Calumet GSA Manual - Start-Up
GSA Gas-Fired Steam Boilers – Boiler Manual
14
Part Number 550-110-738/0703
Check for gas leaks
Before starting the boiler, and during initial operation,
smell near the floor and around the boiler for gas
odorant or any unusual odor. Do not proceed with
start-up if there is any indication of a gas leak. Repair
any leak at once.
Propane boilers only — Your propane supplier mixes
an odorant with the propane to make its presence
detectable. In some instances, the odorant can fade
and the gas may no longer have an odor.
• Propane gas can accumulate at floor level. Smell near
the floor for the gas odorant or any unusual odor. If
you suspect a leak, do not attempt to light the pilot.
• Use caution when attempting to light the propane pilot.
This should be done by a qualified service technician,
particularly if pilot outages are common.
• Periodically check the odorant level of your gas.
• Inspect boiler and system at least yearly to make
sure all gas piping is leak-tight.
• Consult your propane supplier regarding installation
of a gas leak detector. There are some products on
the market intended for this purpose. Your supplier
may be able to suggest an appropriate device.
7
Start-up
Preparation
Determine if water treatment is needed
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to
boiler will occur, resulting in substantial property
damage.
Eliminate all system leaks. Continual fresh makeup
water will reduce boiler life. Minerals can build up in
sections, reducing heat transfer, overheating cast
iron, and causing section failure.
Consult local water treatment companies for unusually hard water
areas (above 7 grains hardness) or low pH water conditions (below
7.0). Boiler water pH of 7.0 to 8.5 is recommended.
Fill the system with water
1. Do not fill (except for leakage tests) until boiler is ready to be
fired.
2. Fill to normal waterline, halfway up gauge glass.
3. Boiler water pH 7.0 to 8.5 is recommended.
4. Follow skimming procedure, right.
Skimming the boiler
Clean all newly installed steam boilers to remove
oil and grease. Failure to properly clean can result
in violent fluctuations of water level, water passing
into steam mains or high maintenance costs on
strainers, traps and vents.
Do not use petroleum-based cleaning or sealing
compounds in boiler system. Severe damage to boiler
will occur, resulting in substantial property damage.
1. Provide 1½" piping from skim tapping to floor drain.
2. Adjust waterline to midpoint of skim tapping. See Figure 3,
page 7.
3.
Follow “Lighting Instructions” found on boiler or on pages 18
and 19 of this manual, to fire boiler to maintain temperature below
steaming rate.
4. Feed in water to maintain water level. Cycle burners to prevent
rise in steam pressure.
5. Continue skimming until discharge is clear. May take several
hours.
6. Drain boiler. While boiler is warm, but not hot, flush all interior
surfaces under full pressure until drain water runs clear.
7. Remove skim piping. Plug tapping.
8. Close drain cock. Fill with fresh water to waterline. Start burners
and steam for 15 minutes to remove dissolved gases. Stop
burners.
9. Check traps and air vents for proper operation.
10. Process may need to be repeated after several weeks of
operation.
Inspect base insulation
DO NOT proceed with boiler operation unless boiler
and system have been filled with water and all
instructions and procedures of previous manual
sections have been completed. Failure to do so could
result in severe personal injury, death or substantial
property damage. Before starting the boiler . . .
• See pages 18 and 19, for “Lighting Instructions”.
• Verify the boiler and system water level is correct
(no more than ½ of gauge glass or less than ¼" above
bottom of gauge glass).
• Verify the “Preparation” procedures, on this page,
have been completed.
Operate boiler
Check to make sure insulation is secure against all four sides of
the base. If insulation is damaged or displaced, do not operate
boiler. Replace or reposition insulation.
Failure to replace damaged insulation or reposition
insulation can result in a fire hazard, causing severe
personal injury, death or substantial property
damage.
The boiler contains ceramic fiber and fiberglass
materials. Use care when handling these materials
per instructions on page 32 of this manual. Failure
to comply could result in severe personal injury.