• Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • CONTRACTORS
  • ENGINEERS
  • RADIANT & HYDRONICS
  • INSIGHTS
  • MEDIA
  • RESOURCES
  • EMAGAZINE
  • SIGN UP!
cart
facebook instagram twitter linkedin youtube
  • CONTRACTORS
  • BATH & KITCHEN PRO
  • BUSINESS MANAGEMENT
  • HIGH EFFICIENCY HOMES
  • TECHNOLOGY
  • WATER TREATMENT
  • PMC COLUMNS
  • PMC COLUMNS
  • Dave Yates: Contractor’s Corner
  • John Siegenthaler: Hydronics Workshop
  • Kenny Chapman: The Blue Collar Coach
  • Matt Michel: Service Plumbing Pros
  • Scott Secor: Heating Perceptions
  • ENGINEERS
  • CONTINUING EDUCATION
  • DECARBONIZATION | ELECTRIFICATION
  • FIRE PROTECTION
  • GEOTHERMAL | SOLAR THERMAL
  • PIPING | PLUMBING | PVF
  • PME COLUMNS
  • PME COLUMNS
  • Christoph Lohr: Strategic Plumbing Insights
  • David Dexter: Plumbing Talking Points
  • James Dipping: Engineer Viewpoints
  • John Seigenthaler: Renewable Heating Design
  • Lowell Manalo: Plumbing Essentials
  • Misty Guard: Guard on Compliance
  • RADIANT & HYDRONICS
  • RADIANT COMFORT REPORT
  • THE GLITCH & THE FIX
  • INSIGHTS
  • CODES
  • GREEN PLUMBING & MECHANICAL
  • PROJECT PROFILES
  • COLUMNS
  • SPONSOR INSIGHTS
  • COLUMNS
  • Codes Corner
  • Natalie Forster: Editorial Opinion
  • Guest Editorial
  • MEDIA
  • PODCASTS
  • VIDEOS
  • WEBINARS
  • RESOURCES
  • INDUSTRY CALENDAR
  • DIRECTORIES
  • EBOOKS
  • PM BOOKSTORE
  • CE CENTER
  • MARKET RESEARCH
  • CLASSIFIEDS
  • EMAGAZINE
  • EMAGAZINE
  • ARCHIVE ISSUES
  • CONTACT
  • ADVERTISE
  • PME EMAGAZINE ARCHIVES
search
cart
facebook instagram twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • CONTRACTORS
    • BATH & KITCHEN PRO
    • BUSINESS MANAGEMENT
    • HIGH EFFICIENCY HOMES
    • TECHNOLOGY
    • WATER TREATMENT
    • PMC COLUMNS
      • Dave Yates: Contractor’s Corner
      • John Siegenthaler: Hydronics Workshop
      • Kenny Chapman: The Blue Collar Coach
      • Matt Michel: Service Plumbing Pros
      • Scott Secor: Heating Perceptions
  • ENGINEERS
    • CONTINUING EDUCATION
    • DECARBONIZATION | ELECTRIFICATION
    • FIRE PROTECTION
    • GEOTHERMAL | SOLAR THERMAL
    • PIPING | PLUMBING | PVF
    • PME COLUMNS
      • Christoph Lohr: Strategic Plumbing Insights
      • David Dexter: Plumbing Talking Points
      • James Dipping: Engineer Viewpoints
      • John Seigenthaler: Renewable Heating Design
      • Lowell Manalo: Plumbing Essentials
      • Misty Guard: Guard on Compliance
  • RADIANT & HYDRONICS
    • RADIANT COMFORT REPORT
    • THE GLITCH & THE FIX
  • INSIGHTS
    • CODES
    • GREEN PLUMBING & MECHANICAL
    • PROJECT PROFILES
    • COLUMNS
      • Codes Corner
      • Natalie Forster: Editorial Opinion
      • Guest Editorial
    • SPONSOR INSIGHTS
  • MEDIA
    • PODCASTS
    • VIDEOS
    • WEBINARS
  • RESOURCES
    • INDUSTRY CALENDAR
    • DIRECTORIES
    • EBOOKS
    • PM BOOKSTORE
    • CE CENTER
    • MARKET RESEARCH
    • CLASSIFIEDS
  • EMAGAZINE
    • EMAGAZINE
    • ARCHIVE ISSUES
    • CONTACT
    • ADVERTISE
    • PME EMAGAZINE ARCHIVES
  • SIGN UP!
Columns

The boiler gas train

Understanding this critical safety system can save your customers costly repairs.

By Ray Wohlfarth
Ray Wohlfarth
February 20, 2014

One of the most misunderstood portions of the commercial heating system is the gas train. The gas train is a series of components that safely feed natural or propane gas into the burner.

The first component of the gas train is the sediment trap, more commonly referred to as the “dirt leg.” This is used to catch any dirt or moisture that may be entrained in the natural gas feed to the building. It is typically a nipple and cap located on the run of the tee. The gas feed is on a right angle coming from the bull of the tee.

The American Society of Mechanical Engineers Controls and Safety Devices for Automatically Fired Boilers (ASME CSD1) recommends a strainer before the other horizontal components in the gas train. Although not commonly installed, it is a good idea as it also will protect the gas train components from dirt.

Just past the strainer is the upstream manual gas valve. This manual gas valve usually has a 1/4 in. or 3/8 in. plug on the upstream side of the gas valve. The pipe plug is where the pipe or tubing should be attached to the burner pilot assembly. The pilot connection should be on the upstream side of the valve to allow the safety controls to be tested. The valve handle should be oriented so that it is parallel to the gas flow when open and perpendicular to the gas flow when closed. This allows you to quickly see whether the gas valve is open or closed.

