Section 3

SECTION III Part 1 - INSTALLATIONSECTION III Part 1 - INSTALLATION

Section III - Part 1

High and Low Pressure Steam Boilers

Installation and ArrangementPart 1 - High and Low Pressure Steam Boilers

3-1. Description of Boiler Room Items

1).Reinforced Concrete Pad

A concrete pad of sufficient thickness, preferably with a reinforced mat is important in the planning of a boiler installation. The wet weights are listed in this section on the Boiler Dimension Charts to assist planning for the proper pad. The pad should be level so that all parts of the boiler skid assembly are firmly in contact with the solid support.

York - Shipley strongly recommends that a qualified engineer review the design of the pad(s) used to support all boiler room equipment to meet all federal, state and local codes and site conditions relative to ground conditions and related factors such as seismic conditions, etc.

2).BoilerYork - Shipley 400 Series Boilers are of horizontal three-pass fire-tube design. York - Shipley's standard low pressure steam heating boilers models (SPL) are designed for 15 PSIG pressure. York - Shipley's standard high pressure steam power boilers models (SPH) are designed for 150 PSIG pressure. Higher pressure power boilers are also fabricated by York - Shipley. The main firing tube or furnace, where combustion takes place, is generally located near the center of the pressure vessel. The smaller, convective tubes are located around the furnace and make up the 2nd and 3rd pass of the boiler. All joints are welded in accordance with the requirements of The American Society of Mechanical Engineers ("ASME") as set forth in the ASME Boiler and Pressure Vessel Code, an internationally recognized code. York - Shipley's low pressure boilers (a boiler which steam or other vapor is generated at 15 psi or less for use external to itself) are fabricated in accordance with Section IV, Heating Boilers of the ASME Boiler and Pressure Vessel Code. High pressure boilers are fabricated in accordance with Section I, Power Boilers, of the ASME Boiler and Pressure Vessel Code. Accordingly high pressure boilers are stress relieved and radiographed as required by Section I of the ASME Boiler and Pressure Vessel Code. All boilers and pressure vessels fabricated by York - Shipley are built in full compliance with the requirements of the ASME Boiler and Pressure Vessel Code. In addition, the fabrication of each boiler and pressure vessel is performed under the scrutiny of an independent inspector authorized by the National Board of Boiler and Pressure Vessel Inspectors (the "National Board"). In addition, each boiler and pressure vessel is registered with the National Board. Documentation of the inspection and the registration number is found, among other place, on the boiler which is stamped with the inspectors number and the boiler's registration number.

York - Shipley offers both a wetback and a dry back boiler design in its 400 Series Packaged firetube boilers. The principal difference in these two designs is in the rear turning box which directs the hot combustor gases from the firing tube or furnace to the second pass convective tubes.

In a dry back boiler, the turning box is comprised of a refractory lined arch and a refractory lined rear cover or rear door. This design offers full access to the second pass tubes from the rear of the boiler by virtue of the near cover of rear door. In this design all tubes can be removed from the front or rear of the boiler.

In a wet back boiler, the turning box is comprised of a water cooled arch and a water cooled rear water wall. Access to the second pass tubes is restricted from the rear of the boiler to a manway which permits access to the turning box. In this design, certain second pass tubes can only be removed from the front of the boiler. The remaining tubes generally can be removed from the front or rear of the boiler.

3).Steam Outlet Connection

The standard steam outlet connections on York - Shipley is high pressure steam ("SPH") boilers; Series 442, 448 and 460, are threaded. Series 464 and larger boilers are 300# flanged. The standard steam outlet connections on York - Shipley's low pressure steam (SPL) boilers are 150# flanged. Accessory items, such as header valves, non-return valves and others of similar nature are available in either 300# or 150# designs.

4).Manhole One manhole is installed on Series 460 and larger (100 HP and larger) as standard equipment for inspection and maintenance of the internal surfaces of the boiler. The manhole is generally 12 x 16 on all high pressure units and generally 11 x 15 on low pressure units.

5).HandholesHandholes, generally 3-1/2" x 4-1/2", are also placed in boilers for inspection and maintenance of the internal surfaces of the boiler.

During installation make sure all components have sufficient clearance so that functions of each manhole and handhole, as well as the components, can be maintained.

6).Test TeeCare should be taken to ensure the test tee is not obstructed.

The test tee is provided for the convenience of inspectors when calibrating the steam pressure gauge on all York - Shipley steam boilers. It also serves to relieve the vacuum created by steam condensing upon shut down of the boiler.

7).Lifting LugsLifting lugs are provided on the top of the shell at the front and rear for lifting the boiler into position. These lugs should be used for all overhead lifting. A spreader bar should be used when lifting from a single point.

