third Pass) 53754 53754 7 2 Rear Cover Clamp Assembly 114769 114769 8 10 Nut, Hex., Brass, 1/2" 13NC-2 53687 53687 9 10 Washer, Lock, Int-Ext, 1/2" 108170 108170

10 1 Rear Cover Assembly 174023 174023 11 Insulation 2" Thick Fiberglass, 390 Sq. Ft. 455 Sq. Ft

Type All Rangewool 100774 100774 12 1 Front Cover Assembly - Left 174028 174028 13 1 Front Cover Assembly - Right 174031 174031 14 45 Washer, Lock, lnt-Ext, 5/8" 109220 109220 15 21 Nut, Hex., Brass, 5/8" llNC-2 53691 53691 16 1 Inspection Cover 21139 21139

·17 16 Nut, Hex. Cad. Plated, 1/2" 13NC-2 53689 53689 18 12 Washer, Flat, 1/2" 105151 105151 19 1 Top Panel 1st Section 178623 178623 20 1 Top Panel 2nd Section 178667 178667 21 1 Top Panel 3rd Section 178707 116955 22 1 Right 1st Casing Panel 174039 174039 23 1 Left 1st Casing Panel 174040 174040 24 1 Right 2nd Casing Panel 174041 174041 25 1 Left 2nd Casing Panel 174043 174043 26 1 Right 5th Casing Panel 126437 126436

1 Right 6th Casing Panel 126437 27 1 Left 5th Casing Panel 126439 126436

1 Left 6th Casing Panel 126439 28 Spacer Insulation 2" x 3" x 48" (40) 107690 (46) 107690 29 468" Rope, 1 "Diameter (Front Cover) 53755 53755 30 6 Ring, Handhole Insulation Retaining 151353 151353 31 1 Rope Retaining Arrangement 149079 149079 32 2 Hinge Assembly - Front Cover 158668 158668 33 2 Casing End Cover 114380 114380 34 1 Sealing Strip Clip 111278 111278 35 Nut, Hex., Cad. Plated, 3/8" 16NC -2 (4) 53682 ( 3) 53682 36 Washer, Lock, lnt-Ext, 3/8" (4) 57432 ( 3) 57432 37 Strap (Signoid) 5/8" x .020 Thick x 200 Ft. Lg. 240 Ft. Lg.

Galvanized & Waxed 102875 102875 38 Clip (Signoid) 5/8" (29) 52348 (35) 52348 39 12 Screw, •10, Rd. Hd., Type "A", 105164 105164

1/ 2" Lg. 40 Screw, Cap, Hex. Hd., 1-1/8" 7NC X 105145 105145

5-1 / 2" Lg. 41 2 Nut, Hex., 1-1/8" 7NC 105148 105148 42 2 Washer, Plain, 1-1 / 8" 7NC 105154 105154 43 2 Cover Clamps 137284 137284

2 Cover Clamps 144232 144232 44 3 Left 3rd & Right & Left 4th Casing 126436 126436

1 Right 3rd Casing Panel 184568 178666 45 1 Hinge Assembly (Rear Cover) 174037 174037 46 1 Hinge Ring 155562 155562 47 2 Rod 91974 91974 48 12 Nut, Hex., Cad. Plated, 1/2" 13NC-2 53698 53689 49 24 Nut, rlex., Cad. Plated, 5/8" 11 NC-2 105146 105146 50 1 Washer, Peepsight 121012 121012 51 1 Glass, Peepsight 78522 78522 52 1 Gasket, Peepsight 78521 78521 53 1 Gasket, Peepsight 84330 84330 54 214" • Rope, 1" Diameter Single Braided 107790 107790

riberglass, ~360-AAA Grade 55 7 Insulating Block NEC-350 106726 106726 56 1012• Plicast 24 Llll-24 107823 107823 57 2 Washer, Square 141375 141375

- 17 -

LO""....CJ'f JruQ!AS su..~ r()IP ,~,Vl(j ~«tNT :.~1!



OPTIC.'.AL FA::, rt: w~ APR tiT /"'?~- Pf~ C ;va<

-=~ l

OPTJONA(. FAJ Tff'IIN6 Art c;l r~ "'{:JJt~D A05S 'tO.U ~ATl


- 18 -

LOCifrf S"1UO.S AS .5H()I;w.l 'i'.J- TUIIID .A'tJ.S (l.;V~€ Pti:!Tl.S ClM&tr R~'-'C 70 ~tJO C" ~L(.

-



Ref. No. No. Rqd.

2 3 4 5 6 7 8 9

10 11

12 13 14 15 16 17

,,8 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

38 39

40

41 42 43

44

45 46 47 48 49 50 51 52 53 54

l l l l

265

45 21 21 2

360" 2

12 12 l

l l

26 26 l

16 16 l l l l l l l l l

52 550"

6 l 2 2 l 3 3

41 12

2 2 2 2 5

l l l 2 2 6

1400# l l l l

Part Name

Boiler Fabrication Assembly Front Tube Sheet Rear Tube Sheet Furnace Tube Boiler Tubes (Refer to page 13 for Boiler Tube Size)

Front & Rear Cover Studs Nut, Hex., Brass, 5/8" llNC-2 Washer, Plain, 3/ 4" Third Pass Cover Plate Rope, l/2"(Third Pass) Rear Cover Clamp Assembly Nut, Hex., Cad. Plated, l/2" l3NC-2 Washer, Lock, Int-Ext, l/2" Rear Cover A~sembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 380 Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Flat, 5/ 8" Nut, Hex. , Cad. Plated, 5/8" llNC-2 Inspection Cover Nut, Hex., Cad. Plated, l/2" l3NC-2 Washer, Flat, l/2" Top Panel lst Section Top Panel 2nd Section Top Panel 3rd Section Right lst Casing Panel Left lst Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 6th Casing Panel Left 6th Casing Panel Spacer Insulation 2" x 3" x 48" Rope, l"Diameter (Front Cover) Ring, Handhole Insulation Retaining Rope, Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex., Cad. Plated 3/8" l6NC -2 Washer, Lock, Int-Ext, 3/8" Strap (Signoid) 5/8" x .020 Thick x 300Ft . , Galvanized & Waxed Clip (Signoid) 5/ 8" Screw, #10, Rd. Hd., Type "A", l / 2" Lg. Screw, Cap, Hex. Hd., l-l/8" 7NC x 5-l/2" Lg. Nut, Hex., l - l / 8" 7NC Washer, Plain, l-l/8" 7NC Cover Clamps Cover Clamps Left 3rd & Right & Left 4th & 5th Casing Panel Right 3rd Casing Panel Hinge Assembly (Rear Cover) Hinge Ring Rod Washer, Square Insulating Block #EC-350 Plicast 24 LWI-24 Washer, Peepsight Glass, Peepsight Gasket, Peepsight Gasket, Peepsight

- 19 -

700 (178684) Part No.

178685 178686 178687 159156 129352

91974 53691

105153 173682 53754

129405 53689

108170 173651 100774

173673 173678 105152 105146 21139 53689

105151 178688 178689 180959 173660 173662 173664 173666 129397 129398 107690 53755

151353 149368 155556 141521 111278 53682 57432

102875

52348 105164

105145

105148 105154 137284 144232 129395

173671 173668 155562 91974

141375 106726 107823 121012 78522 78521 84330


SERIES 582 HOT WATER

~ .... ,"" ... ~ 'ltr1'r,.... .tU,., l'tA TNt~ -..u CDC• l!fCA'I

t.OCGTt nuos o1t1 ~'M ~'~OMJJ (Oit(~ "'•'fl ,,,..,.,, II(;'( "VCJoiJCJ'-""<U

- - ~

I

\'\,. I / rn (Wll'ft()lii(L ,..,.rv-...

"'OTt.· A..-01'. ~ .ftAII Ct>IUI "''t06t .._ .....,. C' UM CCI'W't:« AC .. Q"r. /#llJ47.

L.f)Otrr. fn.K IIJ J~

~ "'IlS'"'-" N. ..... c~•v• .. ss..,.


- 20 -



Ref. No. No. Rqd.

2 3 4 5 6 7 8 9

10 11

12 13 14 15 16

,17 ·18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

38 39

40

41 42

43 44 45

46 47 48 49 50 51 52 53

1 l 1 l

175

45 21 21 2

252" 2

14

1 l

24 24

l 12 12 1 1 1 1 l l l 1 1

38 420"

6 l 2 2 l 3 3

29 12

1 2 2 2 3

205"

1 1

95Q:i 1 l 6 1 2

Part Name


Front & Rear Cover Studs Nut, Hex., Brass, 5/8" llNC-2 Washer, Plain, 3/4" Third Pass Cover Plate Rope, l/2"(Third Pass) Rear Cover Clamp Assembly Nut, Hex., Brass, 1/2" l3NC-2

400 ( 184054) Part No.

184050 178620 185055 158014 114191

91974 53691

105153 173996 53754

117901 53687

Rear Cover Assembly 174008 Insulation 2" Thick Fiberglass, Type 100774 AW Rangewool, 380 Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Flat, 5/8" Nut, Hex., Cad Plated, 5/8" llNC-2 Inspection Cover Nut, Hex., Cad Plated, 1/2" 13NC-2 Washer, Flat, 1/2" Top Panel lst Section Top Panel 2nd Section Top Panel 3rd Section Right lst Casing Panel Left lst Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 5th Casing Panel Left 5th Casing Panel Spacer Insulation 2" x 3" x 48" Rope, l" Diameter (Front Cover) Ring, Handhole Insulation Retaining Rope Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex ., Cad Plated, 3/8" l6NC-2 Washer, Lock, Int-Ext, 3/8" Strap (Signoid) 5/8" x .020 Thick x 120Ft. Lg., Galvanized & Waxed Clip (Signoid) 5/8" Screw, #10, Rd. Hd., Type "A" 1/ 2" Lg. Screw, Cap, Hex . Hd., 1-1/8" 7NC x 5-1 / 2" Lg. Nut, Hex ., 1-1/8" 7NC Washer, Square Washer, Plain, 1-l / 8" 7NC Cover Clamps Left 3rd & Right & Left 4th Casing Rope, 1" Diameter Single Braided Fiberglass, #360-AAA Grade Glass, Peepsight Gasket, Peepsight Plicast 24 LWI-24 Washer, Peepsight Gasket, Peepsight Insulating Block #EC-350 Hinge Assembly (Rear Cover) Hinge Ring

- 21 -

173997 173999 105152 105146 21139 53689

l 05151 185196 116501 116502 174003 174004 185692 174006 126429 126430 107690 53755

151353 151544 158668 117979 111278 53682 57432

l 02875

52348 105164

105145

105148 141375 105154 137284 126427 107790

78522 78521

107823 121012 84330

106726 173987 155562

#

I +

I

Jl L ~};; '-

LOCATE 24 STUDS AS SHOWN FASTENING FRONT COVER

FOR


SERIES 588

CA~I\G

OPTIONAL FASTENING

HOT WATER

OP110NAL fA!l1f.NilriC. AI\~(;T FOR. THIRD PAS~ (OVV~. PLA' f.

ARRG'T FOR REAR COVER


- 22 -

~'~ I.OCAlt. l'l ~TUO' ,.., 3HOIIJ .. , fOil THIRD AA~5 to.ILR PLAT~ C~MtNT P.OPl TO .I:ND or :l+lf.LI.

ASSY

~CTIOiJ

Of P£EP51~f 0


Ref. No.

2 3 4 5 6 7 8 9

10 11

12 13 14 15 16

f 17 . 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

38 39

40

41 42

43 44 45 46 47 48 49 50 51 52 53 54

55 56


No. Rqd.

1 1 1 2

223

45 2

21 2

275" 2

10 10 1

1 1

45 21

1 2

12 1 1 1 1 1 1 1 1 1

40 465"

6 1 2 2 1 3 3

29 12

2 2 2 2 2 1 2

12 24

1 1 1 1

214"

7 950#

Part Name


Front & Rear Cover Studs Right & Left 4th Casing Panel Washer, Plain, 3/4" Third Pass Cover Plate Rope, 1/2"(Third Pass) Rear Cover Clamp Assembly Nut, Hex., Brass, 1/2" 13NC-2 Washer, Lock, Int-Ext, 1/2" Rear Cover Assembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 390 Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Lock, Int-Ext, 5/8" Nut, Hex., Brass, 5/8" llNC-2 Inspection Cover Right & Left 3rd Casing Panel Washer, Flat, 1/2" Top Panel 1st Section Top Panel 2nd Section Top Panel 3rd Section Right 1st Casing Panel Left lst Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 5th Casing Panel Left 5th Casing Panel Spacer Insulation 2" x 3" x 48" Rope, 1" Diameter (Front Cover) Ring, Handhole Insulation Retaining Rope Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex., Cad Plated, 3/8" 16NC-2 Washer, Lock, I nt-Ext, 3/ 8" Strap (Signoid) 5/8" x .020 Thick x 120Ft. Lg., Galvanized & Waxed Clip (Signoid) 5/ 8" Screw, #10, Rd . Hd., Type "A", 1 /2" Lg. Screw, Cap, Hex . Hd., 1-1/8" 7NC x 5-1/2" Lg. Nut, Hex., 1-1 /8" 7NC Washer, Square Washer, Plain, 1-1/8" 7NC Cover Clamps Cover Clamps Hinge Assembly (Rear Cover) Hinge Ring

Nut, Hex., Cad Plated, 1/2" 13NC-2 Nut, Hex., Cad Plated, 5/8" llNC-2 Washer, Peepsight Glass, Peepsight Gasket, Peepsight Gasket, Peepsight Rope, l" Diameter Single Braided Fiberglass, #360-AAA Grade Insulating Block #EC-350 Plicast 24 LWI -24

- 23 -

500 (185077) Part No.

