New Boiler Build for New Steam System.

 
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coaledsweat
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Post by coaledsweat » Tue. Nov. 01, 2016 7:19 am

Galvanized pipe? Is that what your current system is plumbed with?


 
unhippy
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Post by unhippy » Tue. Nov. 01, 2016 4:43 pm

There is no current system

I know galv is not normally used on hot water heating systems in the states....but was here(with a couple of conditions attached).....now they put all plastic in because its cheaper and easier to install.

1: it must be on a sealed boiler system....some of the old set ups ran open systems, it can't be used on them

2: the entire system must be galv, you can't have it mixed with black pipe....its all or nothing

3:all transitions to and from copper for run outs and returns must be thru a brass nipple, preferably a long one....same goes for the transition from pipework to boiler in both directions

I'm also taking measurements on the finished pipe lengths so that if it corrosion causes problems I can prefab replacement pipes & combined with a list of fittings, just swap it out in future.

As one plumber pointed out, he knows the metallurgy is all wrong......but he only has to go and fix problems when someone breaks these rules.....like trying to use a dielectric union in place of a brass transition....

Hopefully with my system being in constant vacuum will help reduce the corrosion as well.

Callum

 
unhippy
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Post by unhippy » Sun. Jan. 22, 2017 4:56 am

The boiler is coming home this week :D

Just got some time and got the ash deflectors and the doors and seals in there....so the base is finished up except for the exhaust collar which I can attach later once its at my house.

Ash deflectors and sealing gasket in place.
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Main ash door and fly ash dropbox door.
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Looking in the main ash door.
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What holds the doors closed.....i wanted something that couldn't be accidentally bumped or knocked unlatched.
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The whole base unit...wheelbarrow style
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Got the boiler door all done except the gasket.....i ran out of gasket 2" short :mad:
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Door heat shield.
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Same type door fastening as before but with a step off handle to go thru the 2" insulation.
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The whole shebang......it stands 5'3" to the top of the insulation....sorry about the pic being sideways
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Callum

 
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lsayre
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Post by lsayre » Sun. Jan. 22, 2017 5:19 am

Amazing! It will be the Rolls Royce of Boilers when you finish it.

 
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StokerDon
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Stoker Coal Boiler: Gentleman Janitor GJ-5, Van Wert VA-600, Axeman Anderson130 X3.
Hand Fed Coal Furnace: Harman SF3500 reduced down to 3 grates connected to its own plenum
Coal Size/Type: Rice, Chestnut and whatever will fit through the door on the Harman
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Post by StokerDon » Sun. Jan. 22, 2017 8:53 am

Isn't kind of hot down there to be work'in on boilers?

Looks great! Your fly-ash clean-out section is a great idea. That's the biggest clean-out door I've seen on a residential boiler. Are you planning on putting a big ash pan in there to catch the fly-ash?

-Don

 
lzaharis
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Post by lzaharis » Sun. Jan. 22, 2017 10:48 am

Your new toy, er steam boiler looks fabulous Callum.
I can see many years of pleasant low pressure
steam making with it.

The fly ash basket door is a plus for sure and would
make quite a difference with coal burning making it
so much easier.

Have you decided on a combustion air blower and the
volume of air needed?

I really like the solid underfed pot for coal burning
as it seems like a very good design with few if any
potential problems from fines and excess fly ash.

 
unhippy
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Post by unhippy » Sun. Jan. 22, 2017 1:56 pm

StokerDon wrote:Isn't kind of hot down there to be work'in on boilers?

Looks great! Your fly-ash clean-out section is a great idea. That's the biggest clean-out door I've seen on a residential boiler. Are you planning on putting a big ash pan in there to catch the fly-ash?

-Don
Yeah i'm putting a pair of Stainless ash tubs in there....and it's not too hot here to work on boilers....wet and miserable down here and up country one skifield got 18" over the weekend.....
Global warming is awesome.....at this rate by the time i'm at retirement age I will be able to ski all year round :D
lzaharis wrote:
Have you decided on a combustion air blower and the
volume of air needed?
The stoker came complete with the combustion blower.......i just took it off as it the easiest thing to break when i'm swinging the boiler around on the overhead gantry close to the base unit.
lsayre wrote:Amazing! It will be the Rolls Royce of Boilers when you finish it.
Naa...a roller model would have automatic hopper filling and ash removal......(oh wait...what are these drawings for?.....) :D

Callum


 
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CoalJockey
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Post by CoalJockey » Sun. Jan. 22, 2017 4:40 pm

Looks awesome, your work is very neat and professional. Can't wait to see it complete and makin' heat!

:up: :up:

 
unhippy
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Post by unhippy » Mon. Jan. 23, 2017 12:45 am

CoalJockey wrote:Looks awesome, your work is very neat and professional. Can't wait to see it complete and makin' heat!

