Step f. After all sections have been drawn up, retention rods must be installed. Do not release hydraulic pressure until the retention rods are in place.
Step g. Locate the threaded 5/8” retention rods, washers, tension springs and nuts supplied in ‘BAC’ Boiler Assembly Carton. Assemble both top retention rod assemblies as shown in Figure 5, Detail B, using the proper arrangement per Table VI. The tension spring should always be located at the rear of the boiler. These rod assemblies can be lowered directly into slotted lugs on each side of the upper nipple port. Hand tighten the rear nuts only, do not torque nut at this time.
All casting legs have two (2) holes. Slide the lower retention rods through the upper hole in each leg. Start the front or rear, which ever is easiest, per the arrangement shown in Table VI. With the rods in place, install a 5/8” flat washer and 5/8” hex nut on each rod protruding through the front legs. On 8 through 18 section block assemblies, additional rods and couplings nuts are required to span the distance. On these larger sizes, thread couplings on front rods to mid point of coupling (halfway), pull next rod forward to meet front coupling. Hold front coupling, not front rod, while threading rear rod into coupling nut until it contacts front rod at mid point.
Repeat this process until both lower rods protrude through rear section legs. In the following order, place a 5/8” flat washer, 5/8” tension spring and 5/8” hex nut on both rods. Hand tighten rear nut only to remove all slack from the lower rod assemblies. Use a torque wrench adjusted for 20 ft/lb of torque to tighten four (4) rear hex nuts. In lieu of a torque wrench, use a combination wrench to tighten nuts approximately ¾ turn beyond hand tight, to set tension.
Excess length of
Step h. Release tension on hydraulic pumps and rams and remove.
C.HYDROSTATIC TEST - After the boiler sections have been assembled, it is essential that the boiler be hydrostatically tested before the jacket frame, insulation, internal wiring, piping or jacket is installed. This test is an ASME Code Requirement.
1.Block Assembly must be free of air, provide valve in 4” bushing on top supply tapping to purge air during the filling process. Plug all boiler tappings and fill entirely with cold water.
CAUTION
DO NOT install gauge until after hydrostatic testing the boiler. Gauge failure may result.
2.Assembled boilers shall be subjected to a hydrostatic test of not less than 1½ times the maximum allowable working pressure, as established by the relief valve supplied with the boiler. For example, a boiler with a 50 psi relief valve must be subjected to a test pressure of 75 psig to 85 psig.
WARNING
Failure to properly hydrotest all boilers at the correct pressure may result in section assembly failure in operation.
3.EXAMINE BOILER CAREFULLY, INSIDE AND OUTSIDE, to insure against leaks from cocked nipples or through concealed breakage caused in shipping and handling. This precaution is for your protection and will simplify handling of necessary replacements and adjustment claims.
4.After making certain that there are no leaks, drain boiler and remove plugs from boiler trim and other connections.
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