WARNING

Do not sling the boiler.

8).Rear Covers and Door (Dry back boilers)

All dry back boilers are provided with a two-piece rear cover which can be removed for inspection, cleaning, maintenance and/or tube removal of the third pass tubes.

The lower cover or rear door provides access to the rear turning box, furnace and second pass tubes for inspection, cleaning, maintenance and tube removal. The rear door is available with a swinging hinge as an option up to 80 HP. The 100 through 1300 HP have a swinging hinge as standard. Provide adequate clearance in rear for maintenance, cleanout, rear cover removal or rear door swing and, if required, tube removal.

Rear Covers and Manway (Wet back boilers)

Wet back boilers are generally provided with a two piece rear cover which can be removed for inspection, cleaning, and/or the tube removal of the third pass tubes.

Access to the second pass tubes is through a manway which permits access to the rear turning box, furnace and second pass tubes for inspection, cleaning and maintenance, but not tube removal. The manway is available with a swinging hinge as an option up to 80 HP. The 100 HP through 1300 HP have a swinging hinge as standard equipment. Provide adequate clearance in the rear for cover removal, manway swing and, if required, rear tube removal for the third pass tubes.

9).Rear Cover MountingRear covers are normally held in place and sealed with studs and nuts. Wedge pins are available as optional items on dry back boilers.

10).Water GaugeAll steam boilers are supplied with a water gauge to provide a visual indication of the water level within the boiler. The water gauge glass is attached with valved fittings to a water column. The lower gauge glass fitting is provided with a drain connection.

11).Safety (Explosion or Puff) Relief DoorsOptional relief doors are available and mounted in upper rear cover sections.

DANGER

Persons must keep clear of relief doors due to danger of bodily contact by door in the event of a puff or combustion explosion.

12). Flue Gas Outlet

Standard boilers have a flanged vertical connection.

13).Front Cleanout CoverFront cover is provided with an access plate for cleanout without removal of the entire front cover. The front cover is attached with studs and nuts. Removal provides for inspection, cleaning and tube removal. The front cover is also available with optional hinges. Series 564 and larger are provided with hinges as standard equipment. Always provide adequate clearance for maintenance, cleanout and front door swing or removal.

14).Rear Observation Port

The lower section of the rear cover includes an observation port for viewing the burner flame.

15). Pressure Gauge, Siphon and Cock

All steam boilers are provided with a steam pressure gauge suitable for the design pressure of the boilers. The gauge is fitted with a siphon and shut-off cock and located at the top center of the boiler.

16).Stack ThermometerAn optional thermometer is available. This is mounted in the vertical flue gas outlet.

17).Safety Relief Valve(s)The 500 Series boiler Series are provided with adequate pressure safety valve(s) as required by ASME code. Standard safety valves are set at the maximum design pressure of the boiler shell, unless otherwise requested. Should the pressure exceed this rating the relief valves open to relieve the excessive steam produced. This prevents boiler rupture.

It is recommended that exhaust steam piping be run to a point outside the building where it can be released without injury to personnel or property. Another practice is to run this piping through the roof.

DANGER

Exhaust steam piping from safety relief valves must terminate where the steam can be released without danger or injury to personnel.

All low pressure SPL and high pressure SPH units are equipped with side outlet safety valves. Low points in all safety exhaust lines should be dripped to remove all water.

On low pressure units the exhaust piping size is the same as the safety valve size. On high pressure units, the exhaust piping size is one pipe size larger than the valve.

Safety Valve With Drain & Vent Assembly

19 & 20).Jacket and InsulationThe boiler shell is insulated, jacketed and painted with high temperature enamel paint. The jacket should be protected as much as is possible during storage and installation.

21).Burner

a). Series 542, 548 and 560

1). Light Oil, Gas or Gas/Light Oil

The horsepower determines the burner used, 25-30 HP boilers use the "NV" burners, 35-80 HP boilers use the "FV-20" burner and those units with 100-150 HP use a model "FV-40" burner. These burners are pressure/mechanically atomized #2 oil and/or external mix gas type. FV burners are guaranteed low fire start. Optional operation sequences are available.

2). Heavy Oil or Gas/Heavy Oil

Models 40-80 HP firing heavy oil #4, #5 and #6 and combination gas and heavy oil use the "F" burner. Models 100- 150 HP use the "FV-40" burner. These burners are low pressure air atomized and/or external mixed gas type. The heavy oil and gas burner combination are guaranteed low fire start. Optional operating sequences are available.

b). Series 564 and 576

1). Light Oil, Gas or Gas/Light Oil

All boilers use the "FV-60" or FV-100 model burner. These burners are pressure mechanical atomized #2 oil and/or external mix gas type. Number 2 oil burners are also available air atomized.

