Practical water heating rev 3


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Practical water heating rev 3

  1. 1. Critical but simple maintenance guide for the concrete industry to help you get more life and greater efficiency out of your product. Joe DeFrank Owen Blevins Bobby Giannetti
  2. 2. Variety of Heating and Cooling Equipment <ul><li>Heating Equipment </li></ul><ul><ul><li>Bulk Storage Oil/Gas Unpressurized Hot Water Heaters </li></ul></ul><ul><ul><li>Boilers (Pressurized Vessels) </li></ul></ul><ul><ul><li>Instant Hot Water Heaters (Direct Contact) </li></ul></ul><ul><li>Chilling Equipment </li></ul><ul><ul><li>Chillers </li></ul></ul><ul><ul><li>Ice machines </li></ul></ul><ul><ul><li>Liquid Nitrogen </li></ul></ul>
  3. 3. Warning: Do not attempt any of the following operations without adult supervision… <ul><li>Seriously, please follow ALL OSHA rules and regulations while performing any of the following inspections and adjustments. </li></ul><ul><ul><li>Above all, safety first! </li></ul></ul><ul><ul><li>Use common sense. </li></ul></ul><ul><ul><li>If you have the people and resources, use them. </li></ul></ul><ul><ul><li>If you don’t, pay for those services… </li></ul></ul>
  4. 5. Practical Water Heating & Chilling Tips <ul><li>Always perform tank inspections 2-3 weeks prior to tank operation </li></ul>
  5. 6. Calcium and Sediment Build-Up <ul><li>Check the inside of your tanks at the beginning of each heating season </li></ul><ul><li>Calcium build-up on the fire tube will reduce heat transfer </li></ul>
  6. 7. Temperature Control <ul><li>Temperature-control thermo wells should be checked </li></ul><ul><li>Build up on the temperature-control thermo well will effect the accuracy of controls and thermometers </li></ul>
  7. 8. Zinc Anode Rods <ul><li>Four installed in tank </li></ul><ul><li>Check monthly </li></ul><ul><li>Replace as needed </li></ul>Before After
  8. 9. Efficient Airflow and Safety Switches <ul><li>Clear airflow provides proper combustion </li></ul><ul><li>Clear all debris from air intake and blower units on burner. </li></ul><ul><li>Inefficient air intake = inefficient heating </li></ul><ul><li>Test manual reset on high-limit temperature control </li></ul><ul><li>Inspect low-water burner safety control during annual tank drainage </li></ul>
  9. 10. Pump Maintenance <ul><li>Unheated water discharge pump should be drained after daytime operation </li></ul><ul><li>Insulated and heated pumps do not require daily draining </li></ul>
  10. 11. Clear Fuel Lines <ul><li>Oil nozzles should be changed yearly </li></ul><ul><li>Oil filters and fuel supply screens should be cleaned or changed each heating season </li></ul>
  11. 12. Ignition Set Points <ul><li>Change and adjust all ignition set points </li></ul><ul><li>Example:  electrodes and high tension leads </li></ul>
  12. 13. Refractory
  13. 14. Combustion Chamber <ul><li>Check refractory combustion chamber for damaged pieces </li></ul>
  14. 15. Stack Maintenance <ul><li>Cover stack in summer months if using tank for chilled water </li></ul><ul><li>Condensation in fire tube will damage the combustion chambers </li></ul>
  15. 16. Tank & Insulation Inspection <ul><li>Conduct exterior tank inspection </li></ul><ul><li>Confirm that aluminum and insulation covering is intact </li></ul>
  16. 17. Vent Maintenance <ul><li>Tank vent must be free of debris </li></ul><ul><li>Examples: bird nest or ice </li></ul><ul><li>Ice formed on vents will cause tank to collapse </li></ul><ul><li>Emergency manhole vent should not be tightened </li></ul>
  17. 18. Energy Savings <ul><li>Stack heat recovery system will increase unit efficiency by 15% </li></ul>
  18. 19. Energy Savings <ul><li>Blending Valves increase efficiency of hot or chilled water by giving operators exact temperature control. </li></ul>
  19. 20. CHILLERS <ul><li>Chiller should  be drained and filled with Glycol during winter months </li></ul><ul><li>Fans should be kept unobstructed </li></ul>
  20. 21. <ul><li>Clean coil using compressed air before start-up </li></ul><ul><li>During concrete plant operation, check evaporator coil for dust build-up </li></ul>