185136 178664 185185 158014 114191

91974 186005 105153 174036 53754

114769 53687

108170 174023 100774

174028 174031 109220 53691 21139

186001 105151 185950 185951 185952 174039 174040 185999 186004 126437 126439 107690 53755

151353 149079 158668 114380 111278 53682 57432

102875

52348 105164

105145

105148 141375 105154 137284 144232 1740375 155562

53689 105146 121012 78522 78521 84330

107790

106726 107823

uun l.b-PIJDS M JutJ/tt#lt I"Coot "'"' ro-re Fe:Jitff CDC"e.


SERIES 582 HIGH PRESSURE

---~ f'IU'PNHIIO u•t'T f"'ta rNt~D Mt.S c»>IIU AATI

LOC 4T l rz 1'n.OS RS ~'Of r'NIIlQ ,..,._, cowor• PtA~ CE"'UUIr ~ 70 bi/JO' ,J,NC....L

.... s@:;;::: ()PT'()NAL '.U~

,.,.,_. ~7 f"'M 1;1(.¥ '""'~" ~ ,_ IWIT C' ~U• C'Ot'!.: ...... T N·/114~

LOCitr t ' -5 Tl.Of 4 J !Udlltlf ~ ~rtNINQ ~44

C0\'~4 IUS'Y'


- 24 -

Ref. No.

2 3 4 5 6 7 B 9

10 11

12 13 14 15 16

·17 lB 19 20 21 22 23 24 25 26 27 2B 29 30 31 32 33 34 35 36 37

3B 39

40

41 42 43 44 45

46 47 4B 49 50 51 52 53 54



No. Rqd.

1 1 1 1

175

43 22 22 2

252" 2

24 14

1

1 1

21 21

1 12 12

1 1 1 1 1 1 1 1 1

3B 420"

6 1 2 2 1 3 3

29 12

2 2 2 3

205"

1 1

95011 1 1 6 1 1 2

Part Name


Front & Rear Cover Studs Nut, Hex., Brass, 5/B" llNC-2 Washer, Plain, 3/4" Third Pass Cover Plate Rope, l/2"(Third Pass) Rear Cover Clamp Assembly Nut, Hex., Cad Plated, 1/2" 13NC-2 Washer, Lock, Int-Ext, 1/2" Rear Cover Assembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 3BO Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Lock, I nt-Ext, 5/B" Nut, Hex., Brass, 5/B" llNC-2 Inspection Cover Nut, Hex., Cad Plated, 1/2" 13NC-2 Washer, Flat, 1/2" Top Panel 1st Section Top Panel 2nd Section Top Panel 3rd Section Right 1st Casing Panel Left 1st Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 5th Casing Panel Left 5th Casing Panel Spacer Insulation 2" x 3" x 4B" Rope, 1" Diameter (Front Cover) Ring, Handhole Insulation Retaining Rope Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex., Cad Plated, 3/B" 16NC-2 Washer, Lock, Int-Ext, 3/B" Strap (Signoid) 5/B" x .020 Thick x 120Ft. Lg., Galvanized & Waxed Clip (Signoid) 5/B" Screw, #10, Rd. Hd., Type "A", 1/2" Lg. Screw, Cap, Hex. Hd., 1-1/B" 7NC x 5-1/2" Lg. Nut, Hex., 1-1/B" 7NC Washer, Plain, 1-1/B" 7NC Cover Clamps Left 3rd & Right & Left 4th Casing Rope, 1" Diameter Single Braided Fiberglass, #360-AAA Grade Glass, Peepsight Gasket, Peepsight Plicast 24 LWI-24 Washer, Peepsight Gasket, Peepsight Insulating Block #EC-350 Hinge Assembly (Rear Cover) Right 3rd Casing Panel Washer, Square

- 25 -

400 (173995) Part No.

173976 173980 173990 173977 114191

91974 53691

105153 173996 53754

117901 536B9

108170 17400B 100774

173997 173999 109220

53691 21139 536B9

105151 174001 174002 114304 174003 174004 174005 174006 126429 126430 107690 53755

151353 151544 15B668 117979 11127B

536B2 57432

102B75

5234B 105164

105145

10514B 105154 137284 126427 107790

78522 78521

107823 121012 84330

106726 173987 174007 141375

I

~

I +

I

I I I

' 1"1 "_L_ ----,______ - - _ _l

.L LOCATE 24 STUDS AS SHOWN FOR FASTENING FRONT COVER



11EF11AC TO~Y :,ECTION

0

OPTIONAL FASTENING ARRG 1 T FOR REAR COVER

OP1'10Nj.L fA!:iE.~I).IG

AR!\.(,T FOR THIRD PA~~ (O'Jf.r't PLJ..~ L

-lf'i i..OCAlf. 11 :STUD~ A~ ~HO\LJN, fOit THIRD PA~5 CCN.r;R. PL..A.Tf~

C~M!N'T ROPl TO t.ND Of ~Hf...LL

LOCATE 9 STUDS AS SHOWN FOR FASTENING REAR COVER ASSY


- 26 -

SfCTlOJrJ OF P£EPSI~T

0



500 600 Ref. No. {174022) {174060) No. Rqd. Part Name Part No. Part No.

1 Boiler Fabrication Assembly 174044 174061 1 Front Tube Sheet 174046 174046 1 Rear Tube Sheet 174045 174045 1 Furnace Tube 173977 173977

223 Boiler Tubes {Refer to page 13 114191 116696 for Boiler Tube Size)

2 45 Front & Rear Cover Studs 91974 91974 3 3 Left 3rd, Right & Left 4th Casing Panel 126436 126436 4 21 Washer, Plain, 3/4" 1 05153 105153 5 2 Third Pass Cover Plate 174036 174036 6 275" Rope, 1/2" (Third Pass) 53754 53754 7 2 Rear Cover Clamp Assembly 114769 114769 8 10 Nut, Hex., Brass, 1/2" 13NC-2 53687 53687 9 10 Washer, Lock, I nt-Ext, 1/2" 108170 108170

10 1 Rear Cover Assembly 174023 174023 11 Insulation 2" Thick Fiberglass, 390 Sq. Ft. 455 Sq. Ft

Type AW Rangewool 100774 100774 12 1 Front Cover Assembly - Left 174028 174028 13 1 Front Cover Assembly - Right 174031 174031 14 45 Washer, Lock, Jnt-Ext, 5/8" 109220 109220 15 21 Nut, Hex., Brass, 5/8" 11 NC-2 53691 53691 16 1 Inspection Cover 21139 21139

1 17 1 Right 3rd Casing Panel 184569 174042 18 12 Washer, Flat, l/2" 105151 105151 19 1 Top Panel lst Section 174001 174001 20 1 Top Panel 2nd Section 174002 181155 21 1 Top Panel 3rd Section 114304 181209 22 1 Right lst Casing Panel 174039 174039 23 1 Left lst Casing Panel 174040 174040 24 1 Right 2nd Casing Panel 174041 174041 25 1 Left 2nd Casing Panel 174043 174043 26 1 Right 5th Casing Panel 126437 126436

1 Right 6th Casing panel 126437 27 1 Left 5th Casing Panel 126439 126436

1 Left 6th Casing Panel 126439 28 Spacer Insulation 2" x 3" x 48" {40) 107690 {46) 107690 29 465" Rope, l"Oiameter {Front Cover) 53755 53755 30 6 Ring, Handhole Insulation Retaining 151353 151353 31 1 Rope Retaining Arrangement 149079 149079 32 2 Hinge Assembly - Front Cover 158668 158668 33 2 Casing End Cover 114380 114380 34 1 Sealing Strip Clip 111278 111278 35 4 Nut, Hex., Cad Plated, 3/8" 16NC-2 53682 53682 36 4 Washer, Lock, I nt -Ext, 3/8" 57432 57432 37 Strap (Signoid) 5/ 8" x . 020 Thick x 200 Ft. Lg . 240 Ft. Lg.

Galvanized & Waxed 102875 102875 38 29 Clip {Signoid) 5/ 8" 52348 52348 39 12 Screw, #10, Rd. Hd., Type "A", 105164 105164

1/2" Lg. 40 Screw, Cap, Hex. Hd., 1-1/8" 7NC X 105145 105145

5-l/2" Lg. 41 2 Nut, Hex., 1-1 / 8" 7NC 105148 105148 42 2 Washer, Square 141375 141375

2 Washer, Plain, l-1 / 8" 7NC 105154 105154 43 2 Cover Clamps 137284 137284 44 2 Cover Clamps 144232 144232 45 1 Hinge Assembly {Rear Cover) 174037 174037 46 2 Hinge Ring 155562 155562 47 48 12 Nut, Hex., Cad Plated, 1/2" l3NC -2 53689 53689 49 24 Nut, Hex., Cad Plated, 5/8" 11 NC-2 105146 105146 50 1 Washer, Peepsight 121012 121012 51 1 Glass, Peepsight 78522 78522 52 1 Gasket, Peepsight 78521 78521 53 1 Gasket, Peepsight 84330 84330 54 Rope, l" Diameter Single Braided 107790 107790

214" Fiberglass, #360-AAA Grade 55 7 Insulating Block #EC-350 106726 106726 56 1012# Plicast 24 LWI-24 107823 107823

- 27 -



C.I:TJ0."'4l. rAJrt~tt:"'f4 "'"~l r{)tll Dil~lJ A<S} 1:0.cR A.AT(

';>f(fiO~ OF P_C[p '§.!__G!i!_

~ ;,.ocmt nux RS

5H()<N"' r,;J.. T#-111/D ~l ((..Vt ( Pll.:'f5 (t.M~T p.r"( ro tr1D tY :'JH~LL.

Lf>j:. ~( .srvo! A.S sw~ ,•"" u • .s.'"Eh ·.oc~ 'EXWT =.:vte Ot. T1,: ·.AL t::,A :_ IT/VtH$

A !; R6'T r-;p l:"fCQI C:.YCR' ;~~~:¥.,~~~;~r ~zrtt -: v.: P - 4.Ss f ·

When drawing or part number lists more tloan one item specify item desired.

- 28 -



Ref. No.

2 3 4 5 6 7 8 9

10 11

12 13 14 15 16

•17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

38 39

40

41 42 43 44

45 46 47 48 49 50 51 52 53 54 55 56 57

No. Rqd.

1 1 1 1

265

47 21 21 2

350" 2

12 12

1

1 1

26 26

1 16 16 1 1 1 1 1 1 1 1 1

52 840"

6 1 2 2 1 4 4

41 12

2 2 2 5

2 1 1 1

2 6

140Qi: 1 1 1 1

Part Name


Front & Rear Cover Studs Nut, Hex., Brass, 5/8" llNC-2 Washer, Lock, I nt-Ext, 5/8" Third Pass Cover Plate Rope, 1/2" (Third Pass) Rear Cover Clamp Assembly Nut, Hex., Brass, 1/2" 13NC-2 Washer, Lock, Int-Ext, 1/2" Rear Cover Assembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 360 Sq. Ft. Front Cover Assembly - Left Front Cover Assembly - Right Washer, Lock, Int-Ext, 5/8" Nut, Hex., Cad Plated, 5/8" llNC-2 Inspection Cover Nut, Hex., Cad Plated, 1/2" 13NC-2 Washer, Lock, Int-Ext, 1/2" Top Panel 1st Section Top Panel 2nd Section Top Panel 3rd Section Right 1st Casing Panel Left 1st Casing Panel Right 2nd Casing Panel Left 2nd Casing Panel Right 6th Casing Panel Left 6th Casing Panel Spacer Insulation 2" x 3" x 48" Rope, l"Diameter (Rear Cover) Ring, Handhole Insulation Retaining Rope, Retaining Arrangement Hinge Assembly - Front Cover Casing End Cover Sealing Strip Clip Nut, Hex., Cad Plated, 3/8" 16NC-2 Washer, Lock, Int-Ext, 3/8" Strap (Signoid) 5/ 8" x .020 Thick x 300Ft. Lg., Galvanized & Waxed Clip (Signoid) 5/8" Screw, #10, Rd. Hd., Type "A", 1/2" Lg. Screw, Cap, Hex. Hd., 1-1 /8" 7NC x 5-1/2" Lg. Nut, Hex., 1-1 /8" 7NC Washer, Plain, 1-1/8" 7NC Cover Clamps Left 3rd, Right & Left 4th & 5th Casing Panel Cover Clamps Hinge Assembly (Rear Cover) Right 3rd Casing Panel Hinge Ring

Washer, Square Insulating Block #EC-350 Plicast 24 LWI-24 Washer, Peepsight Glass, Peep sight Gasket, Peepsight Gasket, Peepsight

- 29 -

700 (173650) Part No.

