Smith Cast Iron Boilers 19A SERIES BOILER INSTALLATION INSTRUCTIONS, Correct, Hydrostatic Test

PAGE 5

19A SERIES BOILER

INSTALLATION INSTRUCTIONS

TABLE 3

STEP 1	UPPER RIGHT	5 FT. LBS.
STEP 2	LOWER LEFT	5 FT. LBS.
STEP 3	UPPER LEFT	5 FT. LBS.
STEP 4	LOWER RIGHT	5 FT. LBS.
STEP 5	UPPER RIGHT	25 FT. LBS.
STEP 6	LOWER LEFT	25 FT. LBS.
STEP 7	UPPER RIGHT	50 FT. LBS.
STEP 8	LOWER LEFT	50 FT. LBS.
STEP 9	UPPER LEFT	10 FT. LBS.
STEP 10	LOWER RIGHT	10 FT. LBS.

Prepare additional intermediate sections and install in the same manner described above. Be sure each section is properly sealed against water leakage and flue gas exfiltration. Be certain the angle rails remain level and provide support for each section as it is assembled. Check each section for vertical position.

When all sections, including the front section or back are in place, check all draw rods to insure iron-to-iron contact at ports. DO NOT APPLY EXCESSIVE TORQUE. See TABLE 3 for recommended torques.

HYDRONIC

SEAL

CORRECT

HYDRONIC

SEAL

INCORRECT

SEALING

FIGURE 3

7.HYDROSTATIC TEST

Plug tappings, fill boiler with water and vent air from top of boiler. Check for leaks. Leakage at seals may be due to misalignment of hydronic seals. Loosen draw rods, reposition seals and retest as above.

All completed boilers shall satisfactorily pass the hydrostatic tests as prescribed by A.S.M.E., Code Section IV.

1.Steam Boilers – The assembled boiler shall be subjected to a hydrostatic test of not less than 45 PSIG.

2.Water Boilers – The assembled boiler shall be subjected to a hydrostatic test pressure not less than 1-1/2 times the maximum allowable working pressure.

3.The required test shall not exceed the test pressure by more than 10 PSI.

Excessive torque on draw rods may damage castings. Do not exceed the torque shown in TABLE 3.

In a cold environment, hydronic seals may not quickly conform to sealing surfaces when properly compressed. Under such conditions, hydrostatic testing with cold water might show weeping or leaking at the seals. To avoid this possibility, delay filling the boiler with cold water for a few hours after assembly, or use warm water, if available, for the tests.

If there is seepage about chaplets or minor leakage, consult the Smith Company representative for advice regarding A.S.M.E. Code approved repairs by peening or plugging.

8.STEAM PIPING

A steam piping schedule is shown in TABLE 4. Pitch piping to allow condensate to flow in the same direction as steam. Makeup water connections must be made to the return piping, not directly to the boiler. Install blow-down valves as required.

See FIGURE 4 for recommended acceptable steam piping arrangement.

TABLE 4

BOILER SIZE	NO. OF 3" RISERS	HEADER	EQUALIZER
3 THRU 5 SECTION	1	3"	1-1/2"
6 THRU 10 SECTION	2	4"	2"
11 AND 12 SECTION	2	5"	2-1/2"

STEAM SUPPLY

TO SYSTEM	GATE VALVE
3" STEAM RISER(S)
SUPPORT DISCHARGE
PIPE	STEAM HEADER
EQUALIZER
	*
CONNECTION
TERMINATE DISCHARGE	BOILER WATER LINE
PIPE SO AS TO AVOID	41 1/4" ABOVE FLOOR
DISCHARGE ON PERSONS
GATE VALVE
ALTERNATE RETURN
CONNECTION	2" BELOW MINIMUM
C.W. MAKEUP
	BOILER WATER LINE
CONNECTION
GATE VALVE	* SAFETY VALVE
RETURN	BLOWDOWN VALVE
CONNECTION	TO DRAIN

TYPICAL STEAM PIPING DIAGRAM

FIGURE 4