2). Heavy Oil or Gas/Heavy Oil

All models firing heavy oil #4, #5 and #6 and combination gas and heavy oil use the "FV-60" or FV-100 burner. These burners are low pressure air atomized and/or external mixed gas type.

b). Series 582, 588, 596 and 5112

1). Light Oil, Gas or Gas/Light Oil

All boilers use the "FA" model burner. These burners are low pressure air atomized #2 oil and/or external mix gas type.

2). Heavy Oil or Gas/Heavy Oil

All models firing heavy oil #4, #5 and #6 and combination gas and heavy oil use the "FA" burner. These burners are low pressure air atomized and/or external mixed gas type.

22).Control Panel

a). Series 542, 548 and 560

The "NV" burner does not have a "control panel" as such. This boiler includes a junction box which provides means for connection to the available power supply. "FV" and "F" burners include a control panel in front of the burner which includes the on-off switch, flame control, the motor starter etc. in a hinged box with a latch. Power connection for the burner is made inside the panel.

b). Series 564 and larger

The control panel includes on-off switch mounted on the side of the boiler, flame control, motor starter, etc. in a hinged box with latch. When alarm bell is supplied, it is mounted on the control panel.

23).Indicating LightsOptional lights and bells are available to indicate safety or sequential conditions.

24).Blower Air Safety Switch

a). Series 542, 548

An air safety switch is standard on gas, gas and oil and heavy oil and is optional on straight light oil.

b). Series 560 and larger

Air safety switch is standard on all burners.25 & 26).Limit And Modulating Controls

a). Series 542, 548 and 560

All steam boilers have 2 limit controls as standard equipment. One control is the operating limit and is used automatically to turn the burner on and off when the desired operating pressure is reached. The second control is the high (safety) limit used as an additional safety control to prevent the boiler from developing excessive pressure. As an optional feature the safety control can be furnished with a manual reset. Low pressure steam limits have an upper range of 15 psi and high pressure limits have an upper range of 150 psi. The safety limit controls are normally set slightly below the safety valve setting.

When a boiler is equipped with a firing rate motor either modulating or two position high/low, an additional control is furnished to regulate the position of the firing rate motor. This control is normally adjusted at a pressure setting lower than both limit controls.

b). Series 564 and larger

All steam boilers have 2 limit controls as standard equipment. One control is the operating limit and it is used to automatically turn the burner on and off when the desired operating pressure is reached. The second control is the high (safety) limit used as an additional safety control to prevent the boiler from developing excessive pressure. As an optional feature the safety control can be furnished with a manual reset. Low pressure steam limits have an upper range of 15 psi and high pressure limits have an upper range of 150 psi. The safety limit controls are normally set slightly below the safety valve setting.

All boilers include a firing rate motor referred to as modulating (mod) motor with controller furnished to regulate the position of the firing rate motor. This control is normally adjusted at a pressure setting lower than both limit controls.

27).Low Water Cut-OffAll steam boilers are equipped with a low water cut-off control. This control interrupts the operation of the burner whenever the boiler water line drops below a safe level. The standard low water cut-off (LWCO) is a combination manual reset, alarm switch and feed water pump control all mounted in a water column. The water column includes gauge cocks, water gauge glass, try cocks and drain valves. The water gauge is to provide a visual indication of the water level within the boiler. The water gauge glass is attached with valved fittings to the water column. The gauge glass fitting is provided with a drain connection.

The main consideration for the LWCO is that ample space be provided and no pipes or obstruction be permitted to interfere with their function.

IMPORTANT

Be sure to flush your boiler water level control(s) daily while

boiler is in operation. Failure to follow this procedure can cause the control to malfunction resulting in serious boiler damage

and personal injury.

CAUTION

When flushing control, hot water and steam will flow out the drain pipe. Control must be flushed at least once a day while boiler is in operation. Opening blowdown valve also checks the cutoff operation. While burner is on, open blow-off valve. Float should drop. Boiler feedwater system will be turned on and then the burner will stop; hot water and steam will flow out the drain pipe flushing away sediment.

CAUTION

If burner does not shut off during blowdown, replace control immediately. Continue draining water from control until water is clean. Close valve. Water level should be restored automatically through feedwater system.

WARNING

Low water cut-off piping must not be insulated.

28).Auxiliary Low Water Cut-Off

The second optional low water cut-off can be piped in the same manner only mounted on the opposite side of the boiler and the blow-down valve connected to blow-down piping.