173606 173610 173616 173607 ]zg352

91974 53691

109220 173682 53754

129405 53687

108170 173651 100774

173673 173678 109220 105146 21139 53689

108170 173658 173659 180959 173660 173662 173664 173666 129397 129398 107690 107790 151353 149368 155556 141521 111278 53682 57432

102875

52348 105164

105145

105148 105154 137284 129395

144232 173668 173671 155562

141375 106726 107823 121012 78522 78521 84330

<:l.f. ,~~ ·- "6-

.:f•··t l• : .... .C! ~! ;-: ..... ': r'(l"!*: f .... ·:-::.rl



lOOITt ''VD3 A.! s..c~rw•U-ICOO'll COvlt ."U•U

When drawing or part number lists more than one item specify item desired,

- 30 -

~d!~ 'l}r' ' ')[CTION CW P(f"P ~~6~T

Ref. No.

2 3 4 5 6 7 8 9

10 11

12 13 14

•15 '16 17

18 19 20 21 22 23 24

25 26 27 28 29 30 31 32

33 34 35 36 37 38 39 40 41 42

43 44 45 46 47 48 49 50 51



No. Rqd.

1 1 1 1

263

1 1

52 24 54 2

960" 20 24 20

1

1 1 1

30 1

12

1 1 1 1 1 1 5

2 1

56 6 2 2 2

60 6

2 4 1

18 2 1

2 2 2 1 1 1 1

950= 1 3

Part Name

Boiler Fabrication Assembly Front Tube Sheet Rear Tube Sheet Furnace Tube Boiler Tubes (Refer to page 13 for Boiler Tube Size) Rear Hinge Assembly Pivot Plate Rear Hinge

Front & Rear Cover Studs Nut, Hex., Brass, 5/8" llNC-2 Washer, Lock, Int-Ext, 5/8" Third Pass Cover Plate Rope, l" (Third Pass) Rear Cover Clamp Assembly Nut, Hex., Brass, 1/2" 13NC-2 Washer, Lock, Int-Ext, 1/2" Rear Cover Assembly Insulation 2" Thick Fiberglass, Type AW Rangewool, 628 Sq. Ft. Front Cover Assembly - Right Front Cover Assembly - Left Center Left Casing Assembly Nut, Hex., Cad Plated, 5/8" llNC-2 Inspection Cover Screw, #10, Rd. Hd., Type ''A'', 1/2" Lg. Top Panel 1st Section Top Panel 2nd Section Top Panel 3rd Section Right Front Casing Assembly Left Front Casing Assembly Right 2nd Casing Assembly Left 2nd & Left & Right 3rd. & 5th Casing Assembly Center Right Casing Assembly Rear Left Casing Assembly Spacer Insulation 2" x 3" x 48" Ring, Handhole Insulation Retaining Hinge Assembly (Front Cover) Ring, Front Cover Hinge Rod, Front Cover Hinge Strap (Signoid) 5/8" x .020 Thick x 300Ft. Lg., Galvanized & Waxed Clip (Signoid) 5/8" Cover Clamp

Nut, Hex., Cad Plated, 3/8" 16NC-2 Washer, Lock, Int-Ext, 3/8" Rear Right Casing Assembly

Nut, Hex., Cad Plated, 1/2" 13NC-2 Washer, Plain, 1-1/8" 7NC Screw, Cap, Hex. Hd., 1-1/8" 7NC x 5-1/2" Lg. Nut, Hex., 1-1/8" 7NC Washer, Square Casinq End Cover Washer, Peepsight Glass, Peepsight Gasket, Peepsight Gasket, Peepsight Plicast 24 LWI-24 Insulating Block #EC-350

- 31 -

850 (155570) Part No.

155177 154814 154814 155178 155179

156004 156039 91974 53691

109220 154706 107790 154742

53687 108170 154781 100774

154486 154480 197868 105146 21139

105164

155537 155538 155539 155540 155541 155542 155543

155544 155545 107690 151353 155556 155562 91974

102875

52348 144232

53682 57432

173082

53689 105154 105145

105148 141395 157243 121012 78522 78521 84330

107823 106726

COMBUSTION CHAMBERS

On all SPH, SPL & SPW Models the Air Cone Shield Refractory, the Chamber Tile and the Target are mounted in the firing tube.

The Air Cone Shield is made of Rock Spar Refractory Material. The Chamber Tile and the Target are made of Corindin Refractory Material.

All the refractory pieces are laid in and joined with cement when insta1led in the firing tube.

SERVICE MAINTENANCE

1. Check flame periodically and inspect to see that there is no flame impingement.

2. If carbon formation occurs, shut down and clean chamber. Burner should be adjusted as this formation is not normal.

3. Inspect chamber every year and repair cracks or expanded joints.

4. If necessary to install new combustion chamber, follow instructions and dimensions shown on the following pages.

INSTRUCTIONS FOR INSTALLING NEW TARGET OR AIR CONE SHIELD IN FURNACE TUBE

Before attempting to cement the target in position in the firing tube, it is good practice to lay the bricks up dry at the end of the firing tube. By laying the bricks in dry it is easier to determine the amount of cement needed on the back of the brick and the ends of the brick. This is also a check to see if the bricks are proper for the size of the boiler.

Now cement the first brick and position place the remaining pieces in position. the same amount of cement at all points target centered.

according to dimension, cement and When cementing the bricks try to keep

on the brick. This will keep the

It is good to tap the bricks when in position so they will set in the cement. When placing the top bri cks allow a clearance of one-quarter inch (1 / 4") to three-eighth inch (3/8") at the top of the f iring tube for expansion of the bricks.

INSTRUCTIONS FOR INSTALLING NEW CHAMBER TILE IN FURNACE TUBE

Before attempting to cement the chamber t ile in position it is good practice to lay the bricks up dry at the end of the firing tube. This will let you gauge approximately how much cement is needed on the back of the bricks and between the joints .

This is also a check to see if the bricks are proper for the size of the boiler.

Now cement the f ir st bri ck and position. Tap the bricks with a mall et to set them in the cement. Continue to build up the sides. The top brick will be the key bri ck and because of the tongue and groove in the bricks , will have to be put in from the fr ont or rear, whichever is the more convenient. If the fit is too tight to allow this brick t o slide in, tap the bricks so they will move downward and to the outside of the firing tube.

- 32 -

By doing this enough room can be gained to slide tl1is brick in place. Do not make it too loose, it must be engaged in the tongue and groove. Also keep one-quarter inch (1/4") to three-eighth inch (3/8") clearance on the top for expansion of the bricks.

When 2 or more rows of liner bricks, are used, stagger the brick in the firing tube.

Smooth out the cement at the joints and do not allow any cement to protrude above the surface of the brick. This could affect the air pattern. Also do not allow any brick to be higher than the air cone refractory where they join in the firing tube. This could also change the air pattern and could cause trouble with proper combustion.

INSTRUCTIONS FOR INSTALLING PLASTIC REFRACTORY IN REAR ARCH

Before replacing the refractory in the rear arch, check the pipe hangers to be sure they have not broken loose at the weld, and reset them according to the thickness at the refractory if necessary. These pipe hangers are very important for holding the refractory in place until it has time to set.

If a tar or heavy pitch is available, coat the pipe hangers. Plain newspaper can be used if wrapped around the hangers in such a fashion that it will not be knocked off when hammering the refractory in the boiler. The purpose of this is to allow a clearance on the hangers during expansion and contraction of the boiler after the material has been burned off.

Plastic refractory shall be of a pliable consistency that can be worked very easily with the hands. Never attempt to put refractory in a boiler if it is dry as it will not knit properly and may fall out.

Most plastic refractory comes in cakes. Break up one or two cakes in small pieces, about the size of your hand or smaller, and place in the bottom of the boiler for convenience.

Start putting the refractory around the pipe hanger in the lowest position of the arch, with a two and one-half pound (2-1 / 2 lb.) hammer, start tamping the refractory around the hanger. Continue to add sma l l pieces and keep working the material together, filling out the width of the arch and building up the thickness.

Continue up the side by working pieces of the material into each other. Continually check to see that you have the proper thickness as it is not good practice to try to add, it will not knit into refractory after it has been set.

Continue to knit the refractory up to the top center of the boiler.

The second side should now be completed in the same manner as the first side.

After the refractory has reached the point where the firing tube is, the refractory must be tapered in order to blend in with the diameter of the firing tube. This blending can be done with a small trowel and any other dressing can be done the same way before the refractory becomes too hard to work.

Now the bottom of the boiler can be finished.

There are no hangers needed for support and the bottom is not as critical as the sides and top. Do not use large pieces. Continue to knit small pieces together as on the sides and top.

- 33 -

Start the bottom at the ends where the sides started. Make sure that material is well knitted in good with the sides because by this time material has started to air dry and set.

As you are building up the refractory some of the material will move out beyond the sealing strip. Cut this off even with the sealing strip with your trowel and this will also allow you to continue checking the thickness of the refractory.

The following points are also very important:

Before removing the old refractory make a note of the thickness at different positions on the boiler. If you have the thickness greater than it should be the rear head will not enter properly.

Check the refractory at the tube sheet so the refractory is approximately three-eighth inch (3/8") lower than the tubes. This is done so a tube roller can be used if necessary.

Be sure to have a nice blend around the firing tube so there is no obstruction.

It is not necessary to smooth out the refractory. It is better if it remains rough as it will dry out better.

If possible, plan the job so that when it starts it can be completed without a long delay to insure proper setting and knitting.

Never try to save time by putting in the blocks or large pieces. They will not adhere to each other and will fall out.

After the job is finished, check the sides and top to make sure it has not sagged. If it has, a little tamping might be necessary to make it cling better around the hangers. This happens sometimes if the material is very fresh and is soft. If this is recognized when opening a carton, it can be broken in small pieces, and left to dry out to its proper consistency.

Do not over-tamp with hammer, watch the material knit into the material already hammered and stop hammering. Continued hammering only displaces material and more material often has to be added for thickness and more time consumed.

- 34 -

REFRACTORY ARRANGEMENT SERIES 582 & 588 400 and 500 H.P. (157284)

SERIES 588 600 H.P. (158609) LIGHT OIL & GAS-LIGHT OIL COMBINATION

~ J

f'IOTt ·

- lYT r.Roo.--£ rc rat.Lt)N S!f,Jt,P{ " ' A.R (N

COoQT W1l;~ HOOKS INtT,.PrTCrl

REFRACTORY ARRANGEMENT

Ref. No. No. Rqd. Part No.

)2 COTbust ion Chamber Refr•ctory 126405 8 hrget Tile 85173

900N Plutlc Refractory (Air Set) SISII 2)0N Fr•nctl 1'\ort•r 51201

6 Target Tile (lnner Rlng) 85174

SERIES 582 & 588 400 AND 500 H.P. (158606) SERIES 588 600 H.P. (158607)

GAS Ref. No . No . Rqd . Part No.

8 TArget Tile 85173

102 . 4(;0 ( 500 h p

~~6oCHF--l'l

Norr:-co,qr Wlft HOOt< WITH PIT'CN

- 35 -

'"' 6..roa.1f ro Fou.o w JKA,q" 0' A/?CN

6 Target Tile (Inner Ring) 85174 900# Plastic Refractory (A i r Set) 51511

40i1 fr•ncil ~rtar 51201

REFRACTORY ARRANGEMENT SERIES 582 & 588 400 AND 500 H.P. (158605)

SERIES 588 600 H.P. (157757) HEAVY OIL & GAS - HEAVY OIL COMBINATION

*Available in l Qt. can (ti51465)

.vor~ · COIIT wl.lU HOt:iKJ 'tlf'ITH IIVTCN

Ref. No. No. Rqd. Part Name

I 2 48 Combust ion Chamber Refractory 3 8 Target Tile 4 2SOu Franci\ Mortar S 40 Oz Refractory Surf a ce Seal (France) 6 9SOn Plastic Refractory (Air Set ) 7 6 Targe t Tile ([nner Ring)

REFRACTORY ARRANGEMENT (157922) SERIES 596 700 H.P.

