Practical water heating rev 3

Critical but simple maintenance guide for the concrete industry to help you get more life and

greater efficiency out of your product.

Joe DeFrankOwen Blevins

Bobby Giannetti

Variety of Heating and Cooling Equipment

Heating Equipment

•Bulk Storage Oil/Gas Unpressurized Hot Water Heaters

•Boilers (Pressurized Vessels)

•Instant Hot Water Heaters (Direct Contact)

Chilling Equipment

•Chillers

•Ice machines

•Liquid Nitrogen

Warning: Do not attempt any of the following operations without adult supervision…

Seriously, please follow ALL OSHA rules and regulations while performing any of the following inspections and adjustments.

•Above all, safety first!

•Use common sense.

•If you have the people and resources, use them.

•If you don’t, pay for those services…

Practical Water Heating & Chilling Tips

Always perform tank inspections 2-3 weeks prior to tank operation

Calcium and Sediment Build-Up

Check the inside of your tanks at the beginning of each heating season

Calcium build-up on the fire tube will reduce heat transfer

Temperature ControlTemperature-control thermo

wells should be checked

Build up on the temperature-control thermo well will effect the accuracy of controls and thermometers

Zinc Anode RodsFour installed in tank

Check monthly

Replace as needed

Before

After

Efficient Airflow and Safety Switches

Clear airflow provides proper combustion

Clear all debris from air intake and blower units on burner.

Inefficient air intake = inefficient heating

Test manual reset on high-limit temperature control

Inspect low-water burner safety control during annual tank drainage

Pump MaintenanceUnheated water discharge pump

should be drained after daytime operation

Insulated and heated pumps do not require daily draining

Clear Fuel Lines

Oil nozzles should be changed yearly

Oil filters and fuel supply screens should be cleaned or changed each heating season

Ignition Set Points

Change and adjust all ignition set points

Example: electrodes and high tension leads

Refractory

Combustion Chamber

Check refractory combustion chamber for damaged pieces

Stack Maintenance

Cover stack in summer months if using tank for chilled water

Condensation in fire tube will damage the combustion chambers

Tank & Insulation Inspection

Conduct exterior tank inspection

Confirm that aluminum and insulation covering is intact

Vent Maintenance Tank vent must be free of debris

Examples: bird nest or ice

Ice formed on vents will cause tank to collapse

Emergency manhole vent should not be tightened

Energy Savings

Stack heat recovery system will increase unit efficiency by 15%

Energy Savings

Blending Valves increase efficiency of hot or chilled water by giving operators exact temperature control.

CHILLERSChiller should be drained and filled with Glycol during winter monthsFans should be kept unobstructed

Clean coil using compressed air before start-up

During concrete plant operation, check evaporator coil for dust build-up