Boiler Installation for Houston, Austin, and San Antonio
For a proper installation and in order to receive the best in operating life and efficiency from your Boiler System, it is essential to follow the Manufacturer’s Minimum Standards and all the Requirements of State and Local Codes. The installation must also follow all Safety Codes including the ASME Boiler and Controls Codes, National Fuel Gas Code (NFPA 54/ANSIZ223.1), National Electric Code (NFPA 70), Uniform Codes and other applicable National, State, Local and Servicing Gas Supplier Codes. Only trained and qualified personnel should install, startup, operate, adjust, repair or maintain this boiler equipment.
GOES Heating Systems is equipped with Code required information to ensure the correct and accurate way to install your new boiler system. However, should you choose to install the boiler system yourself, here is a simple (non-inclusive) guideline to help you determine whether or not you are ready to install yourself:
First, you will need to select the right boiler. Some items to keep in mind are:
– The Size of the Boiler (The Boiler must be of adequate capacity to handle the maximum hourly load of the particular application, plus radiation losses. It is considered good practice to install a Boiler of sufficient capacity to handle future expansion requirements or to allow space for an additional future Boiler. On critical or large installations, it is recommended to install two or more Boilers, each sufficient size to handle the minimum load so that the operation is not interrupted when one of the Boilers is being serviced. If the load is not definitely known, it is advisable to consult the boiler manufacturer or competent personnel to determine the load.)
– Approved Type Quality of the Boiler (The Boiler should be a quality, approved Boiler, manufactured and furnished in full compliance with the Safety Requirements of the A.S.M.E. Code. The Boiler selected should be safe, efficient and easy to maintain to provide economical and reliable service. The Parker Sectional Bent Water Tube is highly recommended as it provides one of safest, most economical and long life systems that is easy and inexpensive to maintain.)
– Trim and Controls (The Boiler should be equipped with fully automatic controls to provide automatic and safe operation. All Trim and Controls should comply with Local Code, the State Safety Orders, the A.S.M.E. Codes and Underwriters’ Laboratories. A flame safeguard, operating control, high limit, primary and secondary low water cutoffs and dual safety shutoff fuel valves are considered essential on all Boilers.)
– Proper Boiler Specifications (The complete Boiler Specifications should be thoroughly reviewed for the proper working pressure required, the most economical fuel available and proper electrical requirements.)
Second, you will need to be certain that all Permits for the installation and operation of the boiler have been taken out and installation conditions approved by the Building Inspection Jurisdiction. Permits are usually required on the Boiler and Utilities including Gas, Electrical, Water, Vent and Plumbing Connections. Some States and Cities require a Field Inspection by a State or National Board Commissioned Boiler Inspector and a “Permit to Operate” issued before the Boiler is placed in service. Heavy Penalties and Unsafe Conditions may result when these Permits and Inspections are not obtained from the Inspection Jurisdiction. If Local Codes or Insurance Carrier require additional or special controls, the boiler manufacturer should be consulted so that the equipment can be furnished as required.
Third, consult with Local Codes for Boiler Room and Fire Resistive Separation if required and refer to Paragraph IV. The Standard Boiler is not recommended for outside installation without providing the required protection from weather and drafts. An approved floor sump or drain must be provided in the Boiler area to accommodate safety valves, boiler drains and leaks from any source. Floors should be properly planned and graded to the floor sump or drain to prevent water damage. When Boiler Rooms are necessary, two access doors are always recommended and normally required. The larger door should be adequate to permit the Boiler to be moved in and out without disassembly. Location of the Boiler Room should be selected as conveniently near the load as possible with all installation factors considered. Do not install the boiler in any location where flammable liquids or vapors are likely to be present or drawn. Keep the area around the boiler free of combustible materials, gasoline, paint, thinner, solvents and other flammable liquids and vapors. Adequate space should be arranged for the Return System, Blowdown Tank and the Water Treatment Equipment. Boilers can be installed in smaller areas than the recommended size but the area should never be less than the minimum shown on the Boiler Room Specification Sheet.
