Loos refractory? What have I done?

errandboy

I was attempting to clean my HB Smith - Mills 156K BTU oil fired boiler that is about 35 years old.



The upper chamber was relatively simple to brush and vacuum.  The lower chamber appeared to be a mess, with years of accumulation of debris.  The rear of the chamber had a cardboard type piece of refractory that was being pushed forward by an accumulation of debris behind it.  I will try to replace that piece.

The debris appeared to be an accumulation of red dust, black soot and a sand like material.  I dutifully removed all of it, but I am now wondering if this was loose refractory material, such as vermiculite.  There was literally 3 to 5 inches of the stuff that I took out.  Do I need to dump it back in before I fire the boiler?  Can I use firebrick instead? 



A couple of photos are attached.  Thank you in advance for any advice that you have.

Unknown

It`s probably vermiculite,

that was usually added to the base-portion(sections are above this), keeping the heat from transferring to the concrete floor. Not all that unusual.

I would just find some, and put-it back.



Looks like you`re-in for a target-wall (cardboard type piece of refractory),, then you should be good to go. :-)



PS-Don`t fire with too wide a spray angle(looks like it was),, then you`ll reduce any flame impingement on the sides of the sections.

Steamhead

If there's a lower opening

you could use a "bathtub" chamber that comes in one piece and needs no backfill.



What firing rate are you using? What burner?

errandboy

Firing rate

The burner is a Carlin 100 CRD.  The prior nozzle was a 1.0 - 60 degree that I just replaced with a .75 - 60 degree. 

I have ordered a new target wall, but I am temporarily firing the boiler with the shredded remnants of the old one covering about one-third of the back wall.  The boiler has a DHW coil.  I currently have the high limit set at 170 and the low limit set at 130, which is adequate for meeting DHW needs and to provide early season heat.  Do these settings present any issues with respect to the health of the boiler?

Thanks for the input.

Unknown

Respect to the health of the boiler?

It sure will! Partially covering the target-wall(if not repaired quick) will most certainly lead to impingement burn-through of this already older boiler.



Makes me wonder how long it was like this before you detected it?



If you get-by this winter,,, I would start looking at a replacement . :-)