32).Forced Draft FanAll steam boilers are equipped with forced draft blowers which operate independent of high stacks or chimneys. The forced draft blower provides all the air required for proper combustion.

33).Modulating LinkageThe modulation motor and linkage provides proportioning of the fuel and the air to the burner. This assembly maintains proper fuel to air ratio throughout the entire range of boiler operation.

34-48).Condensate Return System

The condensate tank is provided to collect all condensate return from the steam system. The tank should be of sufficient capacity to provide all the water required for 10 minutes of boiler operation without adding any make-up water to the tank. This should be equivalent to 15% of the hourly output of the boiler.

Feedwater pumps are directly driven by electric motors, and are used to feed water to the boiler on demand by the boiler level control. The pumps are sized to deliver approximately 1.3 to 2 times the evaporation rate of the boiler at maximum operating pressure.

The feedwater tank must be elevated to create a positive head on the feed water pump. The required head depends on the temperature of the water in the tank and the design of the feedwater pump.

For temperatures above 200F, consult the factory for correct water level heights and pump selections.

For 200F water level in the tank should be 7 from C/L of the pump.

For 190F water level in the tank should be 5 from C/L of the pump.

For 180F water level in the tank should be 4 from C/L of the pump.

The tank is equipped with a gauge glass (item 37) make up valve (item 41), thermometer (item 42) and an opening in the tank to accommodate the installation of other components which might be necessary.

When the temperature in the tank goes below 180F or when more than 5% fresh make-up water is added to the system, a tank heater assembly should be added to the tank. This assembly consists of a tank heater element and the necessary pressure and temperature control valves (items 38, 39 and 40) to maintain the desired tank temperature and prevent damage to the boiler(s).

When more than 5% make-up water is required, a water meter (item 46) should be installed to indicate the amount of water added to the system. This information is a helpful indication of the amount to water treatment required.

Item 43 shows the condensate line to the tank. This line should be equipped with a wasting tee and valve (item 45) to prevent oil and foreign matter from getting into the tank during initial start-up of the system. High pressure returns should enter the tank at the water line. A connection can be supplied for this purpose.

44). Condensate Vent to the Atmosphere

The condensate return tank should be vented to the atmosphere to prevent the tank from collapsing due to vacuum build-up on shut downs. It will also protect the tank against excessive pressure build up. A pressure relief valve should be installed in the tank as an additional precaution against excessive pressure.

The condensate vent will provide a passage for venting oxygen liberated by the heating of water. The vent will also provide the necessary protection in the event excessive water is returned from the system to the tanks.

The vent should be sized in accordance with the Table 3-1 below. The vent piping should run full size with as few fittings as possible and with no reduction in size or restrictions. The vent piping should pitch upward so water cannot be trapped inside. Precautions must be taken to prevent freezing of the vent line.

Table 3-1. Vent Pipe Size

Connection PipeTank Gallons

3/43/422-100

11101-150

1-1/21-1/2151-350

22351-500

2-1/22-1/2over 500

Height of Condensate vent piping not to exceed 12' - 0" from tank.

NOTE

Upon start-up, waste (dump) the condensate until all oil is out of the piping system. Upon cleanout of the piping system, condensate may be returned to the condensate receiver tank.

High pressure condensate should enter the tank below the waterline.

Low pressure condensate should enter the tank at the top.

IMPORTANT

Do not put water treatment into the condensate

tank feed water.

When multiple installations are made, a common receiver is located in a central position and piped according to the installation drawing. It is recommended that each unit have its own pump, discharge line and pressure gauge and be operated as an independent unit with an independent water level from the float pump switch on the unit. The discharge pump line is to be equipped with a swing check and stop valve. When the condensate tank is higher than the boiler waterline a spring-loaded check valve is also required to prevent the boiler from flooding after shutdown.

53). Steam Piping Main Bleed Trap

During certain periods of operation steam will condense in the header and remain there unless drained. In pressure piping, water caught in the rapid flow of live steam causing hammering condition has been known to cause severe damage and destruction in steam lines and fittings.

Any change in elevation should be provided with drains or automatic traps to drain. Eliminate any possibility of the accumulation of water in the piping.

All traps should be installed with suitable strainers and valves to facilitate cleaning and repair of the traps.

54). Stop Valve

At times it may become necessary to take a boiler off line and allow the others to remain in operation. This is necessary to clean the fire side or water sides of the units or to facilitate normal service of the equipment.

Stop valves allow the unit to be cut off from the entire system without disrupting the other boilers that are needed to provide the steam load. The valve shall be dripped with the trap and accessories when necessary.