LIGHT OIL & GAS-LIGHT OIL COMBINATION Rd. No. No. Rqd . Par-t Name Part No.

38 Combust i on ( harr(:ler Refractory 138936 8 Target Tile {Ou ter Ring) 13850 7

2:;10.-: Franc i 1 Mor tar S 1201

950:: Plasti c Ref r ac tory ( Ai r Set) 51511 6 Tar get Ti le ( Inner Ring ) 138 508

r----- 100 -------"""

r-zzi I I

I '"l

( LIT 61toCV$ Tl) FOi.LO £4' SNAP£ OF AI(CJ(

- 36 -

Part No.

126405 as 173 S I 20 I SS60 7 ¥SIS II 8SI7 4


GAS

NOT~:

Ref. No. No. Rqd.

8 lOON

6 9SON

CvT t;Ao~ TO FOLL.OW JNA~ Of' MCN

Co-<r 11'1-f£ flPE IWOI<$ WITH PITCH·

hrget Tt le (Outer Ring) Fr•nci I ~n•r hrget Tile (Inner Ring) Plutic Refractory (Air Set)


HEAVY OIL & GAS-HEAVY OIL COMBINATION

*Available in l Qt. can (#51465)

~...-r TJII/f..lT ;' (Nt4_6,"1 ...,,.,., ,A,;f,.-.4'<:. J£M ®

..,,. Cf'l4r IYI/fl /'t'P£ _tJ, S r. ; J,. '-1 1CN.

- 37 -

Ref. No. No. Rqd.

I

Part Name

2 S7 Con'tbust1on Chamber Refractory 3 8 Torget Tile (Outer Ring) 4 2SO.tr Franc i1 Mortar S 32 Oz Refractory Surhce Seal (France) 6 9S0b' Plastic Refractory (Air Set) 7 6 Target Tile (Inner Ring)

I J8S07 s 1201

I J8So8 S I Ill

Part No.

138936 138507

S12Q1 SS607 >f. 51511

138508

REFRACTORY ARRANGEMENT (158405} SERIES 5112 850 H.P.

LIGHT OIL & GAS-LIGHT OIL COMBINATION

* Available in 1 Qt. can (#51465)


1 8 Air Cone Refractory Shield 2 34 Combustion Chamber Refractory 3 8 Target Tile (Outer Ring) 4 250# Francil Mortar 5 32 Oz Refractory Surface Seal-France 6 1150# Plastic Refractory 7 6 Target Tile (Inner Ring) 8 2 Air Cone Support

NOT f. -

._~ c,..;r w,-_f ~NO..V'?.S ·" '"'~ ,.,rc,.,

QIT '".II?(;'({ 1'0 fOLL :>...., ~rl't:JtCN

REFRACTORY ARRANGEMENT SERIES 5112 850 H.P. (173222}

GAS


1 2 3 4 5 6 7 8

8 Air Cone Refractory Shield

12 Target Tile (Outer Ring) 100# Francil Motar 32 Oz Refractory Surface Seal-France 5400# Plastic Refractory 6 Target Tile (Inner Ring) 2 Air Cone Support

*Available in 1 Qto can (#51465)

CIT ::OfGCt( 1Go IOU OW ~ 0' .. 04

- 38 -

Part No.

155520 155578 15S579 51201 55607 -1c 51511

138508 130519

Part No.

155520

155579 51201 55607 .~ 51511

138508 130519


HEAVY OIL & GAS-HEAVY OIL COMBINATION

*Available in 1 Qt. can (#51465) '

l Tilt ~ H~M. S1:e (tr. z;

Ref. No. No. Rqd.

I 8 2 57 3 8 4 250# 5 32 Oz 6 1150# 7 6 8 2

I'JaTl-

Part Name

Air Cone Refractory Shield Combustion Chamber Refractory Target Tile (Outer Ring) Franci I Mortar Refractory Surface Seal-France Plastic Refractory Target Tile (Inner Ring) Air Cone Support

I .......... ·~~ ." ... , Cc..QT WillE ..GNCI-4G.(!:S WlrH #'ITCH

I , ~- ------ ---141l-- - ~---, ,.,

OIT ~lOC-i( 10 IOU.O¥f 3HoVC: 01' ~CH

- 39 -

Part No.

155520 155578 155579 51201 55607 ~ 51511

138508 130519

REMOVAL AND REPLACEMENT OF REAR COVERS AND GASKETS

1. Remove the two bolted angles which secure the joint between the lower cover and the two upper covers.

2. Remove the nuts (or wedge pins) and lift off the two upper covers.

3. Remove the nuts (or wedge pins) and swing open the lower cover.

4. NOTE: Any of the three covers can be removed without disturbing the other two.

5. Replace all gaskets before replacing the rear covers. Use a cement (such as 3M) to hold both the fiberglass tape gasket and the one inch (1") rope gasket in place during re-assembly. Use butt joints (no overlap) for a good seal. The joint on the one inch (l") rope gasket must be at the bottom of the cover.

6. On the rear refractory assembly, it may be necessary to tighten or loosen the adjusting nuts to assure proper alignment.

7. Coat all studs with grease or anti-seize lubricant.

8. With the heads in place, attach washer and nuts, (or wedge pins) but do not tighten.

9. Attach the two bolted angles but do not tighten. Check to see that all covers are properly set on the gaskets for a good seal. Tighten the nuts on the two bolted angles just enough to compress the one inch (1") rope gasket.

10. Tighten the rema1n1ng nuts (or wedge pins) for a good seal. (Note: The wedge pin clevis can be adjusted by turning it in or out as needed for proper take-up).

REPLACEMENT OF REAR COVER REFRACTORY

1. Remove the rear cover above as described elsewhere in service manual.

2. Remove the old refractory and scrape the head thoroughly to assure a clean, flat surface for good bonding of the new refractory.

3. Place the rear cover on the floor with the peepsight down. (A suitable framework should be placed under the cover to keep it level.)

4. Place in the peep sight nipple a length of one and one-half inch (l-l/2") pipe long enough to extend beyond what will be the refractory surface. (Any tube of approximately two inches (2") 0.0. will do.) Care should be taken to see that the peep sight glass is not broken.

5. Mix the refractory as described on the bag and pour it into the rear cover. Mixture should be allowed to set for 24 hours.

6. Remove one and one-half inch (l-l / 2") pipe from refractory and trim around the peep sight hole if necessary.

7. Place rear cover back on boiler and tighten nuts as described elsewhere in the Service Manual.

- 40 -

REAR COVER ASSEMBLY (174008} Series 582 All

NOTE: FOR PARTS DEPT. USE ONLY. REPLACEMENT REAR COVER ARRG'T. 187821

1---------?;j_ ------

REF. NO. NO. RQD. PART NAME PART NO.

l l Rear Cover 174009 2 l Wrapper Sheet (Upper) 174010 3 l Wrapper Sheet (Lower) 117897 4 l Upper Flange 174011 5 2 Side Flange 174012 6 l Bottom Flange 174013 7 l Peep Sight Cap 195408 8 l Nipple, Pipe, E.H., T .O.E., 2" X 7" Lg. 191959 9 2 Handle 121346

10 l Lifting Bracket Assembly 118312 ll 12 Anchor 9" Lg. 191956

- 41 -

REF. NO.

1 2 3 4 5 6 7 8 9

10 11

II

REAR COVER ASSEMBLY (174023) Series 588 All

* NOTE: FOR PARTS DEPT. USE ONLY. REPLACEMENT REAR COVER ARRG'T. 187822

3 ~---- 152. -- ---------·

e \ 7

NO. RQD. PART NAME PART NO.

1 Rear Cover 174024 1 Wrapper Sheet (Upper) 174027 1 Wrapper Sheet (Lower) 114315 2 Handle 121346 1 Upper Flange 174011 2 Side Flange 174025 1 Bottom Flange 174026 1 Peep Sight Cap 195408 1 Nipple, Pipe, E.H., T.O.E., 2" X 7" Lg. 191959 1 Lifting Bracket Assembly 118312

12 Anchor g" Lg. 191956

- 42 -


* NOTE: FOR PARTS DEPT. USE ONLY. REPLACEMENT REAR COVER COVER ARRG 1 T. 192427

~ ~===~r7

23-

20 18

8 ll J"_j ~

14

11 9

1 , zrr ~------ 8~----------------------~

------3{ ~ 3 ~ B ;(,

"A:, 12

.{ ~··

REF. NO. NO. RQO. PART NAt~E PART NO.

1 Rear Cover 173652 2 Wrapper Sheet (Lower ) 173653 3 4 Wrapper Sheet (Up per ) 173654 5 6 1 Upper Flange 173655 7 2 Side Flange 173656 8 1 Bottom Flange 173657 9 1 Peep Sight Cap 195408

10 1 Nipple, Pipe, E. H., T. 0. E., 2" X 7" Lg. 191959 11 2 Handle 121346 12 2 Angle, 2" X 2" X 1 / 4" X 63" Lg. 143538 13 12 Anchor, 9" Lg. 191956 14 1 Lifting Bracket Assembly 184737 15 2 Bar, HRS, 1/2" X 2" X 43" Lg. 191960

- 43 -


* NOTE: FOR PARTS DEPT. USE ONLY. REPLACEMENT REAR COVER COVER ARRG'T. 192428

14 6 r / 1

r-----?ll------------1

12 .{ v-:::: tt'-4'

REF. NO. NO. RQD. PART NAME PART NO.

1 1 Rear Cove r 154774 2 1 Wrapper Sheet (Lower} 154 775 3 2 Wrapper Sheet (Sides} 154776 4 1 Wrapper Sheet (Upper) 154777 5 6 l Upper Flange 154778 7 2 Side Flange 154779 8 l Lower Flange 154780 g l Peep Sight Cap lg5408

10 l Nipple, Pipe, E.H., T. 0. E., 2" X 7" Lg. lglg59 ll 2 Handle 121346 12 2 Angle, 2" X 2" X l / 4" X 76" Lg. 154773 13 17 Anchor, 7" Lg. 191956 14 l Lifting Bracket Assembly 156027 15 16 2 Bar, HRS l/2" x 2" x 51-L/2" Lg. 192124

- 44 -

REMOVAL AND REPLACEMENT OF FRONT COVER AND GASKETS

1. Remove the nuts which fasten the front cover to the boiler.

2. Unscrew the two (2) special hinge bolts evenly until the head clears the studs on the boiler, then swing the doors out of the way. (Note: These hinges are designed with a safety clip to prevent the hinge bolt from disengaging thereby preventing the front cover from falling.)

3. Replace all gaskets before replacing the front cover. Use a cement (such as 3M) to hold the fiberglass tape gasket in place during re-assembly. Use butt joints (no overlap) for a good seal.

4. Swing the cover into place, then tighten the two (2) special hinge bolts evenly until the head is back in place on the studs.

5. Coat all studs with grease or anti-seize lubricant.

6. First tighten the nuts evenly on the center firing tube.

7. Next, tighten the nuts evenly around the outer edge.

- 45 -

LEFT FRONT COVER ASSEMBLY (173997) SERIES 582 ALL

Ref. No. No. Rqd. Part Name Part No.

1 Front Cover, L,H, 173998 2 Front Insulation Cover, L.Ht 156984

3 Outer Collar 117918 4 Inner Collar 156981 5 Front Insulation 156982 6 Handle 13455

RIGHT FRONT COVER ASSEMBLY (173999) SERIES 582 ALL

Ref. No. No. Rqd, Part Name Part No.

1 Front Cover, R.H. 174032 2 1 Front Insulation Cover, R. H. 174033 3 1 Outer Collar 174034 4 1 Inner Collar I 56981 5 1 Front Insulation 174035 6 1 Clean-Out Cover 8428 7 1 Clean-Out Cover Insulation 7878 8 4 Bolt, Hex. Hd. Brass 3/8" 59836

16NC2 X I" Lg. 9 Handle 13455

'

- 46 -


Ref. No. No. Rqd. Part N~

I I Front Cover, L.H. 2 I Front Insulation Cover, 3 I Outer Coli ar 4 I Inner Coli ar 5 I Front Insulation 6 I Handle


Ref. No. No. Rqd. Part N~

Front Cover, R.H.

Part No.

174029 L.H. 17t.o30

174034 156981 174035 13455

Part No.

