NIBCO

The Magnetic Boiler Filter XL is designed to protect larger residential boilers from iron sludge that can accumulate in a hydronic system. Commonly installed on the system run, it captures ferrous and non-ferrous debris before it can reach the boiler using a high-powered 12,000 Gauss magnet and plastic filter.

The drain makes it simple to remove accumulation, with a strapped cap that can be used to actuate the drain valve and a large filter body that increases time between service. A service tool is also included to help install and maintain the filter with ease. G-threads make it simple to swap out your choice of press, MIP, FIP, or sweat G-union end connections in sizes 1¼” or 1½”. The MBF XL can withstand 250°F and 145 PSI CWP.

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All plumbing systems should be designed with future servicing in mind. In a typical closed-loop system, maintenance usually involves a four-step process: draining the existing fluid, flushing with a descaling/cleaning solution, rinsing out the solution, and refilling with new fluid. During installation, contractors will designate a purging station and a filling station in anticipation of such a process. Each station would consist of a hose drain to purge or fill, and a ball valve to isolate it from the rest of the system.

To consolidate components and to avoid draining the system completely, contractors began fabricating combined purging and filling stations. A pair of assemblies each consisting of a boiler drain, tee, and close nipple would be installed, with a central ball valve placed in between the two stations for isolation. By opening the drain valves and closing the ball valve in the middle, the system loop would open. Then, when new fluid was introduced via the filling station, the flow would displace old fluid through the system and out the decoupled purging station on the other side of the ball valve. Through some clever fabrication, what was once a four step process was now just one step.

Though this assembly does its job to simplify the process, it’s not without its drawbacks. Field fabrications, though functional, are an inelegant solution. Contractors need to take into account the bulkiness of such an assembly when designing the system layout, which can be a challenge when space is limited. Aside from the lengthy footprint, this assembly also introduces three valves and four fittings into the system, increasing labor and leak paths with each component used. These disadvantages have long been accepted by contractors as a necessary evil in designing a system that expedites the purging and filling process.

Enter the Webstone Purge & Fill. An all-in-one forged brass valve alternative, it eliminates 6 leak paths and saves the installer nearly one hour of labor. Its patented design not only streamlines installation, but it also employs the same principals explained above to facilitate future servicing of the closed loop. The three-way ball quickly isolates the flow between the two hose connections, allowing new fluid to enter the system through the top fill drain. The fluid will then flow through the system, forcing out the old fluid until it completes the circuit through the bottom purge drain. By displacing the old fluid with the new, contractors can avoid the timely process of draining and filling the system between each step of the maintenance process.

The Purge & Fill was designed for use anywhere that requires routine maintenance of the fluids within a closed-loop. In applications where piping systems are exposed to the elements, a heat transfer fluid like propylene glycol is added to the water to prevent freezing. This fluid mixture will run through the loop, utilizing a heat exchanger to prevent direct contact with any potable water distribution. Over time, this fluid must be replaced, and the piping system should be cleaned or descaled if needed. This is an ideal application for the Purge & Fill because it allows the loop to maintain normal operating conditions as it is simultaneously purged and filled during servicing.

In solar heating systems, the valve can be placed within the heat collection loop. Here the fluid mixture will circulate through the solar collectors, gathering heat that is then distributed to the potable water through the heat exchanger.

In snowmelt applications, the valve can be placed within the heat distribution loop, where the fluid mixture will pass through the heat exchanger and distribute heat through a series of tubing under an outdoor surface.

The fluid mixture’s levels within either loop in must be checked and replaced periodically to ensure proper operation and maintenance of the system. With the Purge & Fill installed in each loop, the fluid can easily be inspected, flushed, and refilled as needed.

Available with threaded or sweat connections and in sizes ¾” through 1 ½”, the Purge & Fill is suitable for any closed-loop system. Its single body forged brass construction features heavy duty brass and hi-flow hose drains. The reversible handle is accompanied by an adjustable packing gland and blow-out proof stem that offer versatility and dependability throughout the life of the product.