:up: :up:
I try to avoid wrinkles in ma' duct tape :D

 
unhippy
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Post by unhippy » Thu. Jan. 26, 2017 5:27 am

It was a big day at 'Coaled Hill Manor & Estate'.....the center of the central heating system came home. :D

Sorry about the pics being on their side...i don't know how to rotate them on here :x

Base unit on deck...
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We even layed out the red...plywood?
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It has to come all the way over here
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Whats that square box thing on the truck?
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'One does not just lift 1/3 of a ton of boiler' without hydraulics (unless your a masochist)
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Dropping it onto the base, thats dad with his back to the camera guiding it into place, i'm hiding behind the boiler looking in thru the firebox door to make sure the locator tabs all seated correctly.
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About to go out the other end of the deck and onto the floor for the soon to be built boiler shelter.
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Out on the floor platform....and half way thru the fun of maneuvering a 6' long (including the detachable 'wheelbarrow' handles) on an 8'x8' platform.
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Final adjustments
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That'll do there lads....time for tea and scones.
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Callum

 
lzaharis
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Other Heating: kerosene for dual fuel Keystoker/unused

Post by lzaharis » Thu. Jan. 26, 2017 11:32 am

unhippy wrote:It was a big day at 'Coaled Hill Manor & Estate'.....the center of the central heating system came home. :D

Sorry about the pics being on their side...i don't know how to rotate them on here :x

Base unit on deck...
z1.JPG
We even layed out the red...plywood?
z2.JPG
It has to come all the way over here
z4.JPG
Whats that square box thing on the truck?
z6.JPG
'One does not just lift 1/3 of a ton of boiler' without hydraulics (unless your a masochist)
z7.JPG
z8.JPG
Dropping it onto the base, thats dad with his back to the camera guiding it into place, i'm hiding behind the boiler looking in thru the firebox door to make sure the locator tabs all seated correctly.
z9.JPG
About to go out the other end of the deck and onto the floor for the soon to be built boiler shelter.
z12.JPG
Out on the floor platform....and half way thru the fun of maneuvering a 6' long (including the detachable 'wheelbarrow' handles) on an 8'x8' platform.
z14.JPG
Final adjustments
z15.JPG
That'll do there lads....time for tea and scones.
z16.JPG
Callum
===========================================================================
Thats a nice looking toy you have there doing the heavy lifting for you.

All I can say is beautiful!, and that is with barely no drooling on my keyboard.

I cannot wait until I see it running with that burn pot and the secondary fly ash collector.

I forgot to ask this question earlier Callum, does the burn pot have a cleanout door or hatch for coal fines or is the draft great enough to flush it out when the fire builds up? Is the end support bearing on the burn pot for the auger a steel Hardox sleeve?

 
unhippy
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Post by unhippy » Thu. Jan. 26, 2017 1:50 pm

The pot doesn't have a cleanout, which I was a little concerned about when I was considering the unit before I purchased it until I found someone in ireland that has the same burner that I do...she runs it on dross coal out of the bottom of the bins at her local coal yard and hasn't had any issues with it clogging on fines......she pulls the stoker and cleans it out once a year.

The end support bearing is cast on cast......time will tell I guess.

Callum

 
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StokerDon
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Stoker Coal Boiler: Gentleman Janitor GJ-5, Van Wert VA-600, Axeman Anderson130 X3.
Hand Fed Coal Furnace: Harman SF3500 reduced down to 3 grates connected to its own plenum
Coal Size/Type: Rice, Chestnut and whatever will fit through the door on the Harman
Other Heating: Noth'in but COAL! Well, Maybe a little tiny bit of wood

Post by StokerDon » Thu. Jan. 26, 2017 7:51 pm

That is frigg'in AWESOME! Will this "boiler shelter" have a nice tall masonry chimney?

One point of criticizum. With those nice go-kart racing wheels on it, I would have gone with a little fancier paint job.

-Don

 
unhippy
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Post by unhippy » Fri. Jan. 27, 2017 1:23 am

StokerDon wrote:That is frigg'in AWESOME! Will this "boiler shelter" have a nice tall masonry chimney?

One point of criticizum. With those nice go-kart racing wheels on it, I would have gone with a little fancier paint job.

-Don
Living in the Shaky Isles gives me a serious aversion to "nice tall masonry" anything...the shelter will have a chimney made from 6" exhaust tube like used on heavy machinery.....i still actually have to make the mounting collar for that :roll:

My paint scheme is a variation of 'welder repair' chic :D

Callum

 
unhippy
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Post by unhippy » Sat. Feb. 04, 2017 1:51 am

Been building ma' boiler shelter shed....That will be camouflaged as a greenhouse :)
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From the other side
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Actually starting to look like something
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Enough for today....doing the doors, chimney plate and roof vents tomorrow.....and going to get the tarps that will cover it until the polyweave greenhouse film I ordered gets here (its been delayed :roll: )
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Shhhhhh.....don't tell the boss but its about 1/4" out of square across the diagonals :x

Callum


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