I 2 3 4

I I I I

Front Insulation Cover, R.H. Outer Collar

174032 174033 174034 156981 174035

- 47 -

5 6 7 8

9

Inner Collar I Front Insulation I Clean-Out Cover I Clean-Out Cover Insulation 4 Bolt, Hex. Hd. Brass 3/8"

J6NC2xi"Lg. I Handle

8428 7878

59836

13455

-... LEFT FRONT COVER ASSEMBLY (173673)

SERIES 596 ALL

Ref. No. No. Rqd.

1 2 3 4 5 6

Part Name

Front Cover, L.H. Front Insulation Cover, L.H. Outer Collar Inner Collar Front Insulation Handle


~ Ref. No. No. Rqd. Part Name

1 1 Front Cover, R.H. 2 1 Right Front Insulation Cover 3 1 Outer Collar 4 1 Inner Collar 5 1 Insulation 6 1 Cleanout Cover 7 1 Cleanout Cover Insulation 8 4 3/8" 16NC2 Hex Hd Cap Screw

4-.t: 1" Lg. Brass 9 Handle

- 48 -

Part No.

173674 173675 129366 173676 173677 13455

Part No.

173679 173680 129366 173676 173677

8428 7878

59836

13455


~ Ref . No. No. Rqd Part Name Part No.

I front Cover L.H. 154481 2 Left front Insulation Cover I $4482 3 Outer Collar 154483 4 Inner Co II ar 154484 s front Insulation 154485 6 Handle 13455

I~

I

~


+ + r----- --.."

\ · 34 J

' l I

Ref. No . No . Rqd. Part Name Part No .

I Front Cover 154487

2 Ri ght front Insulation Cover 154488

3 Outer Co II ar 154483

4 Inner Collar 154484

5 I Insulation 154485

6 I C I e an-Out Cover 8428

7 I C I ean-Out Cover Insu1ati on 7878

,,,---\·· I ___ l _ _i

8 4 3/ 8" 16 NC- 2 Hex Hd Bo It I" Lg. 59836

I I

/· I

- 49 -

Brass 9 Handle 13455

P-1

Puff Door Frame

7640

P-2

CROSS-SECTIONAL VIEW OF PUFF DOOR {83650)

SPH - SPL - SPVV

P-4

P-3

Optional Equipment

P.,~~ I I I I I

:1 I i I; I I

lL L_ .J.

c. MtN . OPEN/N~

P-4 P-5

Puff Door

P-6

P- 1

Puff Door Puff Door Retaining Spring Puff Door Gasket Spring Retainer Shaft

7642 7643 114324 7645 83649

- 50 -

P-7

Driv-Lok Pin

2 59727

GASKETS - HANDHOLE & MANHOLE

SPL & SPH 400 to 850

SPW 400 to 850

BOILER MAINTENANCE

HANDHOLE GASKET

3-1/2 X 4-1/2 6 - 42305

7 - 42305

MANHOLE GASKET

11" X 15" 1 - 42306

- 42306

Approvals: A.S.M.E. - and Local Ordinances

Steam-Pak Generators are built in rigid accordance to and bear the State stamp of A.S.M.E. Licensed insurance company inspectors check every step of manufacture from steel mill to shipping platform. In addition, they carry the approval of the National Board of Underwriters', New York City Board of Standards and Appeals, and have met fully all known conditions established by state and local boards.

BOILER CONSTRUCTION

Designed for Automatic Operation, Engineered for Extra Safety and Long Life.

In designing the Steam-Pak boilers, York-Shipley engineers have given special attention to accessibility of all points for any service they may require.

Steam-Pak boilers are fabricated in York-Shipley's own boiler plant where modern production techniques assure top quality at lowest possible cost. Boiler construction is three-pass, forced draft, horizontal fire tube design. All joints are full welded fabrication with straight fire tubes precision fitted into boiler heads. On high pressure boilers all shells are annealed, stress relieved and x-ray tested for possible defects. All construction is in accordance with A.S.M.E. and Boiler Inspection Codes.

EXTERNAL CLEANING AND CARE

External surfaces are in contact with hot gases and in order to obtain maximum efficiency, this surface should be cleaned as often as necessary. As a suggestion, a thermometbr has been placed in the stack connection, and when the temperature is over 550 F. on SPW or SPL and 650°F. on SPH, cleaning is necessary.

WATER LINE

Water line should be three inches (3") The water column is provided with pump a three-qu arter inch (3/4") variation. it does, wet steam will result.

above the highest tube in the boiler. switch to control the water line within This water line must not fluctuate. If

- 51 -

INTERNAL CLEANING AND CARE (See Care and Repair of Water Side of Boiler)

Manhole is provided on Boiler. Boiler is provided with handholes located so that all internal parts of the boiler that come in contact with water can be cleaned and inspected. The manufacturer recommends that to insure the proper life of your boiler, the water be treated by a reputable company in the boiler water treating business.

BLOWING DOWN BOILER

Boiler must be blown-down often enough to prevent solids from building up in boiler. The more fresh water put in the boiler, the more accumulation of solids, and results in tube failures. Boiler must be blown down for five seconds every day. Low water cut-off and water column likewise should be blown down every day while operating to insure shut down upon low water conditions.

SURFACE BLOW

If water level is fluctuating and pr1m1ng due to oil on surface of water, a pressure should be built in the boiler and oil removed by opening the surface blow off valve.

EXTERNAL CARE OF BOILER

The construction is simple, so a specific part of the upper pass can be inspected or cleaned without dis-assembling the complete rear head. Boiler assemblies include rear davits to swing the rear head, with tapered pins in place of screwed nuts as optional items.

The rear head covers are designed to be gas tight, and therefore, care must be taken when removing and replacing.

The boiler shell: This is the most costly single part of a unit and frequently the part most neglected. The "Fire-side" of a boiler should be cleaned periodically, since a dirty boiler is a fuel waster .

Clean boiler flues as follows:

1. Knock out all taper pins or remove the nuts around the lower rear head, pull the head loose from the boiler and swing it away on the davit.

2. Using flue brush, brush through the tubes to the front end of the boiler.

3. Soot and scale may be removed from the front end of the boiler by removing the cleanout cover located below the windbox on the front cover plate.

4. Check the rear head and baffle refractory and patch any cracks or spawls with high temperature cement. If refractory requires replacement, a sectional assembly may be obtained from the factory through the York-Shipley representative in your area, Baffle can be replaced with Plastic Refractory or similar material.

5. If necessary, replace the one inch (1") fiberglass rope around the edge of the rear refractory with a new piece of rope.

6. To close rear head, swing it into place. Next, drive each wedqe pin through its lug with flat surface toward the boiler or replace the nuts, until it begins to bear against the rear head. Then start hammering the

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pins in, alternating from side to side and from top to bottom and bottom to top so as to tighten head as evenly as possible, or tighten nuts in the same manner.

7. All tapered pins should have the taper pointing down to prevent pin from falling out. If pin enters too far into the eye socket, readjust socket by turning the eye socket to the right, bringing it close to the boiler. This will be necessary when the rope starts to compress.

8. SHUTDOWN UNIT TO CLEAN PEEP SIGHT. The Peep Sight can be cleaned by unscrewing the two inch (2") cap, two gaskets and glass. Clean glass and replace screw cap - only hand tight.

CARE AND REPAIR OF WATER SIDE OF BOILER

A. FEED WATER TREATMENT

York-Shipley, Inc. recommends to all its customers and agents that reliable water treatment companies be consulted in regard to the proper treating of boiler water. This company cannot possibly advise customers in all parts of this country, and abroad, of local conditions which make it mandatory that water be treated.

There are many qualified Water Treatment Companies located throughout the country. These people are specialists in this field. Their trained representatives visit the job site, analyze the water, and prescribe the treatment.

While we still retain our original position in assuming no responsibility for water treatment, we have prepared the following information as a general discussion in an attempt to better educate our customers, service organizations, and field representatives in the importance of maintaining the water side of boilers.

Before discussing the various commercial processes by which feed water can be treated, it would be well to clarify the objectives of water treatment. We must, of course, start with an analysis of the chemical and physical characteristics of the water under consideration. These being known, we should select the most suitable and economical method for conditioning for a given plant. The basic objectives are:

1. Prevention of hard scale on the heating surfaces of the boiler and its component parts.

2. Elimination of corrosion.

3. Control of pH.

4. Control of "carry-over" to eliminate deposits on system components.

1. The first objective was the earliest one recognized. A coating of scale reduces heat transfer and simultaneously raises the temperature of the metal surfa5es exposed to heat. When temperatures of boiler surfaces reach 750 F., there is serious danger of overheating and failure usually results.

The amount of resistance to heat transfer is dependent upon the type of scale produced, its insulating effect, and thickness. Some scales of 1/32" thickness can produce metal failure due to the scale's high

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insulating effect. Other scales can build up to an increased thickness before metal failure occurs.

Scale usually forms on the hottest portions of the boiler surface. The furnace tube and lower section of the rear tube sheet are the most common points of scale accumulation.

The effect of metal failure may result in the loosening of tubes in the joints of the lower section of rear tube sheet (beginning of first tube pass). The furnace tube, may fail due to build up of hard scale deposits, or tubes may burn out.

2. The second objective, corrosion elimination, is associated with the elimination of dissolved oxygen and carbon dioxide, (as mentioned under "Boiler Water, Its Treatment and Cautions", in this manual), the first defense against oxygen corrosion is usually the complete deaeration of feed water either in a deaerating heater or in a deaerating hot well of a surface condenser.

If traces of oxygen still remain, they are customarily removed by the addition of sulphite to the feed water on the feed-pump discharge line. (Compound should never be introduced "through" the feed water pump as impeller damage will occur and pump capacity will be lowered to the point where it is insufficient to meet the demand and unit will lock out on low water.)

It is also necessary to protect the boiler surfaces. The maintenance of suitable hydrogen-ion concentration of pH inside the boiler being thus required.

Corrosion troubles in low pressure heating boilers -which usually operate at a pressure below 15 PSIG, and are often of the horizontal fire tube type - often occur unnecessarily.

During the past years, many boiler tubes, reported defective, have been examined to determine the reason for their failure. In very few cases have any defective qualities in tubing been the cause of the corrosion. In the vast majority of instances, the necessity for replacement has been traced to conditions of environment.

In power boilers, it is a rare occurrence to find corrosion of the type common to heating boilers. This is because operators of power boilers realize the importance of proper water and fire side conditions and take care to avoid such problems.

The users of heating boilers are, first of all, usually not aware of the possibilities of corrosion. Often they have little idea what causes it and lack the know-how and experience to combat it.

There is a trend, today, to minimize the importance of employing qualified boiler operators. This trend seems to be developing through the mistaken feeling that the units will operate satisfactorily with little or no maintenance. Schools seem primarily concerned with the expense side of the operation which in far too many cases result in an unqualified person assuming responsibility for boiler maintenance.

The industry also seems to be deluged with purported "experts" in the field of water treatment who through incompetence, or lack of know-how, treat units improperly. Often it is found that the treatment concentrates on only one of four items previously mentioned with the net result of unit failure .

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Owners of units employing water treatment should be particularly careful to completely examine the credentials of those who represent themselves as 11 treatment experts 11 • York-Shipley recommends that only nationally known companies be considered.

3. The term 11 pH 11 has been discussed previously as important in the consideration of proper water treatment and it may be well to pause here to discuss and clarify the exact meaning of the hydrogen-ion concentration of water and its importance in proper treatment of boiler water. The pH value is an index of the fraction of hydrogen present that is ionized. The value given to pH, in terms of numbers, is used as an index of acidity or alkalinity.

Regardless of its state, source, or environment all water is always either alkaline, acid or neutral. The degree in any case is indicated by the water's pH value or number .

The pH of any water can be determined through testing a sample of water drawn directly from the boiler. Inexpensive testing kits are available. The majority of kits used associate various shades of colors with various pH values. Therefore, a color-blind person might have difficulty in determining the correct value.

pH value of exactly #7 indicates the water is neither acid nor alkaline. This water is 11 neutral 11 •

pH values below #7 indicate the water sampled is in the acid region. The lower the number below #7 the more acidic is the sample.

pH values greater than #7 indicate the water sample to be in the alkaline region, and again, the higher the number, the more alkaline is the sample.

The pH value of any water can be controlled through chemical treatment, and that is the only way it can be controlled.

All metals are more or less soluble in water and, upon entering a water solution, take on electrical charges. The ability to enter solution depends, however, on the pH value or number.

Below a pH #5, the water is actually sufficiently acidic to dissolve the steel and under these conditions, no pits form. Instead, the corrosion is relatively uniform and the steel gradually gets thinner until it is too weak to hold the pressure, or a small hole develops.

Between a pH of #5 and 9.4, pitting takes place at a rate depending on the concentration of oxygen in the water. Therefore, while operating the boiler, it is necessary that all air or as much air as possible be excluded from the boiler water.