Inspired by the field fabrication solutions that came before it, the Purge & Fill is part of Webstone’s Pro-Pal series; a line of step-saving valves designed with the professional in mind. The result is a cleaner looking installation, with fewer components and more efficient system operation. Like all Webstone products, the Purge & Fill is guaranteed for life.

One of the nation’s largest aerospace firms planned to expand and modernize existing capabilities at an occupied research and development facility in southern California. Xcel Mechanical Systems, based in Gardena, CA, was hired to design and build the mechanical, plumbing and process piping elements of the new project. To minimize risk and maximize labor efficiency, the Xcel team selected NIBCO® Press fittings and valves as a smart solution for the multi-phase project.

“Leveraging press technology mitigates the inherent risks of working with open flame within an occupied space,” said Jason Gordon, Xcel Mechanical’s vice president of operations. “We chose NIBCO Press for this job for multiple reasons, including safety, time and labor savings, and aesthetics,” said Gordon, whose firm has been a preferred design-build mechanical contractor on the sprawling campus for more than two decades. “NIBCO is a proven brand name in our industry. That’s important to us because the products we select are a reflection on our company.”

After four carefully planned construction phases, three and a half years of steady and precise work, the $8 million HVAC, plumbing and piping elements of the estimated $50 million laboratory modernization project are nearing completion.

The total renovation project included remodeling existing labs located on the ground floor of a three-story, 1960s-era research and manufacturing facility; labs which must be constantly redesigned and reconfigured to meet the specific requirements of each new contract award. The owner’s primary goal was to convert the subdivided lab space into a large open floor plan, creating the opportunity to build-out a modern, flexible and scalable “factory of the future” that would maximize the total available 160,000-square feet of lab and manufacturing space and 57,000-square feet of office space.

The building was stripped down to concrete on all four sides, exposing what was left: columns, high ceilings, and slabs. The original building design included old stanchion supports with piping and electrical systems running up from the floor. To free up valuable floor space, the new design features steel overhead utility racks that now run 500-600’ feet across the exposed ceiling for a nice clean application. Major mechanical and plumbing systems were removed and redesigned to align with the new design.

Project team members, from left: Wes Whittle (Piping and Plumbing Superintendent); Foreman Shawn Gibson (Pipefitter, Welder); Jason Gordon (VP of Operations); Foreman Ray Adams (Plumber, Pipefitter); Tim Brown (Service Technician); Steve Prisk, CSHO, ASH (Safety Director).

The Safety Factor

In this facility, the mains on the overhead utility distribution racks are sized 2” down to ¾”.  Separately, the HVAC system has chilled water and heating hot water lines measuring up to 4” in diameter. Some of those lines drop down from a chilled water system located on the roof that serves a newly installed air handler.

“Typically, we would use steel for those 4” lines,” Gordon said. “But since the piping ran down an existing shaft, there were safety concerns around welding or grooving the 4” steel. And then there was the weight factor and what would be required to run steel pipe down that shaft versus copper,” he said.

“For these reasons, my foremen advocated for the additional material spend on copper. Obviously, the material cost is considerably more but we felt the safety benefits and labor savings would offset it,” Gordon said. “We are a strong believer in getting perspective from our foremen. If they support the plan, believe in the products they are installing, and it makes sense financially, then it’s a win-win.”

Gordon said using NIBCO Press on the project also meant not having to go through the facility’s Hot Work permitting process which typically adds time to any project. “The customer liked that the NIBCO product removed a certain level of risk, and also the smell of soldering and flux from an operational lab environment,” he said. “So, in the end, our customer was happy. Our safety team was happy. And our field personnel were happy.”

Labor Savings is Big

NIBCO Press is easy to install which helps reduce labor costs while keeping projects on schedule. “Material is material, but labor is what makes or breaks a job,” Gordon said. The project’s process piping system consists of three copper lines, one each for compressed air, nitrogen, and industrial vacuum systems. Each run is 400-500’ long and includes multiple connection points. Gordon said the press product made working in smaller areas and also making multiple connections overhead much easier from both a safety and labor efficiency perspective. “We fabricated a fair amount of material used in this job, but with a multitude of small overhead connection points located 6-12’ apart along these lengthy runs, the copper press solution was key. We saved a minimum of 30-40% on labor on some parts of this job, and significantly more on other parts,” he said.