BOILER MUST BE INSTALLED ON A NON-COMBUSTIBLE FLOOR preferably of concrete and properly designed to support the required weight and to protect against any Fire Hazard. Combustible floors require an Approved Fire-Proof Base, consult Manufacturer. Do Not install on wood, carpet, vinyl tiles, black-top or on concrete with wood or electrical conduit imbedded or directly underneath without consulting Manufacturer for an approved base.
Fourth, Check all boiler clearances.
MINIMUM UL LISTED BOILER CLEARANCE TO COMBUSTIBLES CONSTRUCTION (Atmospheric Nat. Gas Only): Cabinet Sides and Rear: 12″; Cabinet Top: 48″; Single Wall Chimney Connector for Models with Barometric Damper: 12″; Single Wall Vent Connector for Models with Draft Hood: 6″; Steam and Hot Water Piping: 1″.
MINIMUM UNLISTED BOILER CLEARANCE TO COMBUSTIBLES CONSTRUCTION (Unlisted & Power Burner Models): Cabinet Sides and Rear: 18″; Cabinet Top: 48″; Single Wall Chimney Connector for Models with Barometric Damper: 18″; Single Wall Vent
Connector for Models with Draft Hood: 18″; Steam and Hot Water Piping: 1″. RECOMMENDED CLEARANCE FOR ACCESS: Boiler must also be installed with adequate clearance for Maintenance, Repair and Inspection Access. Passageways and Inspection Doors: 18″ (2/3 Cabinet Width in front of one Inspection Door on the 30-150 H.P. Boilers);
Controls: 24″; Boiler Control Panels: 30″ Additional space may be required by the Local Inspection Jurisdiction.
Fifth, Check air supply. The Boiler requires fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air. In confined rooms (rooms whose volume is less than 50 cu.ft. per 1000 BTU aggregate input) or unconfined boiler rooms of tight construction, two permanent air openings shall be provided, one within 12″ of the top and one within 12″ of the bottom of the boiler room.
AIR SUPPLY FROM OUTSIDE BUILDING: If the boiler room is confined or the building is of tight construction, openings shall be provided that communicate freely with outdoors. The two openings should have a total free area of 1 sq.in. for each 1000 BTU of input if attached to horizontal ducts; or a total free area of 1/2 sq.in. for each 1000 BTU if attached to vertical ducts or connected directly through an outside wall. Consideration should always be given to the blocking effect of louvers in determining total free area. Wood louvers may be assumed to have 20-25% free area and metal louvers and grills to have 60-75% free area.
AIR SUPPLY FROM INSIDE BUILDING FOR CONFINED ROOMS: The two openings should have a total free area of 2 sq.in. for each 1000 BTU of input communicating directly with an unconfined space with adequate infiltration. In hot climates additional ventilation should be provided to maintain reasonable temperatures in boiler room. Always leave adequate clearance around the base and legs of the Boiler so that air freely enters the combustion area. Be certain that additional air supply is provided if there are exhaust fans or other equipment installed which draw air from the boiler room. Air supply should be provided from a non-hazardous and clean source so that no flammable vapor, lint or dust is admitted to the boiler room.
THE BOILER AIR SUPPLY MUST BE ISOLATED FROM ANY SOURCE OF CORROSIVE CHEMICAL FUMES SUCH AS PERCHLORETHYLENE, ETC. Consult Local Code or Manufacturer for any unusual conditions.
Sixth, The proper Boiler Venting System is required to assure the necessary draft for efficient combustion and to develop a positive flow adequate to convey all products of combustion safely to outside atmosphere above the building. All venting must be in conformity with accepted engineering practices, to the Manufacturer’s Minimum Standards, and in compliance with the Local Code in every respect. All Vent Systems should be installed in a safe workmanlike manner, properly supported and joints secured to prevent leakage. Never drill holes or screw metal screws into double wall vent.