It is recommded that the pH of boiler water be kept between 8.5 and 10.5 at all times. Periodic check by a reliable treatment company should be made to confirm this setting.

4. The elimination of carry-over of liquids and solids to the heating system can be accomplished by several recognized methods.

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It is assumed that at the time of initial start up the unit had under-gone an inspection of internal surfaces and chemically cleaned when necessary.

It is also assumed that, in cases of new systems, all pipe work had been flushed out. This is accomplished by allowing the return condensate to be wasted to sewer until the condensate returns free and clean from any grease, chips, or other foreign matter. It is important that during this flush out period water treatment be used to eliminate dissolved oxygen and other harmful ingredients found in water that could cause pitting or scaling.

During normal operation it is possible to return undesirable liquids direct to the boiler. Oils remaining in new pipe work, newly installed radiation or process machinery, open condensate return pits, leaks in steam kettles used to cook or process organic or other liquid forming compounds, can and often do find their way into the boiler.

The easiest way to rid the boiler of these liquids or suspended solids which accumulate in the top portions of the boiler is to blow down through the surface blow down connection supplied as standard with each steam unit. In some instances it is necessary to use the surface blow down continuously due to uncontrollable amounts of liquid or surface suspended matters being constantly thrown back into the boiler.

The accumulation of solids in the bottom portion of the boiler can cause metal failure if allowed to build up to engage tube area and thereby retard the flow of heat from tube to water.

These types of solids can be the result of leaks in underground p1p1ng, badly rusted piping, over treatment of boiler feed water, mineral content of supply water, or precipitation of solids from feed water.

These solids will also accumulate in low water cut-off piping and if not flushed regularly will gradually build up and restrict the movement of the low water cut-off float. This creates a false water level and may result in metal failure of boiler components normally submerged in water but which now are not submerged due to the false water line indicated by low water cut-off.

Boilers and low water cut-offs should be blown down regularly. down valve connections are provided at the bottom of the unit. water cut-off piping also includes a blow down connection.

Blow The low

5. The prevention of intercrystalline cracks in boiler metals often referred to as "caustic embrittlement", is probably the least understood. Opinions vary as to cause and effective treatment for this condition.

The use of fusion welded boilers, which have largely replaced riveted boilers has alleviated this difficulty to a large extent. Tubes are still rolled into the boiler plate but the strains in the boiler plate are nil, and very little difficulty has occurred on this account. There have been cases, however, where a tube exposed to heat was not completely covered with water and concentration of salts, heat and thinning of tube wall have resulted in failure.

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B. CLEANING WATER SIDE OF A NEW BOILER

Prior to placing a newly installed unit on the line, the unit should be cleaned internally.

New boilers should be reasonably free from mill scale, corrosion products, and other foreign matter. However, before attempting startup, the cleanliness of the unit should be checked.

If dirty, the unit should be cleaned to remove grease and other organic matter, rust and remaining mill scale, protective coatings applied by the manufacturer to prevent atmospheric corrosion, welding flux, and all other foreign matter normally incident to fabrication and erection.

The objective to be attained in cleaning a new boiler is to produce a clean metal surface on all parts of the boiler which are in contact with water or steam during operation. All water soluble materials, fatty acids, oils and greases, mill scale, rust, paint, and similar materials should be removed. Any solution employed should be a good cleaning agent for these purposes.

1. ALKALI CLEANING: This operation is conducted with alkaline detergent solution to remove foreign material, particularly oil and grease, from the internal surfaces of the boiler.

2. ACID CLEANING: This operation is conducted with inhibited acid solution primarily for the purpose of removing mill scale and products of corrosion. Because of the chemical control required and the hazards involved through the improper use of acids in destroying both ferrous and non-ferrous metals, and in causing the production of explosive gases, work of this kind should be supervised by personnel specially qualified . by training and experience in this highly technical field.

C. INTERNAL CLEANING A BOILER AFTER SERVICE (Laying up a boiler)

Whenever a package boiler is taken out of service for any purpose, it should be internally clean when put back into service or placed in wet or dry storage. Loose material in the form of dirt, trash, mill scale, or deposits should be removed by washing or other mechanical methods.

When a boiler is taken out of service, the unit should be cooled until the water is below the atmospheric boiling point, the boiler should be emptied and flushed out and an inspection should be made to determine what repair work is necessary and what mechanical and chemical cleaning should be done. A decision should then be made to employ dry or wet storage.

1. DRY STORAGE: Is a procedure preferable for boilers out of service for extended periods of time or in locations where freezing temperature may be expected during storage.

The cleaned boiler should be thoroughly dried, since any moisture left on the metal surface would cause corrosion to occur on long standing. Precautions should be taken to preclude entry of moisture in any form, into the water side of the unit.

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To prevent moisture attack during dry storage, moisture abosorbing material such as quick-lime at the rate of two pounds (2 lbs.) or silica gel at the rate of 10 pounds (10 lbs.) for 1000 gallon capacity, may be placed on trays inside the boiler to absorb moisture from the air. The manholes should then be closed and all connections on the boiler should then be tightly blanked. The effectiveness of the materials for such purposes and need for their renewal may be determined through regular internal boiler inspections. Alternately, air dried externally may be circulated through the boiler.

2. WET STORAGE: Wet storage is preferable when boilers are to be placed in storage condition for short periods of time or when it is likely that a standby boiler will be needed for service on short notice. The procedure should not be employed for boilers in locations where freezing temperatures may be expected during standby.

The cleaned boiler should be filled to the top using condensate or feed water, either of which should be conditioned chemically to minimize corrosion during standby and closed. Prescribed concentrations of caustic soda and of scavenger such as sodium sulfite may be employed. Concentrations approximately 450 parts per million (PPM) of caustic soda and 200 PPM of sodium sulfite may be used for this purpose. Water pressure greater than that of the atmosphere should be maintained within the boiler during the storage period.

It should be noted that the percentage of soda and sulfite noted above is greater than recommended for operation of the unit. Therefore, it will be necessary to completely drain the unit prior to placing it on the line and to treat the water during operation according to the recommendation of the boiler water Treatment Company employed.

D. SCALE REMOVAL FROM INTERNAL PARTS OR BOILERS

There seems to be great quantities of information available on the proper methods of water treatment, damage to internal surfaces through lack of treatment, pitting, bagging, corrosion, pH, and other related subjects and there seems to be the same degree of information on how to get rid of the stuff in the event someone does not properly treat the water. From what we have been able to glean from authoritative sources the following methods are available.

# 1 . Meehan i ca 1 #2. Chemica 1

Removal of scale by mechanical means is divided into only one of which applies to the fire tube product. the use of vibrators which are cleaners that vibrate hammerlike action so that the scale is jarred off.

two general classes, This method involves the tube with a

The cleaner consists of a small motor which can convert the energy from steam, air or water into high rotative motion. Attached to this machine is a device termed a "knocker" which when rotated at high speed in the tube vibrates with great force.

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However, this will only remove the scale deposits on the boiler tubes and leaves the scale on the furance tube and tube sheets, or heads. The chemical method would seem to be the best to use although there are certain dangers which should be well understood before the attempt is made.

The chemical method of cleaning the insides of packaged boilers involves the selection of a chemical (acid) which will react with the type of scale present.

Most hard scales are of the calcium or magnesium type, with calcium being the most prevalent. The acid recommended for the elimination of this type scale is known as Muriatic acid, available at all chemical supply houses.

Muriatic acid is dangerous to use and it is strongly recommended that the greatest precautions be exercised in its use. Protective clothing, eye shields, greased face - or masked, with rubber gloves for the hands is our recommendation.

In using this acid the quantities needed must first be determined. By consulting the literature of the boiler on hand, the total gallons required can be determined. The literature will give the dry and wet weight of the unit. By subtracting the dry from the wet weight the total weight of the water may be determined. By dividing this figure by 8.33 lbs. per gallon, the total number of gallons will be determined.

Secure a sufficient quantity of Muriatic acid to mix one to three with fresh water. One quantity of acid to three of water.

After the Muriatic acid has been diluted with water on the one to three ratio,add to this solution pure sodium bichromate - one ounce to one gallon of the above solution.

Place this mixture in the boiler and fill to the top of the manhole.

Bring the boiler temperature to just below the boiling temperature and allow the boiler to remain at this temperature from eight to twelve hours. Be careful not to breathe the fumes which will be given off during this period. Provide adequate ventilation at all times in the boiler room.

Open the manhole and with a strong light, observe the appearance of those portions of the water side which had scale deposits prior to cleaning. After the solution has removed the scale (will fall to bottom or go into solution), it is necessary to neutralize the acid solution to prevent etching or thinning the tubes.

Add to this solution of Muriatic acid and water, soda ash in quantities of 150 to 1. For every 150 pounds of water, add one pound of soda ash, since it comes in dry form.

Bring boiler to just below the boiling point and allow the solution to remain for approximately one hour.

Secure a sample of the remaining solution in the boiler and test to see if the soda ash has neutralized the acid content. If not, add more soda ash and bring unit to boil as per the above.

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After the boiler water has been neutralized , drain unit and flush boiler two times with fresh water. When this is finished, make sure to add sufficient quantities of sodium sulfite to bring the sulfite content to within 25 to 50 PPM. Treat for proper pH as well as any other treatment recommended.

E. CAUSE OF TUBE LEAKS

The boiler tubes will , on ocassion, become loosened in their joints and will require repair.

Normally tubes wil leak at their point of attachment to the tube sheet and this type of leakage will generally occur at the beginning of the first tube pass; the bottom of the tube sheet at the rear of the unit.

This condition will occur through the following conditions:

1. Over firing (exceeding the rating) of the boiler. 2. Thermal shocking of the unit. 3. Hot firing a cold boiler . 4. Scale build up on tubes or tube sheet . 5. Cold condensate returns. 6. Oxygen in water.

1. OVERFIRING THE UNIT : This will cause excessive temperatures in the rear turning box . A point will be reached wherein the rate of heat transfer from flame through metal to water will not be great enough and a gradual increase in turning box temperature will occur. Tube end temperature will begin to rise to 750 degrees and thereby cause the tube joints to become loose. Leaks will occur if condition prevails for ariy length of time.

2. THERMAL SHOCKING: Thermal shocking of a unit describes a condition whereby the hot water in a unit is suddenly replaced with cooler water.

If this condition occurs over an indefinite length of time the tubes, contracting and expanding, may become loosened in their joints and may leak. This condition is particularly important in hot water boilers where the amount of water returned to the boiler is dependent on system pumps and system method of operation.

If the boiler is not protected against cold return water, either through system design or operation, it is advisable to correct this condition at the earliest possible time as damage is a certainty.

York-Shipley, Inc. manufactures a safety control which affords complete and positive protection against thermal shock of water boilers. This proven control is adaptable to any boiler, regardless of its make. The control is completely described in the York-Shipley, Inc. Bulletin ID-61-333 available on request.

3. HOT FIRING A COLD BOILER: Hot firing a cold boiler is another method whereby tubes can be made to weep or leak. In all trade manuals dealing with this subject it is recommended that the unit be brought to temperature slowly by keeping it on a low fire position until the desired temperature is reached .

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It should be noted here that the reverse of this procedure is what is referred to as thermal shocking.

Leaks can also occur if a steaming boiler is suddenly shut down and the condensate return pump shut off at same time. The unit will continue to steam and the water level continue to fall. A point will be reached where tubes will become exposed and overheated. The furnace tube of a unit, in these instances, is usually the point at which the failure is noticeable since sagging or blistering will occur near the hot refractory. This would be the same type of sagging or blistering that would occur in a furnace tube if the unit was fired without water.

4. SCALE BUILDUP ON INTERNAL SURFACES: Will eventually cause the unit to leak. This subject is covered under A-1, B-2 and D.

5. COLD CONDENSATE: Cold condensate return will eventually cause tubes to leak. It is recommended that condensate return temperature be controlled such that the temperature never falls below 160 F.

Users of high pressure steam for processing where a large amount of make up water is necessary should be particularly careful to not only treat this raw water, but to heat the cold water. The easiest way, at a minimum of expence, would be to apply a steam coil or heater in the condensate tank. If the tank is vented to the atmosphere, this method will assist in driving off dissolved oxygen before it reaches the boiler. In this instance it still will be necessary to treat for oxygen through the administration of sodium sulfite according to the recommendation of the boiler water treatment company employed.

6. OXYGEN IN WATER: Dissolved oxygen has been covered under A-2 as well as other parts of this section. It is an extremely important item to be considered. Every owner of new or old equipment should be cautioned to look into this subject very carefully no matter what type of boiler he is using. Hot water boilers, low pressure steam boilers, and high pressure steam units deserve equal attention.

F. CONDENSATION

With the trend increasing in the application of hot water boilers and the simultaneous increasing availability of gas fuel the industry is producing more gas fired hot water boilers than in the past.