Minimizing System Downtime

Through the life of the project, the ongoing challenge was to build safely around the 100-200 employees who were working in the lab areas. The project’s four-phase approach called for temporarily relocating employee teams into other parts of the facility while completing construction one section at a time. “Using NIBCO Press not only reduced labor time, but it shortened shutdown periods, allowing us to get the building back online sooner.”

Looking Good

Although functionality and flexibility played an important role in modernizing this facility, creating a visually appealing space was also a consideration, Gordon said. “Aesthetically the NIBCO Press product is a good-looking product and a clean application overall,” he said. “For nitrogen systems, we would typically purge and braze, and afterward the copper is oxidized. When we install press, the copper looks brand new. It’s a good look.” 

Smart Solution

As the project nears completion, Xcel Mechanical will continue to use NIBCO Press systems to ensure their reputation for high quality and good workmanship is maintained. Press is easy to install and the labor cost savings generated cannot be understated.  The proven performance of Press makes it a smart solution for every job.

For more information, visit www.NIBCO.com or contact Sally Boyer, manager of marketing communications, at boyers@nibco.com.

Whether installing a new boiler or maintaining an existing one, it’s important to consider the inherent issues that can befall a hydronic system and impact the performance of its components. Anticipating these pitfalls and planning accordingly will result in a smarter installation.  By choosing your boiler accessories wisely, you can extend the life of your boiler and maintain its efficiency while guarding against potential problems down the road.

One of the most common issues comes in the form of ferrous debris, a result of normal metal pipe wear that, when left unchecked, can cause major problems. Over time, rust particles and other debris in the heating loop build up, creating an iron sludge that reduces boiler efficiency or even stops it altogether from working. The resulting damage can require expensive repairs, increase heating costs, and reduce the overall lifespan of the boiler.

To combat the accumulated sludge in the pipes, a system flush may be required. Depending on the severity of the issue, this could be a costly and time-consuming process. Moreover, doing so will not reverse any damage that’s already been done to the boiler. By the same token, boiler manufacturers are becoming more stringent about their warranty claim requirements. Installing a boiler accessory as a precautionary measure is the most consistent way to ensure due diligence is being done. The best protection from iron sludge is to prevent it from ever reaching the appliance.

To protect the boiler, consider the Magnetic Boiler Filter (MBF) from Webstone®, a brand of NIBCO. It captures ferrous and non-ferrous debris before it can reach the boiler using a high-powered 12,000 Gauss magnet. Its internal filter knocks out sediment as it enters the unit, breaking down the sludge and maintaining optimal flow rate. The build-up is captured in the body, which has a large storage capacity to increase time between service. The strapped cap is also used to actuate the integrated drain valve, making it simple to remove accumulation when needed, and a service tool is included to help remove the filter housing with ease.

The MBF bodies feature G-thread ends for connection to your choice of MIP, FIP, sweat, or press union fittings. Unions and bodies can be purchased as an installation kit or as separate components depending on the installer’s preference. Optional lead-free dezincification-resistant brass isolation valves are also available to simplify future service. When installed in conjunction with a circulator pump, the flanged ball valve saves space, labor, and leak paths compared to the off-the-shelf assemblies that would normally be required to connect the two appliances. It also mitigates the risk of electrolysis and galvanic corrosion, while allowing virtually no air into the system upon pump replacement. For more simple isolation needs, Webstone offers straight and angled G-union ball valves with reversible handles.

For smaller systems, the ¾” and 1” models feature a universal diverter that allows the MBF to be used in both horizontal and vertical piping orientations on the system return line. For horizontal installations on the system run, the Magnetic Boiler Filter XL model is now available in sizes 1¼” or 1½”. Introduced in 2021, the patent-pending MBF XL is ideal for larger residential and light commercial boiler applications, with a robust 2-layer metal mesh filter and manual air vent.

Webstone offers a wide array of system performance products designed to support efficient operations and protect components. To learn more about how you can work smarter, visit Webstone Valves.