Installation: Ultraliner Boiler Truck: Steam System

Ultraliner Boiler Truck: Steam System

Important Note: The following boiler truck configuration is used by Ultraliner's Field Service crew and is provided as an example only. Ultraliner, Inc. does not endorse the use of any particular manufacturer's equipment. Ultraliner, Inc. does not specify equipment requirements, but rather offers information regarding the general practice of Ultraliner's installers to provide guidance in a contractor's selection of equipment. The interpretation and application of the following information rests solely with the contractor. Each contractor must independently determine the cost, size, design use, and capacity of their own selection of equipment. Each contractor must independently insure the safety of their equipment and the compliance of their equipment with local and national regulations.

Boiler & Boiler Exhaust Pipe:	Boilers tend to be preferred by the majority of Ultraliner's Licensed Installers. The Ultraliner Boiler Truck has a 100 horse power (hp), 100,000 british thermal unit (btu) boiler with a 600 gallon water capacity. If such a boiler breaks down during an installation, there is generally sufficient reserve capacity to complete the installation of the line segment. Most Ultraliner Licensed Installers have a 100 hp (some even have 50 hp), ??,??? btu boiler with a 300 gallon (some even have 150 gallon) water capacity. The smaller boilers do not have sufficient capacity for larger diameter pipeliner installations. The typical 300 gallon boilers do not generally have sufficient reserve capacity to complete an installation if the boiler breaks down. Steam generators have no reserve capacity. Many of the installers who use steam generators will have a back-up steam generator mounted in the truck. In sizing a boiler or steam generator, the capacity for generating sufficient thermal energy (btus) is of utmost importance. Proper boiler or steam generator maintenance is critical to field crew productivity. The boiler exhaust pipe on the Ultraliner Boiler Truck is retractable and designed to exit the side door of the truck. By avoiding cutting the box, the risk of a leak at the exhaust pipe exit was eliminated, thereby simplifying truck maintenance.
Steam Pipe:	The steam pipe should exit the boiler vertically and extend upward as far as possible prior to diverting downward and to the back of the truck. The vertical section of the steam pipe will permit water to condensate and reduce the moisture in the main steam line.
"A" Station Steam Valve:	The "A" station contains a steam valve (the blue handle at the top right corner of the picture) which controls the volume of steam entering the "A" station. The "A" station also contains gauges for monitoring the temperature and pressure of the steam leaving the boiler truck. Extra precautions should be taken to ensure the proper functioning of the "A" station gauges. Installations should not be attempted with broken or improperly functioning gauges.
Water Trap:	A water trap MUST be placed after the "A" station at a lower height. The steam pipe should exit the water trap and then extend upward to the steam hose connector pipe. The water trap will help to purge water condensate from the steam line to help prevent excess moisture from entering the pipeliner. Excessive water in the pipeliner can result in steam surges which behave like a water hammer.
Steam Hose Connector Pipe:	There are several types of steam hose connectors available. Some steam hose connectors may not be OSHA approved for confined spaces. CamLocks are not recommended for use in this application. "BOSS" fittings are widely used by Ultraliner Licensed Installers.
Steam Hoses:	Steam hoses MUST be able to withstand at least 250 degrees F and should be equipped with safe fittings. "BOSS" fittings are widely used by Ultraliner Licensed Installers.
Flow-Through Plugs:	Flow-through plugs MUST be able to withstand at least 250 degrees F and should have at minimum of a 2" opening in the flow-through plug to enable proper steam flow. Most Ultraliner Licensed Installers prefer flow-through plugs which do not have metal restraining rings at their ends. A contractor should have a full range of flow-through plugs. Plugs are generally sized across three pipe sizes (i.e a 6"-8"-10" plug, or a 8"-10"-12" plug). A plug should only be used in a pipeliner corresponding to the middle size. The smallest allowable dimension is too large to fit in a pipeliner of the same nominal size. If a plug is routinely used at the largest allowable dimension, the risk of plug failure will greatly increase.
"B" Station:	Although not actually part of the boiler truck, the "B" station is a critical component of the required steam system. The flow control valve (yellow handle) together with the pressure and temperature gauges are the primary means of confirming adequate temperatures and pressures during the installation process. Extra precautions should be taken to ensure the proper functioning of the "B" station gauges. Installations should not be attempted with broken or improperly functioning gauges.

Relevance of the Steam System to the Installation Process:

Steam is required to heat the pipeliner to render it soft and thermoformable (so that it can be "blow-molded").
Steam transfers heat more readily than hot air. Steam is more efficient and can go to higher temperatures than hot water.
Proper steam system maintenance is critical to field crew productivity.

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Rev: 1/9/2002