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Table of Contents
- 1 Table of Contents
- 2 Superior Boiler Technologies
- 3 Section I
- 4 Basic Boiler Warnings
- 5 Steam Boiler Model Information
- 6 Steam Boiler System Components
- 7 System Components
- 8 General Operations
- 9 Installation & Startup Instructions
- 10 Oem Component Product Data
- 11 General Maintenance
- 12 Troubleshooting
- Download this manual
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Table of Contents
Related Manuals for Triad 300 series
Summary of Contents for Triad 300 series
- Page 1 By Superior Boiler Technologies OPERATIONS MAINTENANCE MANUAL LOW AND HIGH PRESSURE STEAM BOILERS Series 300 through Series 2000 Superior Boiler Technologies 3524 E. 4 Avenue Hutchinson, KS 67501 Ph: 620-662-6693 May 31, 2015...
- Page 2 SUPERIOR BOILER TECHNOLOGIES !!! ATTENTION !!! READ THIS MANUAL AND THE BURNER INSTRUCTION MANUAL VERY CAREFULLY! THEY ARE BOTH VERY IMPORTANT! DO NOT SKIP OVER THE BOILER NOTES AND WARNINGS IN SECTION I. SUPERIOR BOILER TECHNOLOGIES IS A MANUFACTURER AND DOES NOT PROVIDE SITE SPECIFIC ENGINEERING.
- Page 3 - Be careful about old vacuum systems – consult an experienced steam engineer when retrofitting these. BOILER/BURNER STARTUP MUST BE PERFORMED BY AUTHORIZED TRIAD TECHNICIAN OR WARRANTY WILL BE VOIDED.
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Page 4: Table Of Contents
SUPERIOR BOILER TECHNOLOGIES Steam Boiler Operations and Maintenance Manual TABLE OF CONTENTS: Section I BASIC BOILER WARNINGS STEAM BOILER MODEL INFORMATION Section II Packing Slip Wiring Diagrams Section III STEAM BOILER SYSTEM COMPONENTS Section IV GENERAL OPERATIONS Section V INSTALLATION & STARTUP INSTRUCTIONS Section VI OEM COMPONENT PRODUCT DATA GENERAL MAINTENANCE... -
Page 5: Superior Boiler Technologies
AVAILABLE IN THE BOILER ROOM AS A REFERENCE. NOTE: Triad highly recommends that boiler feed water be treated before it enters the boiler. The water in the boiler should have a pH level of The first and most critical step in the between 7.5 and 8.5, and in no case above 9.5. - Page 6 Boiler Room derived from the National Board of Boiler and Pressure Vessel Inspectors (NBBI -- TRIAD Boilers can provide years of dependable Bulletin, Fall, 1997) service with proper maintenance and by carefully following the instructions and information provided in 1) Keep the boiler room clean and clear of all this manual and the burner manual.
- Page 7 the ASME Boiler and Pressure Vessel Codes should to180°F or so to remove oxygen. be followed in all cases. Jurisdictional authorities must be consulted prior to installation. Scale is a very effective insulator that will cause a loss of heat transfer efficiency and eventually tube SUPERIOR very strongly recommends that a sheet failure.
- Page 8 Sodium Sulfite – This is used to remove dissolved oxygen from the feedwater before it gets to the boiler. It reacts with oxygen to produce sodium sulfate (versus sulfite). Feedwater at all times should have slightly more than enough sodium sulfite to consume all the dissolved oxygen.
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Page 9: Steam Boiler Model Information
Failure to follow the directions and warnings can result in property damage or serious injury. Each TRIAD Boiler is certified to meet or exceed the requirements of the American Society of Mechanical Engineers (ASME) Code for pressure vessels. Each... - Page 10 Fuel Train -- connects gas or oil supply to burner, controls pressure, contains shut-off valves. Gauge Glass – special glass tube displaying internal boiler water level. HEP -- Power draft burner; Note: Category I venting in a TRIAD boiler. L.W.C.O. -- Low Water Cut Off -- controls boiler by monitoring water level.
- Page 11 TRIAD MODULAR STEAM BOILERS Series 300 fires at 300 – 399MBH Series 600 fires at 600 – 700MBH Series 900 fires at 800 – 1000MBH Series 1600 fires at 1100 – 1700MBH Series 200 fires up to 2000MBH STANDARD COMPONENTS:...
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Page 12: Steam Boiler System Components
- ON/OFF switch; fuses, terminals and relays for fan TRIAD uses only UL listed controls and UL listed damper control, lockout control, etc. burners and gas trains. Every boiler is a Category I non-condensing gas appliance. -
Page 13: System Components
control, its switch opens and the manual reset trips second stage switch opens which stops the burner to shut down burner operation. operation. The burner switch will be closed once the necessary feedwater has been provided to the If the manual reset is tripped OPEN then a serious boiler. - Page 14 Many codes require periodic testing Air Separation System -- Removes dissolved gases and replacement of relief valves -- the user must from recirculating system water, which TRIAD highly meet local code requirements. Many codes require recommends for open systems.
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Page 15: General Operations
“live” and great caution must be taken before touching any wiring. Turning the ON/OFF switch to TRIAD steam boilers may be used in many different OFF means only that the power to the boiler applications. The boiler is designed to convert water mounted controls is off. - Page 16 above the setting of the Operating Pressure On/Off Operating Pressure Limit Control (L404F1060) Control - L404F1060 or P7810C, which will open the contacts in the control stopping the burner from Typical operating pressure for a low pressure firing. heating application is 3 to 5 psi - plus/minus 1 to 2 psi.