DO NOT SUPPORT THE WEIGHT OF THE VENT ON THE BOILER. The Boiler Vent should preferably be circular and of metal, installed to Local Code Specifications for Vent Material and all Installation Conditions. Do not reduce vent size or connect more than one appliance to a single vent unless in compliance with good safe accepted practices and with approval of the Building Inspection Authority. The Main Vent should run straight up from the Boiler and if horizontal runs are necessary, these should be as straight and direct as possible with a minimum rise of at least 1/4″ per lineal foot. Long horizontal runs are not recommended and must not exceed 75% of the vertical height of the vent above the connector. Proper vent clearance must be provided from any combustible material, wall openings or exit way.
In cold climates, outside vents must be properly insulated. The Draft Hood or Barometric Damper must be installed directly on the Boiler Vent Outlet as shown and in the same room with the Boiler. Do not terminate vents near windows, doors, ducts, air conditioning or air supply fans which might pick up flue products exhausted from the boiler room and return them into the building, causing a serious health hazard to occupants. An unrestricted full size vent cap should be installed on the top of the stack to protect from wind and rain. When installation conditions require special vents or draft inducers, the design and safety controls should be approved by Competent Combustion Personnel. When a draft inducer is required, always install a suitable draft switch and wire this into the boiler control circuit to prevent the boiler from firing unless the draft is proven. If a draft inducer is used, the boiler requires a positive pressure type chimney from the outlet of the inducer to the termination. In planning the vent installation, carefully review these Instructions and consult with the Building Inspection Authority on the Local Code for the Required Approval.
These are the Manufacturer’s Recommended Minimum Standards but all installation materials and conditions must conform to the Local Code Requirements and good safe engineering practices for the particular installation. When installation conditions require special vents or draft inducers, the design and safety controls should be approved by Competent Combustion Personnel. When a draft inducer is required, always install a suitable draft switch and wire this into the boiler control circuit to prevent the boiler from firing unless the draft is proven. If a draft inducer is used, the boiler requires a positive pressure type chimney from the outlet of the inducer to the termination. In planning the vent installation, carefully review these Instructions and consult with the Building Inspection Authority on the Local Code for the Required Approval. These are the Manufacturer’s Recommended Minimum Standards but all installation materials and conditions must conform to the Local Code Requirements and good safe engineering practices for the particular installation.
Seventh, The discharge drain outlet must be piped full size independent of all other piping without any shut-off valves. Safety Valve Drain may be larger than valve inlet size and must always be piped full size. Install piping with sufficient flexibility to allow for free expansion and properly support so there is no strain on the Safety Valve Body and Piping. Pipe to a safe point of discharge to prevent any possibility of personal injury and within 18″ from the floor or into an open receptacle protected by a Splash Shield. If discharge cannot be piped to a completely Safe Location in the boiler room, such discharge should be piped outside the room to a Safe Location. If piped upwardly a drain line should be provided at the low point to keep this line drained. Secure the piping so it cannot rise to cause personal injury when Safety Valve discharges. If piping is a considerable distance, install a union near the Safety Valve Outlet for convenience of changing valve when required. Do not connect the Safety Valve discharge piping to any other piping.
Eighth, Do not use galvanized pipe or fittings on the steam lines, blowoff lines or on the water feed piping from pump to the boiler. Use only black Code pipe, fittings and valves approved for pressures of not less than the MAWP (Maximum Allowable Working Pressure) stamped on the boiler and never less than 100 PSI.
EXCEPTION: Blowoff Piping, Water Feed Piping and Valves for same must be for a pressure of plus 25%, or for 125 PSI when MAWP is 100 PSI. For pressures above 100 PSI (MAWP stamped above 100 PSI) an additional slow opening blowoff valve is required and all fittings between the boiler and blowdown tank must be steel and the pipe must be equal to extra heavy Schedule 80.
WARNING: ALL PIPING MUST BE SECURED SO THAT IT CANNOT COME LOOSE DURING BOILER OPERATION OR BLOWDOWN. DO NOT STAND ON OR APPLY ANY STRAIN TO PIPING, CONTROLS AND VALVES.
Ninth, Check Fuel Supply. Whether you are using Natural Gas, Liquid Petroleum Gas (L.P.G.), Fuel Oil, or Electrical. Do not use a boiler with any other fuel than the one listed on the nameplate. Provisions must be made for adequate fuel supply, proper size fuel lines, proper size gas meter and correct gas pressure if required.