Inherent with gas firing is the production of water vapor in the combustion product. As gas is burned water vapor is automatically produced. It is part of the combustion formula.

Under certain conditions, this water vapor is condensed out of the flue gas to form beads of moisture on tubes and tube sheet. The amount of water produced is entirely dependent on how long these conditions prevail. Due to the high heat in the combustion chamber the water remains in a vapor state and is transported through the flues with the products of combustion. It will remain in the vapor state so long as it is not cooled to its "dew point" (the temperature at which water vapor turns to the liquid state).

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Expdrience has shown that if the flue gases contact any surface which is at 140 F. or lower, small beads of moisture (water) will form on this surface, and will continue to form so long as the surface remains at this temperature and gases scrub over it.

A gas fired hot water boiler is a perfect set up for this type of congensation. If the boiler water temperature is lowered to approximately 140 F. moisture will begin to condense out of the flue gas . This moisture will accumulate on the tubes and on the tube sheet of hot water boilers. If the unit remains at this low temperature for any length of time a substantial quantity of water will be produce and will simulate a leaking boiler.

Some heating systems are designed to vary the temperatures of water supplied to the unit heaters, radiators, convectors, etc., in accordance with the outside temperature. As the weather outside becomes warmer the water temperature to the heaters is reduced. In most cases the boiler water temperature is lowered to control system temperatures.

If this boiler water temperature goes below l40°F., water will condense out of flue gases and water will commence to drip out of the unit.

York-Shipley, Inc. does not recommend that system temperatures be controlled by lowering boiler water temperatures. It recommends that system temperatures be controlled through a device which will blend enough water from the unit with returned from the system to give the desired system temperature.

York-Shipley, Inc. has a control which can be readily applied to any unit to provide for this type of control. Not only does this device eliminate the condensation problems, but it has incorporated into the device a safety control which will protect the unit from thermal shock. The device does not in any way affect the indoor-outside control system . It is compartible with it. This control is described in ou Bulletin ID-61-333, available upon request.

G. INSTALLATION OF NEW TUBES

During the days of hand rolling, the tubes were usually rolled just enough to obtain tight joints, and little or no damage was done to the tube wall or tube sheet. With the use of power driven expanders, the possibility of over rolling and damaging the metal by cold working becomes greater.

l. OVER-ROLLING TUBES: When a tube is severely over-rolled, work hardness occurs and other physical properties are changed. Over-rolling cold works the metal and reduces its ductility and may result in surface tears and reduce its resistance to corrosion. The holding power of the rolled tube is also reduced by over-rolling.

Special attention should be given to the manner in which tubes are rolled in new boilers and replacements in existing installations.

2. TUBE INSERTION: Before any new tubes are installed, all tube ends and tube sheets should be carefully cleaned. The preservative should be removed from the tube holes and the tube ends by wiping with carbon trichlorethylene or an equivalent solution. Any rust should be rem~ved with a fine emery cloth. All tube ends and tube seats must be smooth

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and free from grease, rust, or other foreign particles. The tubes should be installed as soon as possible after they are received, and any tubes that become rusty before being expanded should be removed and re-cleaned. When installing tubes, workmen should be cautioned not to put their greasy hands in tube holes or on polished tube ends, or let the polished ends rub against dirty tubes.

All tubes should project just enough beyond the outside surface of the tube sheets for fire tube boilers so as to provide material for the proper beading of the end of the tube against the outside surface of the tube sheet. While being expanded, the tubes must be held in order to prevent them from moving in or out of the tube hole. The tubes should enter the holes parallel to the center-line of the holes, and have even projection at opposite ends. One end of a tube should not be expanded unless the opposite end has been entered in its hole with approximately the correct projection.

3. LUBRICATION: A vegetable oil such as castor oil, or specially prepared expander lubricant should be used to lubricate the expander rolls and mandrel, as this type lubricant is easier to remove from the surface of the boiler than a mineral oil during the boiling out. Expanders should be washed frequently in kerosene to keep them clean.

4.

On straight expanding, it is advisable to use two (2) expanders, letting one of them cool while the other is in use. The tubes in the bottom of a fire tube boiler should be expanded first so that if any oil drips off the end of the tube from the expanding operation, it cannot get into a tube seat into which a tube has not been expanded.

TUBE HOLES AND EXPANDERS: Tube holes are drilled or reamed somewhat larger than the nominal outside diameter of the tubes. In order to make the tubes tight in the tube holes, it is necessary to cold-work the tube ends and tube holes until the tube ends, if free, have a greater diameter than the tube holes when free. This is accomplished by an expander, which is inserted into the end of the tube. An expander is made up of three or five expanding rolls and one (1) or two (2) flaring rolls, held in place by a body, and a tapered mandrel. The rolls are set at an angle to the centerline of the body so that when the mandrel is rotated in a clockwise direction, it feeds into the body, pushing the rolls out against the inside of the tube. The rotation of the mandrel is continued until the diameter of the tube has been increased the desired amount.

The expanders must be designed to suit the size and gauge of the tubes and the thickness of the seats or tube sheet thickness. The rolls should be tapered so that they will expand the tubes parallel to the seat. The tools should be long enough to expand the tubes one-quarter inch (1/4") to one-half (1/2") past the inside edge of the seat or tube sheet. This gives the tubes a slight bulge at the inside edge of the seat and prevents them from pushing out when the opposite end of the tube is expanded. The large end of the rolls should be rounded off so that they will not dig into the tube as the expander moves forward. Expanders are furnished to suit the different tubes and seat, and the proper expander must be used for each joint.

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5. TUBE ROLLING: When expansion of a tube is started, the expander should be set so that the small end of the flaring roll has just started to enter the tube, and the expander body will move into the tube as the mandrel is rotated in a clockwise direction. The proper setting of the expander can be determined only by experience, as it is necessary to set the expander back farther from the end of the tube when expanding into a thin tube sheet.

If the expander has been properly set, the tube should be properly expanded when the small end of the flaring roll reaches the outside edge of the seat on fire tube boilers. The small end of the flaring roll should not pass the outside edge of the seat as it will cut the tube or pull it out of the tube sheet.

The expansion operation should be slow enough to prevent the tubes from heating up while being expanded. A tube that heats up while being expanded is apt to shrink away from the seat when it cools off.

It is better to have the tubes slightly under-rolled than over-rolled as the under-rolled tubes can be re-rolled if they leak on the hydrostatic test. Over-rolled tubes may have to be removed and new tubes installed.

When a tube has been properly expanded, it will have a slight bulge for a distance of about one-quarter inch (l/4") past the inside seat and the diameter of this bulge should be approximately 0.20 inches greater than the original diameter of the tube hole.

6. FLARING: The flared position, or bell, of the tube outside of the tube sheet on fire tube boilers should equal the diameter of the tube plus 1/8 inch measured at the end of the tube.

7. SIGNS OF OVER-ROLLING: When a tube has been sufficiently expanded, there will be a slight indication of flaking of the mill scale or paint around the outside of the tube roll. Excessive flaking of this mill scale or paint generally indicates over-rolling; and if the flaking starts the expanding operation should be stopped. Quite often, carbon moly or chrome moly tubes will start to flake before they have been properly expanded. A small amount of flaking in these alloy tubes is not objectionable.

H. REPAIR OR REPLACEMENT OF TUBES

Repair or replacement of boiler tubes is sometimes necessary due to scale, shock, corrosion, or pitting.

l. "TOUCHING UP" TUBES: Normally it is only necessary to "touch up" the tubes. York-Shipley recommends in all instances that a hand tube roller be used. It seems to be becoming a habit with some boiler repair people to use a heavy duty machine to roll the tubes. Actually the use of a heavy duty tube roller can cause more trouble than was originally present as in most cases the use of this machine will over-roll tubes and cause them to fail again. Owners of equipment should be careful to supervise tube rolling operations and hand roll only.

In touching up weeping tubes, it is normally necessary to turn the hand operated tube roller a turn and a half from point where expander actually "takes hold" and actually starts to expand.

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2. HAND ROLLING VS MACHINE ROLLING: In performing any tube rolling operation, extreme care should be taken to prevent the bead of the tube from coming away from the tube sheet. A . 002" fee 1 er gauge should be used to check this point. If the tube bead is away from the sheet more than .002", the tube end should be rebeaded with a beading tool.

3. TUBE END APPEARANCE: The appearance of the tube bead will generally indicate the type of repair which is necessary.

If the bead shows mill scale, due to overheating, the tube should be removed and replaced with a new tube. In this case, the tube end will be too soft to take any satisfactory type of beading operation which will last any length of time.

4. REMOVAL OF EXTERNAL SCALE: If the tube sheet is covered with scale or salts great care and attention should be used in removing this scale from underneath the tube bead as any accumulation of scale under the bead will act as an insulator and retard the flow of heat from tube bead to tube sheet. The tube end will become excessively overheated and fai 1 soon.

5. TUBE BEADING INSTRUCTIONS: Tube beading operations should be such that the tube material is mechanically upset and pushed in a solid mass against the tube sheet. There should be no cavity under the bead to act as an insulator, and cause overheated tube ends.

To prevent this from occuring on initial installations, the flaring operations should be carefully controlled. If the tube is flared too severely, the beading operation will be such that the tube end is folded over to meet the tube sheet resulting in a cavity under the bead. A good upsetting operation can be secured through flaring the tube end, after rolling, approximately 7° off the vertical.

6. TUBE REMOVAL: There are occasions where the tubes in a boiler, through over-heating, scaling, pitting, or over-rolling will have to be removed.

In removing damaged tubes from a boiler, proper care shall be taken that the tube holes in the tube sheet are not damaged or scarred.

If fire cracks have developed, or cracks in ligaments started, it is advisable to remove the entire pass of tubes, including the tube sheet.

A new tube sheet, or a portion of one, can be secured from the factory and welded into place. New tubes can then be inserted and fastened as described above .

It is not recommended that the repairs be made to tubes and tube sheets through welding. Welding a fire crack is only a temporary cure. Once a crack has been started in metal, it is impossible to stop it from growing unless a hole is drilled at end of the crack--and this is impracticable.

7. HYDROSTATIC TESTING: The unit should be subject to a hydrostatic test after the touch up or new tube installation.

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8. FIRE OFF INSTRUCTIONS: After the installation, the unit should be fired on low fire long enough to bring it up to temperature, and then allowed to operate on high fire position.

BOILER WATER, ITS TREATMENT ANO CAUTIONS.

For your convenience in better understanding the problems which, on occasion, come up as a result of improper treatment of the water side of boilers, we offer the attached information which deals with the following subjects:

1. Atmospheric Corrosion 2. Fire Side Corrosion 3. Pitting Corrosion 4. Water Line Corrosion 5. General Rules for Avoiding Corrosion 6. Scale Formation 7. "Bagging" 8. "Blistering" 9. "Foaming"

10. "Priming"

Corrosion is a major factor in shortening the useful life of boiler tubes. Actually, more tubes must be replaced in low pressure boilers because of the effects of corrosion than from any other single cause. Boiler design and composition or quality of tubes are seldom found to be primary considerations, but the necessity for replacement of tubes can usually be traced to conditions of environment during service.

In large power boilers, protection against fouling, scaling, and corrosion is generally provided by adequate feedwater heaters and deaerators and the continuous application of effective feedwater treatment. When return condensate is used, as make-up oxygen and carbon-dioxide, the active corrodants, are reduced to low values, and water is kept to the proper degree of alkalinity at all times.

This is not the case, however, with many small boilers such as portable boilers, or those for process or limited power generation, or low pressure boilers for heating. With this type of equipment the auxiliary water conditioning facilities and technical control necessary for satisfactory and economical operation are usually lacking. Fortunately, the problems are not the same and therefore there are rather simple methods available which do not require the services of a technical expert and require only a little care by the owner. When the reasons why boiler tubes serve less than their expected life are clearly understood, simple remedies can be followed which will prolong tube serviceability result in less frequent retubing, lower maintenance costs, and result in fewer outages.

ATMOSPHERIC CORROSION

A piece of steel in the middle of a desert will not rust for a long time, but near the shores of a lake, ocean, or stream, it will rust quite rapidly. Steel does not corrode appreciably in dry air - but only in the presence of moisture.

Likewise, steel will not corrode in clean, alkaline, freshly boiled water if air is kept away. However, corrosion of the steel takes place as soon as the water is exposed to air and has a chance to absorb oxygen. It can be seen

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therefore that clean neutral water alone will not affect steel, but that corrosion will take place in the presence of oxygen also.

htmospheric corrosion may occur in boilers in isolated cases, but generally t here are other factors that contribute to the corrosive attack, and eventually to tube failure, if precautionary measures are not followed.