55). Non-Return Stop and Check Valves

Non-return stop and check valves are normally required on multiple boiler installations. The stop and check valve assembly will prevent the steam produced by the lead boiler(s) from backing up into those boilers not operating at the same pressures. Without this valve the steam produced by the lead boiler will flow into the steam space of other boilers, condense and eventually flood the remaining units.

58 & 64). Insulation, Steam Header and Breaching

It is recommended that all steam and return piping and breaching be insulated. This covering is necessary to limit heat radiation loss. This helps to keep the plant more efficient and cuts down on ambient temperature build up in the boiler room. A good grade of insulation is 85% magnesium. A desirable covering such as canvas should be used over the insulation to prevent deterioration.

59). Blowdown Tank

A blowdown tank is recommended to allow proper blowdown of all units without affecting the drain or sewer connections. There may be as many as five blowdown connections; surface blowdown, water column blowdown, gauge glass blowdown and one or two bottom blowdowns . These should each be connected to the blowdown tank.

The blowdown tank is vented to the atmosphere to prevent the pressuring of drains and sewers. The tank is equipped with a water valve which blends cold city water with the blowdown products. There is a thermometer to adjust cold water to the steam blowdown product to maintain a control temperature.

City, state and local codes sometimes insist on complete protection against live steam or hot water under pressure from being applied to sewer piping.

DANGER

Pressurized blowdown water can cause serious

personal injury if not controlled.

60). "Y" Type Blowdown

The Y type valve is used to regulate the flow of blowdown products from the boiler proper. It is located in series with the quick opening valve positioned down stream from it.

The valve operation controls the amount of water being removed through the blowdown procedure. The quick opening valve is installed as a secondary protection against leaking in the blowdown valve system.

61). Surface Blowdown Valve

Each York - Shipley high pressure boiler is provided with a surface blowdown connection. It is located on the standard water line of the unit. Surface blowdown connections can be ordered as optional tapping on low pressure boilers.

The surface blowdown valve is usually a slow opening type with indicator and should be fitted in the piping assembly with other blowdown piping as required. This connection will provide a means to surface blow the water surface or skim within the unit removing any floating foreign matter.

New boilers operated for the first time will have an excess of grease and other compounds present in the water line of the unit. If this is not removed (suggested boil out procedure, see Section VI) it will cause foaming and priming of the boilers.

62). Quick Opening Bottom Blowdown Valve

The bottom blowdown valves are connected to openings provided at the bottom of the boiler. The quick opening valve is code required and provides secondary protection to the slow opening valve connected in series with it.

Foreign particles such as rust, dirt, minerals and other elements will eventually find their way back into the boiler. If this material is not removed from the bottom of the boiler the chances of malfunction will increase. This build up of sediment on the bottom of the boiler will eventually begin to cover the boiler tubes and cause them to burn out.

Water treatment compound added to the boiler water will dislodge mineral elements and calcium from the boiler. Water in the area where the unit is to be installed must be analyzed by a competent water treatment organization. Follow their recommendations. Proper water treatment will increase the life of your boiler and assist in higher efficiencies and less down time.

63). Steel Breaching Vent Connection

Breaching should be run as directly as possible. When elbows are necessary they should be as large a radius as possible. Individual breaching should enter the common breaching at a 45 angle to prevent flue gas back-up to "down' units on a multiple installation. Vents or breathings for other appliances should not be connected to boiler breaching, since other appliances usually depend on natural draft for optimal operations.

IMPORTANT

Steel breaching vent connection must be

round and not square.

Breaching should be 12 gauge minimum thickness with flanged and gasketed joints and connection to the boiler. A flanged connection is provided at the unit. Vent pipes and breaching should be ROUND rather than square or rectangular to avoid noise and vibration. Vents should terminate at a point where flue gases will not be objectionable.

Dampers or draft regulators should not be installed on jobs with normal conditions.

Breaching should include a cleanout opening at some appropriate location, such as, the end of the common.

All breaching should be insulated for safety and to reduce ambient boiler room temperature.

IMPORTANT

All branches from units joining main stack, should enter on a 45 angle to prevent backup of gases to down units.

CAUTION

Stack exit must be a sufficient distance above the roof to avoid problems due to wind turbulence

(see NFPA 54 and NFPA 31).

Figure 3-1. Connection of Breaching to Stack.

65 & 66). Stack Cleanout Cover and DeflectorThe stack should include a cleanout provision near the bottom and a deflector to the joint where the breaching enters the stack. See Figure 3-1 (page 3-12).