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Page 17: Installation & Startup Instructions
Technologies within five (5) days of receipt. the first boiler and the stack. Additional information is available in the TRIAD Boiler Manual. Also, the For those boilers with leveling legs, the boiler is installation must comply with local codes. - Page 18 The ends of the discharge lines should have no fitting. The relief valve line should be left clearly 4. TRIAD recommends that a MASTER POWER visible so that if it should operate it will be evident DISCONNECT SWITCH AND A FUEL SYSTEM that a discharge has occurred.
- Page 19 The boiler and in this manual. follow chart shows the steaming rates for Triad boilers. 5. Connect the fuel source to the burner.
- Page 20 Recommended Near-Boiler Piping – Series 900 Low Pressure Steam Series 1600 Low Pressure Steam INSTALLATION SECTION V...
- Page 21 Feedwater Information – Steaming Rates and Loop Characteristics SERIES 300 SERIES 600 SERIES 900 SERIES 1600 Firing rate 375 MBH 600 MBH 1000 MBH 1700 MBH Steam pounds/hr produced 1454 Make-up Water Required (gallons per refill): 0.95 1.72 1.72 Steaming Rate before refill starts: 93 seconds 100 seconds 61 seconds...
- Page 22 Continue with a normal shutdown. Observe the I. IMMEDIATELY PRIOR TO STARTUP burner for correct response and physically inspect the burner and firebox sight glass to ensure that the Verify that: flame has been completely cut off. - The breeching has no leaks. Closely monitor several complete cycles to confirm proper operation.
- Page 23 cleaning operation. See section VII. level, typically visible through the gauge glass. The manual blow-down valves on the LWCO You can also refer to the instructions in Section 7 of controls should be operated at least 2 to 3 times a the ASME Boiler Code for more detail on cleaning day during the first two weeks of boiler operation.
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Page 24: Oem Component Product Data
SUPERIOR BOILER TECHNOLOGIES Section VI OEM COMPONENT PRODUCT DATA It is imperative that the documentation in this section be thoroughly reviewed before placing the boiler in operation. These materials include specific operating warnings that must be followed for proper boiler operations. - Page 25 OEM COMPONENT DATA SECTION VI...
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Page 67: General Maintenance
WARNING: NEVER operate the boiler without an ASME approved, steam rated All TRIAD boilers are built to meet or exceed the safety relief valve matched for both Section IV ASME standard and are registered with BTU/hr and pressure relief values. - Page 68 build up in the boiler and system. Establish a During the annual boiler inspection and cleaning, suitable boiler water treatment program to reduce remove the valve and check for deposits in the valve oxygen, scale, sludge buildup, corrosion and to and plumbing.
- Page 69 Water samples should be taken from the lower part pH – This is a measure of the level of acid or base of the boiler, not from an area higher up such as the of water. If too low (acidic) corrosion will increase, if gauge glass.
- Page 70 Inspect the safety relief valve. ANNUALLY or during a lay-up period: If the boiler is not to be returned to service soon, dry Shut down the boiler by following the procedure in the inside with forced warm air and minimize “REMOVING A BOILER FROM SERVICE”...
- Page 71 gauge and carefully open the safety relief Check all venting and breeching for leaks. valve) before performing maintenance. Have the water retested and the water treatment Disconnect the fuel supply from the burner system serviced. and the power to the boiler and all its accessories.
- Page 72 MAINTENANCE SECTION VII...
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Page 73: Troubleshooting
SUPERIOR BOILER TECHNOLOGIES Section VIII TROUBLESHOOTING Turn ON the power. CAUTION: Start with a review of the OEM equipment information found in Check to see if the power switch on the burner’s Section VI of this manual and the burner manufacturer's manual -- note all panel is in the ON position. - Page 74 C. IF - NO “CALL FOR HEAT” – WITH AN P7810C PRESSURETROL D. THERE IS A “CALL FOR HEAT” BUT THE BURNER WON’T FIRE The R7810C control requires line voltage power to operate. Power is provided by a limit circuit that If the vessel steam pressure is not above the connects through both low water cut off controls.
- Page 75 TROUBLESHOOTING THE CONTROLS furnace. Excessive cycling is usually indicative of a primary If you have reached this point in your trouble circulation system that is unable to carry away the shooting, then probably one of the controls on the BTU/hr output of the boilers. The causes can range boiler has failed.
- Page 76 The stack pressure may be too low of a negative, below -0.05”wc, thus “pulling” the burner flame up TRIAD boilers and burners are matched for into the tubes, effectively over firing the boiler. optimum performance. Difficulty in setting the burner...
- Page 77 PUMP RUNS BUT WATER NOT ENTERING inspection stages before repair work begins BOILER A leak involving the fire tubes is usually the result of thermal shock that may have been caused through Possible Vapor Lock – let system cool down and the introduction of water at an excessive check steam traps, make sure return lines not...
- Page 78 TRIAD – Steam Systems Check Sheet (Daily check of gauge glass and blow-down recommended) Site/System: Boiler Model: Date: - to - Week 1: Week 3: Monthly: Boiler operation. Boiler operation. Boiler operation. Normal burner light-off. Normal burner light-off. Normal burner light-off.
- Page 79 IMPORTANT THINGS TO REMEMBER: Follow the near boiler piping suggestions. The steam header MUST be at least 24” above the boiler. Connection to the supply header should be through the top of the header. Do not alter the steam tap at the rear of the boiler. Skim the surface multiple times before placing boiler into normal service.