Another big Church job ( Ron Jr. )

Dale

Nice work as usual Ron, Is there a union in that header, I don't see one. Made your measurement to the drop at the equalizer really fussy. With the risers measurement that must have been a tough one.

Unknown

This is a Lutheran Church in

Port Washington , NY . This is phase 1 - replacing the steamer . There's a huge hot water boiler that'll be replaced right after this one's done .

The old boiler was an American Radiator " Ideal " 6 section . Looks are deceiving - this was one big boiler , and an ugly mess inside . We had a real tight turn to hump these boilers out . Had to hand lift the sections up 2 steps to get them on the handtruck . For reference there's a pic of Kenny and Tom - Kenny's pretending to dead lift ( or do something else ) to the back section . Both of them are over 6 foot 3 .

The last pic is the main pipes - I think that is a 6 by 2 1/2 by 2 1/2 cast iron tee . Tell me that tee can still be found . There is also a zone of hot water off the boiler .

Anyone who's ripped out an old beasty like this knows there is no way to get the old stuff out without making a mess . We scraped up 3 buckets of rusty spooge . Spread some speedy dry on the floor and let it work it's magic . The floor looks pretty clean so far .

Unknown

Day 2 - Burnham V904

We reconnected both 2 1/2 inch steam mains to the header . No drop though , we ran into trouble in this town before .

Kenny and Tony piped in the 3 returns while I played around with the zone off the coil and the float LWCO .

All in all I think we are way ahead of schedule .

lchmb

Now that

Now that is how every install should be!! Incredibly neat, clean and easy to follow. I'd almost think you guy's have this to a science.... Good work my friend!!!! BTW, not willing to temp fate with a drop header? Come on now, how else will the inspector learn? LOL

Steamhead (in transit)

Ron, that looks like

an old Ideal Water Tube boiler. A monster if there ever was one.

Technically, a drop header isn't needed with only one riser to the header unless you have a height issue. With two or more it greatly eases the job of putting the header together.

Looks good so far!

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ScottMP

I think it was Ron who

learned a lesson : Don't try to teach an ignorant inpsector who's power hungry. Is'nt this where the inspector gave you a hard time because you installed an drop header and he had never seen on so " It had to be wrong " ?

Nice work Ron and crew.

Scott

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Constantin

Nice Job, Ron!

Looks like the new beasty is about 1/3 the size of the old one... the header looks really nice and neat.

What's going to run off the coil? The hot water system or a small zone?

Unknown

Steamhead

I'm a true believer that a drop header will separate water from steam better than no drop at all - and send the water back to the boiler . But we went full size 4 inch . The specs call for 3 inch minimum . It should be OK . Took a look today at the rads finally . It's a 2 pipe system and the 2 dry returns are the only place on the system for vents . I'm asking to thrown in Gortons .

Thanks Frank .

Unknown

The coil

is running a fairly large baseboard zone . We set it up so we can flush all the muckety crap out without exposing the coil to it .

This new one is really 1/3 the size . The hot water boiler will be 1/3 the size of the old one too .

Thanks Constantin .

Unknown

No union

on the 4 inch . We build them to last ( God willing ) . We did leave plenty of room to cut the 4 inch riser and throw in a union if something needs to be redone .

Once the 2 steam mains were tied in , connecting the equalizer and returns wasn't too bad . It helps to have plenty of every size 2 inch nipples . As a rough guess we shaved 1/2 a day of work compared to cutting and threading the nips .

Thanks alot Dale .

Unknown

We did

convince the inspector that a drop header was beneficial to any steam boiler . I was real close to dropping it when we tightened the 4 inch ell . Another reason I decided not to drop it was the height of the boiler main - everyone woulda been walking into it , and space is tight on the right side .

Thanks alot Scott .

Unknown

Lchmb

I ain't temptin nuthin' anymore . Not when 4 inch pipe is in play . I do wish manufacturers would include at least one diagram of a drop header with their manuals . We've seen a big dropoff of problem steam systems since we started doing it that way .

Thanks buddy .

Unknown

Your wish....

Your wish shall be granted very shortly in the next printing of the Megasteam I&O Manual Ron. I was informed that we are in the process of putting together Dropped Header drawings for the next printing.

Glenn Stanton

Manager of Training

Burnham Hydronics

U.S. Boiler Co., Inc.

Unknown

Excellent

Burnham is well known for having some of the most informational and well thought out install manuals , and this adds the icing to the cake .

Thanks alot Glenn .

Unknown

Day 4

We got the steam up and running for weekend service . Had some trouble with the oil . We kept getting foam out of the oil de-aerator . Took a solid hour to track down the culprit - either an old 1 inch gate valve or the new Firomatic valve .

We also skimmed and cleaned the returns for a few hours . The water was filthy .

The V9 is a solid piece of iron . Real easy to draw together for a big boiler . And zero issues with the steam - I didn't hear a bang , not a ping , not even a whimper in the 2 or 3 hours we had it going .

The 2nd pic is Kenny's returns . He was proud of 'em .

Monday we start the hot water boiler in a different wing of the church .

aaron_4

nice work

Hello Ron,

I wish this was the Matrix so I could just down load your boiler piping and do the same kind of work. Vary nice work I'll be posting a some pics of a boiler replacement soon and you can take a look.

aaron

kevin coppinger_4

Ron, as usual...

you guys do top notch work...2 questions. Why the 3 vaporstats? And how is the tiger loop and oil filter suported...looks kind of like it could easily get bent over during a blow down. Also..FYI Tigerloop now has a combo unit that does the filter and deareator all-in-one....saves a lot of space and time...kpc

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