68). Fresh Air Inlet Damper

A burner requires sufficient fresh air for combustion, to avoid smoky fires, soot and carbon which will lower the boiler efficiency. An adequate fresh air opening is necessary for both good combustion and to keep ambient temperature in boiler room below 90F. When boilers are not operating fresh air is not necessary. A louver type, motor operated, damper may be used for air control. The burner can be inter-locked with the damper motor to prevent burners from starting until dampers are open. Appropriate ventilation should be furnished into the upper section of the boiler room to reduce the ambient temperature.

Air inlet openings should be screened. See Table 3-2 below for recommended fresh air opening sizes.

DANGER

Fresh air inlet must not be blocked or obstructed at

any time the boiler is operating.

Table 3-2. Recommended Dimensions for Mechanical Fresh Air Louver

Total Boiler HP Free Open Area

3015" x 18"

4018" x 20"

5018" x 25"

6020" x 27"

7525" x 27"

80 25" x 29"

10028" x 32"

12532" x 35"

15035" x 40"

175 and 20040" x 45"

225 and 25045" x 50"

30050" x 54"

350 and 40058" x 62"

50064" x 70"

60070" x 77"

70074" x 90"

850 84" x 96"

NOTE

In all cases, fresh air inlet area must meet the minimum requirement of the local (city or state) jurisdictional code.

69). Chemical FeederVarious types of chemical feeders and/or pumps are optional depending on boiler size and type, characteristics of the water and the type of usage. The chemical company making the water analysis should recommend the type of feeders required to properly dispense their chemicals.

Page 3-15 left blank intentionally

Table 3-3. Boiler Room Item Number Reference

Reference for Figure 3-2 , Figure 3-5 and Figure 3-8

Item DescriptionProvided

1Reinforced Concrete PadBy others

2Boiler

Standard

3Steam Outlet ConnectionStandard

4Manhole (Series 560 and larger)Standard

5Hand Holes

Standard

6Test Tee

Standard

7Lifting Lugs

Standard

8Rear Cover Plates

Standard

10Water Gauge

Standard

11Safety Relief Doors

Optional

12 Flue Gas Outlet

Standard

13Front Cleanout Cover

Standard

14Rear Observation PortStandard

15 Pressure Gauge, Siphon & CockStandard

16Stack Thermometer

Optional

17Safety Relief Valve(s)Standard

19,20Metal Jacket, Boiler InsulationStandard

21Burner

Standard

22Control Panels: NV BurnersNot Required

FV and F BurnersStandard

23Indicating Lights

Optional

24Blower Air Safety SwitchStandard

25Operating & Safety Limits ControlsStandard

26Modulating Control

Optional

27Low Water Cut-Off

Standard

28Auxiliary Low Water Cut-OffOptional

32Forced Draft Fan

Standard

34Condensate Tank

Optional

35Condensate Pump & Motor SetOptional

36Condensate Tank Steam HeaterOptional

37Sight Glass

Optional

38Steam Valve

Optional

39Pressure Reducing ValveOptional

40Temperature Control

Optional

41Water Make-Up FeederOptional

42Thermometer

Optional

43Main Condensate Return LineBy Others

44Condensate Vent to AtmosphereBy Others

45Condensate Wasting ValvesBy Others

46Make-Up Water MeterBy Others

48Feed Stop & Check ValvesOptional

53Main Header Bleed TrapBy Others

54Stop Valve

Optional

55Non-Return Stop & Check ValvesOptional

56Stop & Check Valves Bleeder TrapBy Others

58Insulation - Steam HeaderBy Others

59Blow-Down Tank

Optional

60"Y" Type Blow-Down ValveOptional

61Surface Blow-Down ValveOptional

62Quick Opening Bottom Blow-Down ValveOptional

63Steel Breaching

By Others

64Insulation - BreachingBy Others

65Breaching Cleanout CoverBy Others

66Stack Cleanout Door

By Others

68Fresh Air Inlet DamperBy Others

69Chemical Feeder

Optional

3-2. Series 542, 548 and 560 Boiler Room Arrangement

Typical mechanical arrangement for battery installations showing placement of steam and condensate piping and breaching fabrication for high pressure and low pressure steam with feedwater pumps.

Figure 3-2. Boiler Room Arrangements for Series 542, 548 and 560

NOTE - Dimensions AK, CK and FK are governed by code requirements.

3-3. Boiler Dimensions for Series 542, 548 and 560

Dimensions shown are accurate for layout purposes. Consult factory for certified construction drawings.

Figure 3-3. High and Low Pressure Steam Boiler Dimensions for

Series 542, 548 and 560.

(Refer to Table 3-4 for high pressure steam boiler dimensions for

Series 542, 548 and 560)

(Refer to Table 3-5 for low pressure steam boiler dimensions for

Series 542, 548 and 560)

Table 3-4. High Pressure Steam Boiler Dimensions for Series 542, 548 and 560.