FIRE SIDE CORROSION

Corrosion on the fire side of boiler tubes is caused by moisture, condensing from the atmosphere during periods of shut down, or from flue gases during operation. This type of corrosion is especially troublesome in boiler installations near bodies of water or where the atmosphere is otherwise humid and is accelerated by the use of high-sulfur fuels. Sulfur gases may condense on tube surfaces when the boiler is operated at temperatures between about 160° and 240°F., depending on the kind of fuel and methods of firing.

Som0 boiler0, such as those in greenhouses, operate at water temperature of 140 to 150 F., and under such conditions the condensing gases form sulurous and sulfuric acids which attack the tubes and result in corrosion. If the percentage of sulfur in the oil is high, this situation is worsened during shutdown periods because of high humidity in the air. When shutting down the boiler under such conditions, the fire side tube surfaces should therefore be brushed and flushed to remove the winter's accumulation of soot and other products of combustion; this should be followed by blowing air through to dry out these surfaces. Also, in extremely humid locations, the stack should be disconnected and a tray of unslaked lime placed in the ash pit to keep the fires side dry. This lime must be renewed whenever it becomes mushy, so it will not lose its effectiveness as a drying agent. It follows that the tubes should be kept clean at all times and that an oil low in sulfur should be used.

Cleanliness of tube surface gives the added advantage of increasing the efficiency of the boiler in addition to lengthening the life of the tubes.

Leaky roofs above boilers and loose brickwork have also been known to cause corrosion of this type, both to boiler casing and to fire side surface of water tube boilers. A careful inspection followed by the necessary repairs can eliminate this source of trouble.

PITTING CORROSION

Pitting is probably the most destructive form of corrosion that affects the water side of boiler tubes, and its damage is especially severe in fire tube boilers. It is sometimes easily recognized by the presence of randomly scattered pits. Frequently only a few pits are present and most of the surface is unattacked; in other cases, the pits cover most of the surface, and as a further extreme, the pits all run together and the corrosion takes the form of uniform attack. The frequency of the pits is, to a large extent, determined by the degree of acidity or alkalinity of the water.

Acidity and alkalinity are expressed by chemists in terms of a scale of pH values (hydrogen ion concentration) on which a strongly acid solution (strong muriatic or sulfuric acid) is rated as one and a strongly alkaline (concentrated caustic soda) solution is rated as 14. A neutral water has a pH value of 7. Slightly acid and slightly alkaline water conditions (pH 5 to 9.4) are especially conducive to the formation of pits.

The rate of corrosive attack is also increased by dissolved oxygen in the boiler water. Dissolved oxygen corrosion works in three general ways. (1)

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air bubble pitting, (2) scab pitting, and (3) soft scab pitting. The latter occurs in boiler drums, superheater tube surfaces, steam lines, and other surfaces where the metal is not submerged during idle periods. We can therefore eliminate this type from our discussion since it has little application here. The first two named are of main interest.

Air bubble pitting is caused by the formation of air bubbles on boiler metal surfaces under stagnant conditions. Surface waters are generally saturated with dissolved oxygen because of their exposure to the atmosphere. Oxygen may be present in varying amounts, depending on the temperature of the water, which illustrates that oxygen solubility decreases with increase in temperature.

Well waters usually contain less dissolved oxygen than surface waters, and in deep well supplies dissolved oxygen may be absent, although dissolved carbon dioxide may be present which is also corrosive to steel.

When a boiler is filled with oxygen saturated water, small increases and fluctuations in water temperature tend to throw out the dissolved air as small bubbles, which readily attach themselves to any convenient surface. This can be demonstrated by merely filling a clear bottle with cold tap water and allowing it to stand for a few days. The bubbles will be quite profuse on the sides of the bottle. Pits form under the bubbles due to corrosion caused by the difference in conditions under the bubbles versus the conditions on the steel around the bubbles.

In some cases the pits occur in a straight line and it is easy to come to the conclusion that the weld is involved. This is not true, however, in the vast majority of such examples. Straight line pitting is almost always located along the top of the boiler tube. The air bubbles just discussed remain more easily on the top of horizontal tubes, since they are less affected by water circulation in those locations. The upward water circulation also causes eddy effects above the tubes and conditions are generally more conducive to corrosion.

Sometimes a set of new tubes installed in a boiler has been found to last less than a year whereas the former tubes lasted five to ten years. Obviously something has changed. Often the tubes are blamed for the failure when actually there have been changes associated with the operation and maintenance of the boiler. A different method of starting up may have been used. Circumstances may have been such that the boiler was immediately fired when the old set of tubes were put in, while the new set may have lain in the fresh water for some time and air bubble pitting may have started, leading to the eventual failure of the tubes. The temperatue of the fill-up water may have been different and therefore more air was present in the new installation. The composition of the fill-up water may have changed; a thin scale may have been laid down at the beginning of the life of the old tubes, which served as a protection. Changes in electrical connections may have induced stray currents leading to possible electrolytic corrosion. Small air or steam leaks around pipe joints and valves may have let air into the new set up. Air vents may have become plugged due to jarring of the piping. In short, any number of things may have happened and caused the failure.

A large number of boiler tube failure takes place in the fall when starting up for winter operation. These are due to both the air bubble pittings previously mentioned, and to oxygen sucked into the system through packing, etc.

It is possible to eliminate the effect of these mechanisms during such stagnant periods by adding sodium chromate to the water at the rate of 1 lb. per 50 gallons of boiler water or adding sufficient caustic soda, usually 1/2 lb. per

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100 gallons will do, to bring the pH of the water above 10.5 or 11.0. Either of these chemicals should be left in the boiler during operation to continue to protect the metal surfaces.

It is therefore recommended that when a boiler is freshly filled, it should also be fired immediately until the boiler water reaches a relatively high t emperature so that most of the air in the water will be driven off. In the case of a steam boiler, it should be fired long enough and hard enough to take some steam from the unit to completely deaerate the water in the boiler. It is far better when shutting down to leave the deaerated dirty water in the boiler than to drain and refill without subsequent firing.

It is necessary to pay close attention to pump and valve packing in steam and water systems - as in household heating units - to reduce of make-up water required and to prevent continuous access of air. absence of such additions of air, the oxygen initially present in a system and that introduced with small amounts of make-up water will by a relatively slight amount of corrosion.

circulating the amount In the closed be consumed

There is good reason to believe that scab pitting proceeds under operating conditions at points where penetration from air bubble corrosion has started, especially if no attempt is made to inhibit the corrosion characteristics of the water with chemicals. It is possible, however, to virtually eliminate pitting at operating temperatures by maintaining the boiler water above the theoretical pH of 9.4. A maximum value of 11.0 is considered good practice.

WATER-LINE CORROSION

Water-line corrosion in vertical fire tube boilers is also due to an excess of oxygen in the boiler water. In fact, in areas of very bad water conditions, the water may actually be acid. In either case, the tubes fail by thinning, which is most pronouned at or slightly below the water-line. As in the case of the air bubble pitting, the corrosion is attributed to differences in oxygen concentration which exist in the water at the water-line as against the concentration in the water below the water-line. Excessively hard waters cause a hardness scale to deposit on the tube and shield the tube from oxygen, thus causing corrosion at the water-line by the same mechanism as that of air bubble pitting.

Water-line corrosion may be avoided by making certain that boiler water is sufficiently alkaline and free of oxygen.

So far we have discussed fire side corrosion, pitting and water-line attack. There are other types of corrosion which are not sufficiently common to merit our consideration here except briefly .

Caustic Embrittlement is a subject which is still unsettled. There are many pros and cons on this subject but it is not too common a problem at this time.

Copper water heaters have been suspected as causing some of the pitting failure encountered in boiler tubes. The effect of copper will be confined to the tubes closely adjacent to the copper itself. If the bottom tubes as well as the top tubes are pitted, the copper may be ruled out as a factor since these heaters are usually located in the upper water space.

If the boiler water is so acid that it dissolves the tubes, the only solution is to use chemicals to make the water alkaline or to develope a different source of water.

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GENERAL RULES FOR AVOIDING CORROSION

In reviewing the various types of corrosion encountered in boilers, it is evident that water conditions play a most important part in the failure of boiler tubes. Experience over many years has verified the fact that oxygen dissolved in the feedwater as air probably causes more trouble to users of boilers than any other one condition.

Operators of large boiler installations can usually afford to treat their water more carefully than users of small low pressure boilers. But here are eight general rules to help small boiler operators avoid serious tube corrosion problems and obtain longer tube life with fewer unscheduled shutdowns and more economical maintenance.

l. Keep all boiler fittings and piping tight to keep air out as much as possible.

2. Boil out the boiler with an alkaline cleaner such as trisodium phosphate or a combination of caustic soda and soda ash or one of the newer detergents currently being supplied. This is necessary in order to remove oil or other coatings from the tube surface. These protective coatings are commonly applied to new tubes to prevent rusting during storage and transit, and will cause corrosion if left on the tubes during operation of the boiler.

3. Bring a steam boiler to a good steam output as soon as it is filled after draining to deaerate the water. Heat the water in a hot water boiler to 180 F. for the same reason.

4. Add sodium chromate or caustic soda to the water in the quantities recommended.

5. Preferably use a fuel with low sulfur content, to avoid the corrosive action of sulfur gases.

6. Brush and flush and dry out the insides of fire tubes as often as possible to remove soot and other products of combustion. Also, prevent the accumulation of moisture and condensed sulfur gases.

7. In greenhouses or in damp locations, put a tray of unslaked lime in the ash pit to absorb moisture, and close the boiler. Inspect this lime occasionally and renew when it becomes mushy.

8. Prevent water leakage and do not periodically drain water out of the system. These add to the necessity for the constant addition of make up water, result in loss and dilution of treatment, and introduce air into the system.

Boiler tubes are made with care and precision from the best quality materials available by a number of manufacturers with long experience in this field. Both material and workmanship are governed by ASME and ASTM codes and specifications, to which boiler tubes are made. These are safeguards to insure the quality of the tubing. Millions of feet of these tubes have given long and reliable service in all types of installations where they are used under proper conditions of boiler operation.

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A long and careful study of the courses of boiler tube failures has revealed that the service life of tubes is dependent primarily on environment or conditions of operation of the boiler. Seamless or welded tubes, both made from mild open-hearth steel, have the same general characteristics when exposed to similar corrosive action. It is fairly certain, therefore, that unless systematic and regular precautionary measures are followed to eliminate the factors that cause corrosion in boilers, more or less continuous trouble will be encountered and frequent tube replacement will be necesssary.

After all, these recommendations are easy to follow and require little more than an interest in maintaining the equipment in good condition.

Scale Formation on the water side of boiler heating surfaces is caused by the contact of certain impurities in boiler water with the hot surfaces. Most common among these impurities are calcium, magnesium, and silica. The calcium or magnesium may unite with sulphates or magnesium which are scale forming .

Calcium is common in raw water because it is present in many forms, as marble, limestone, and chalk. Magnesium in various forms is found, too, in raw water from many sources. A well known form is magnesium sulfphate. Silica, found in sand and glass, forms an exceedingly hard, dense scale - actually glasslike.

Scale forming water is said to be "hard". This hardness is either temporary or permanent or both. The temporary hardness may be eliminated by heating the feed water to about 212°F. in an open or deaerating heater where the salts causing temporary hardness are precipitated. The permanent hardness must be controlled by treatment in water softeners or by treatment in the boiler.

There are two definite objections to scale on boiler heating surfaces.

1. Scale is a very efficient "non-conductor" of heat, the degree of non-conduction varying somewhat with its density. Its presence in appreciable thickness means less heat absorption by the boiler water, with consequent loss of boiler efficiency.

2. Because of the fact that scale is a poor heat conductor, the heating surface thus insulated from boiler water on one side and exposed to hot gases on the other may soon reach a dangerously high temperature. Serious damage, rupture of tubes and even boiler shells, has resulted.

Scale formations often increase with the rate of evaporation. Thus, scale deposits will often be heavier where the gas temperatures are highest.

A coating of scale l/16" thick on tubes or boiler surfaces exposed to radiant heat may cause failure of these tubes or surfaces.

Scale deposits are usually an indication of neglect, for scale can be prevented in most cases by proper treatment of the water. When scale has formed to an appreciabl~ thickness, it should be removed; and, once a clean boiler is attained, proper steps should be taken to prevent its recurrence.

Feedwater. All matter, it has been said, is composed of elements. Pure water is a combination of hydrogen and oxygen; that is, two atoms of hydrogen combine with one of oxygen to form H2o. We are all familiar with the fact that water is a good solvent. As a result it does not remain in this pure state very long. As the rain descends, it picks up gases from the atmosphere and dirt in the form of dust and soot. Flowing

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I D-64-440-784 PRINTED IN U.S.A.

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