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Valve Insulation: Here's What the Boiler Pros Do
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Replacing an old boiler is one of those jobs that any HVAC professional can relate to. It's a glimpse into the technology of the times.
Bringing a heating system into the 21st century means providing a building with more efficient equipment that's less prone to intermittent problems. It's also an opportunity to reduce the overall footprint by selecting modern appliances and valves that are more compact and can perform more functions than their early predecessors. With the right accessories for the job, the installer can save themselves time and labor while ensuring their customers are free from callbacks for years to come.
Ancient and Inefficient
It's a challenge Jordan Rogers knows well thanks to his time working as Lead Designer at Fancher Services, Inc., a residential and commercial plumbing service provider in Vestal, New York. Fancher has been locally owned and operated since 1947, offering a full range of residential and commercial plumbing and electrical services.
Rogers has tackled his fair share of "ancient" installations. He was recently tasked to take on a 1950s American Standard G607 hot water boiler at the East Side Congregational United Church of Christ, a community staple in nearby Binghamton, that has been in existence since 1836.
The 870,000 BTU behemoth wasn't just terribly inefficient—it completely consumed the small, cramped basement space it inhabited. Topped with a labyrinth of well-worn valves, fittings and devices, they combined to form a heating system that was both difficult to work with and full of potential points for failure.
The decision was made–everything had to go.
Saving Space and Labor
First on Roger’s list was replacing the old American Standard unit with two 285,000 BTU NTI boilers. The project was a bit more complex than a basic all-zone-valve or all-circulator-pump installation—it involved both. To add more complexity, two of the three zones branched off into precarious places.
To maximize the available space, Rogers outfitted the system with step-saving valves from Webstone®, a brand of NIBCO, that combine multiple components into a single forged-brass solution.
The pumps were installed with Isolator® Uni-Flange ball valves, allowing them to be isolated for service, ensuring virtually no air was introduced into the system during the pump replacement. Its innovative design combines a flange and ball valve, saving time, space, and leak paths from every circulator pump installation. The Isolator is the industry’s original flanged ball valve, and boasts the largest selection of sizes, connection types and optional features available today.
For the zones and indirect water heater, he selected the Pro-Pal® Ball Drain™, an adjustable flow path ball valve, that can be drained from either side of the ball. The ball drain is a popular choice among professionals due to its versatility and its wide array of models that cover a host of installation needs. Also included in the installation were strategically placed Webstone ball valves to isolate various areas and appliances.
Form Meets Function
When asked what led him to choose Webstone over other manufacturers for this project, Rogers explained, "The Webstone mantra of 'fewer connections' saved us time, labor and frustration. The cost is roughly the same, but the labor savings are significant." He adds that the fewer leak paths specifically made a huge difference "in terms of time and preserving the morale of the team."
Installed by master plumber Luke Walz, the final product is a dazzling display of form and function. The panel is outfitted with color-coded LED lights that signal when the system calls for heat (red) or domestic water (blue). The horizontal installation allows easy access to all appliances, accessories and valves for future maintenance and service. Most importantly, the church and its patrons can rely on the new system to provide heat and comfort for years to come.
"This was a labor of love," Rogers said. "Webstone's commitment to innovation only added to the satisfaction of tackling this challenge." For Fancher Heating and Cooling, Webstone is a trusted brand whose products are standard stock items in their warehouse.
To contact Fancher Appliance, Inc., visit www.fancherservices.com.
To learn more about Webstone products, visit www.nibco.com/brands/webstone.