SERIES 500 HIGH PRESSURE STEAM BOILER DIMENSIONS

NOTES

Weights for standard light oil units* Clearance for safety valve steam gauge 6"

** Vertical vent size same as items EE & FF

*** Use front OR rear tube removal dimensions NOT BOTH

Swinging rear cover standard on 100 O.S. and 150 HP

DIMENSIONS SHOWN ARE SUBJECT TO CHANGE WITHOUT NOTICETable 3-5. Low Pressure Steam Boiler Dimensions for Series 542, 548 and 560.

NOTES

* Clearance for safety valves 8" Swinging rear cover standard on 100 O.S. and 150 HP

** Water boilers reverse flow with Aquatemp valve (Optional) Weights for standard light oil units*** Use front OR rear tube removal dimensions NOT BOTH SPW Only

****Vertical vent size same as items BB and CC

DIMENSIONS SHOWN ARE SUBJECT TO CHANGE WITHOUT NOTICE3-4. Steam Header Dimensions for Series 542, 548 and 560

Table 3-6a. High Pressure Steam Header Dimensions for Series 542, 548 and 560.

Number of Boilers

Model HPS-1S-2S-3S-4

542252"3"3"4"

542 302334

542 402334

542 502346

542 602346

548 602-1/2568

548 702-1/2568

548 802-1/25 68

56010035810

560 12535810

560 150381012

NOTE -These sizes are based on approximately 2500 ft/min.

Table 3-6b. Low Pressure Steam Header Dimensions for Series 542, 548 and 560.

(Refer to Figure 3-4 for locations of dimensions S, P, U and AA)

Number of Boilers

Model HPS-1S-2S-3PUAA

542256"8"8"49"31

542 306884931

542 406884931

542 5068104931

548 60810125541

548 70810125541

548 80810 125541

560100812166341

560 125812166341

560 150812166341

3-5. Alternate Steam System Piping for Low Pressure Steam using Hartford Loop System for Series 542, 548 and 560.

Figure 3-4. Low Pressure Steam System Alternative Piping for Series 542, 548 and 560.

(Refer to Table 3-6b for dimensions S, P, U and AA)

3-6. Vent Header Dimensions and Stack Dimensions.

Table 3-7. Vent Header and Stack Dimensions for Series 542, 548 and 560.

Number of Boilers

1234Stack

ModelHP(W) (X)(X)(X)(O)

542 25 8101214*

542 3010121416*

542 4010141620*

5425010141620*

5426010141620*

5486012162024*

5487012162024*

5488012162024*

560 10012182226*

560 12512182226*

56015012182226*

* If 1 boiler use W dimension, if 2 boilers use X etc.

IMPORTANT

Do not install damper or draft control on stacks shown above. When stack diameter exceeds dimensions shown or when stack height is excessive, consult factory.

3-7. Burner Data for Series 542, 548 and 560.

Table 3-8a. Gas Burner Data for Series 542, 548 and 560.

Table 3-8b. Light Oil, Light Oil/Gas Combination

Burner Data for Model 542, 548 and 560.

Table 3-8c. Heavy Oil, Heavy Oil/Gas Combination

Burner Data for Model 542, 548 and 560.

*NV Burner

**FV Burner

***Pressure required at entrance to standard York-Shipley equipment for U.L. gas train

XBurner used on 125 O.S.

O.S.Ohio Special

3-8. Series 564 and 576 Boiler Room Arrangement

Typical mechanical arrangement for battery installations showing placement of steam and condensate piping and breaching fabrication for high pressure and low pressure steam with feedwater pumps.

Figure 3-5. Boiler Room Arrangements for Series 564 and 576

(Refer to Table 3-3 for item description)

3-9. Boiler Dimensions

Dimensions shown are accurate for layout purposes. Consult factory for certified construction drawings.

Figure 3-6. Low and High Pressure Steam Boiler Dimensions for Series 564 and 576.

(Refer to Table 3-9 for dimensions)

Table 3-9. Low and High Pressure Steam Boiler Dimensions for Series 564 and 576.

NOTES

* Use front OR rear tube dimensions NOT BOTH

** Location of rear bottom connection 29

3-10. Steam Header Dimensions

Table 3-10a. High Pressure Steam Header Dimensions for Series 564 and 576.

(Refer to Figure 3-5 for dimension locations)

Number of Boilers

Model

HPS-1S-2S-3

564 1754810

564 2004810

5642254810

56425061012

56430061012

57635061214

NOTE - These sizes are based on approximately 2500 ft/min.

Table 3-10b. Low Pressure Steam Header Dimensions for Series 564 and 576.

(Refer to Figure 3-7 for dimension locations)

Steam

Ht. WaterInd.

Conn.Number of BoilersLineReturn

ModelHP MS-1S-2S-3PR

564 1751012"14"16"5 104

564 200101214165 104

564225101214165 104

564250101416186 104

564300101416186 104

576350101416186 104

3-11.Alternate Steam System Piping for Low Pressure Steam using Hartford Loop System for Series 564 and 576.

Figure 3-7. Low Pressure Steam System Alternative Piping for Series 564 and 576.

(Refer to Table 3-10a and b for dimensions M, R, S and P)

3-12. Vent Header Dimensions and Stack Dimensions.

Table 3-11. Vent Header and Stack Dimensions for Series 564 and 576.

Number of Boilers

Model

HPWXOStack

564 175152130*

564 200152130*

564225152130*

564250183036*

564300183036*

576350183036*

* If 1 boiler use W dimension, if 2 boilers use X etc.

IMPORTANT

Do not install damper or draft control on stacks shown above. When stack diameter exceeds dimensions shown or when stack height is excessive, consult factory.

3-13. Burner Data for Series 564 and 576.Specify #5 burner for #4 and cold #5 oil (18 to 28 API, 50 to 150 SSU at 100F maximum vis.) Specify #6 burner for hot #5 and #6 oil (7 to 22 API, 300 SSU at 122F)

Table 3-12. Burner Data for Series 564 and 576 Light Oil,

Heavy Oil, Gas and Combination Gas/Oil.

* Standard pressure required at discharge of gas regulator

** 250, 300, 500: 50 Hz Blower motor size 25 HP

*** Motor HP shown is for standard mechanical atomization for optional air atomization : 175 & 200 1/2 HP; 250-350 3/4 HP

3-14. Series 582, 588, 596 and 5112 Boiler Room Arrangement

Typical mechanical arrangement for battery installations showing placement of steam and condensate piping and breaching fabrication for high pressure and low pressure steam with feedwater pumps.

Figure 3-8. Boiler Room Arrangements for

Series 582, 588, 596 and 5112.

(Refer to Table 3-3 for item description)

3-15. Boiler Dimensions for Series 582, 588, 596 and 5112.

Dimensions shown are accurate for layout purposes. Consult factory for certified construction drawings.

Figure 3-9. Low and High Pressure Steam Boiler

Dimensions for Series 582, 588, 596 and 5112.

(Refer to Table 3-13 for dimensions)

Table 3-13. Low and High Pressure Steam Boiler

Dimensions for Series 582, 588, 596 and 5112.

(Refer to Figure 3-9 for dimension locations)

3-16. Steam Header Dimensions

Table 3-14a. High Pressure Steam Header Dimensions for

Series 582, 588, 596 and 5112.

Number of Boilers

Model

HPS-1S-2S-3

582 40081416

588 50081416

58860081416

59670081416

5112850101418

NOTE - These sizes are based on approximately 2500 ft/min.

Table 3-14b. Low Pressure Steam Header Dimensions for

Series 582, 588, 596 and 5112.

(Refer to Figure 3-10 for locations of dimensions M, P and R)

Steam

Ht. WaterInd.

Conn.Number of BoilersLineReturn

ModelHP MS-1S-2S-3PR

582 4001214"18"20"7 64

588500121418207 84

588600121418207 84

596700121418208 34

5112850141620249 26

3-17. Alternate Steam System Piping for Low Pressure Steam using Hartford Loop System.

Figure 3-10. Low Pressure Steam System Alternative Piping for

Series 582, 588, 596 and 5112.

3-18. Vent Header Dimensions and Stack Dimensions.

Table 3-15. Vent Header and Stack Dimensions for Series 582, 588, 596 and 5112.

Number of Boilers

1234Stack

ModelHP(W) (X)(X)(X)(O)

585 40028404852*

588 50028404852*

58860028404852*

59670028404852*

511285034486066*

* If 1 boiler use W dimension, if 2 boilers use X etc.

IMPORTANT

Do not install damper or draft control on stacks shown above. When stack diameter exceeds dimensions shown or when stack height is excessive, consult factory.

3-19. Burner Data for Series 582, 588, 596 and 5112.

Specify #5 burner for #4 and cold #5 oil (18 to 28 API, 50 to 150 SSU at 100F maximum vis.) Specify #6 burner for hot #5 and #6 oil (7 to 22 API, 300 SSU at 122F)

Table 3-16. Burner Data for Series 582, 588, 596 and 5112.

3-13-103-9