The gas pressure regulator should be the next component. It will be upstream of all electric valves. The orientation of the regulator is important and is usually right side up, with the adjustment access on top. Inside the top of the regulator is an adjustment screw and a spring. On many regulators, the spring can be changed to allow different gas pressures to the burner.

The regulator usually has a fitting on top that is to be vented to the outside. This vent pipe can sometimes plug and fill with spiders or bees. If plugged, it will not allow the gas to flow, resulting in a no-heat call. A bug screen should be installed on the outdoor termination of the vent pipe. Some new regulators use vent limiters, which do not require venting to the outside.

The next item downstream in the gas train progression is the low-gas pressure switch. As you can guess, it will shut off power to the burner if the gas pressure is below the set point. The high-gas pressure switch will be located between the last manual gas valve and the burner. Many are located atop the burner housing. This will shut off power to the burner if the gas pressure is too high.

These controls usually have a manual reset that will require resetting if they trip. Many gas pressure switches should be vented outside. Gas pressure switches are not installed on every boiler and are typically used when the gas rating of the burner is greater than 2.5 million Btuh.

Safety shutoffs or valves are the next components in the gas train. Most likely it is two redundant electric valves that are to limit the chance of gas leaking into the boiler. If the state or municipality adheres to ASME CSD1, there will be a tapping with a valve and cap immediately after each valve. This is to allow the leak-testing of the gas valves.

Many valve manufacturers recommend leak-testing gas valves using a bubble test. The orientation may be important when installing the gas valves and the installation manual should be consulted to see whether the valves can be installed horizontally or vertically.

Some older gas trains used what was called a Block, Block and Bleed gas train. In between the two normally closed safety shutoff valves was a tee. The pipe from the bull of the tee was attached to a solenoid valve that was normally open. It was installed to vent any gas that may leak past the first electric safety shutoff valve to the outside.

If the system had this type of gas train, the outlet pipe from the solenoid valve was to be vented by itself to the outside. The other gas train components could be combined into a single vent but separate of the bleed valve piping. The solenoid valve should be checked on a regular basis to assure that gas is not leaking through it.

Another manual gas valve or the downstream manual gas valve is installed right past the last electric valve and before the modulating or firing rate valve.

The last component is the firing rate valve. This valve is operated by a modulating motor and will change according to input from the modulating control. It also may be called a butterfly valve. These are not installed on an on/off burner.

 Be careful when using Teflon tape or pipe dope on the gas train threads as many manufacturers will not allow it and could actually void the warranty.

 

Client stories

“Be careful as the flames roll out the side of the boiler when it starts,” our new client warned us when we were going to perform a preseason check of the boiler. We saw what he was warning us about immediately as the boiler started. Flames did indeed roll out of the boiler and licked the boiler jacket.

The cause of this anomaly was the improper installation of the gas pressure regulator, which was downstream of the first electric gas valve. When the electric gas valve was powered off, the gas pressure regulator would open wide. After the gas valve was energized and open, the regulator would be wide open and overfeed the gas to the burner. The gas pressure would regulate itself to the proper setting but not until the flame shot out of the side of the boiler.

To repair the problem, the regulator had to be relocated upstream of the electric valves.

In some areas, a relief valve is required. I have never seen one on any of the projects my company has worked on, but ASME CSD1 recommends the installation.

 “Our gas costs are suddenly very high,” another customer said. “What is wrong with your boiler?” I asked him if anything had changed since the boiler was installed and was assured that nothing had changed. He told me something was wrong with the boiler I installed more than 10 years ago.

When we arrived at the building, we saw that something had indeed changed. Someone had replaced the normally open bleed valve with a normally closed solenoid valve. No one knew who changed the valve. It must have been the Boiler Fairy who anonymously changes components and control settings. The solenoid valve would open when the safety shutoff valves opened, allowing a 1 1/4-in. pipe filled with gas to vent to the outside anytime the boiler was firing.

Once the valve was changed back, the client liked my boiler again.


HELPFUL LINKS:

  • American Society of Mechanical Engineers
  • Contact Us
  • Follow PM on Twitter!
  • Find PM on Facebook!
  • Join PM on LinkedIn! 
KEYWORDS: boiler commercial boilers heating systems

Share This Story

Looking for a reprint of this article?
From high-res PDFs to custom plaques, order your copy today!

Wohlfarth

Ray Wohlfarth is the author of “Lessons Learned in a Boiler Room: A common-sense approach to servicing and installing commercial boilers.” In his spare time, he is president of Fire & Ice in Pittsburgh, Pa. Ray writes a monthly newsletter on commercial boilers. He can be reached at 412/343-4110.

Recommended Content

JOIN TODAY
to unlock your recommendations.

Already have an account? Sign In

  • Worker using the Milwaukee Tool SWITCH PACK drain cleaner

    Pipeline profits: Drain cleaning, pipe inspection create opportunities

    Drain cleaning and inspection services offer lucrative...
    Plumbing News
    By: Nicole Krawcke
  • Uponor employee, Arturo Moreno

    The reinvestment in American manufacturing and training

    Plumbing & Mechanical Chief Editor Nicole Krawcke and...
    Plumbing News
    By: Nicole Krawcke and Natalie Forster
  • March 2024 Women in Plumbing hero image of woman engineer overlayed by circle of hexagon shapes with numbers from 1 to 10

    Celebrating 10 Influential Women in the Plumbing Industry

    Celebrating Women's History Month and Women in...
    Plumbing News
    By: Nicole Krawcke
close

1 COMPLIMENTARY ARTICLE(S) LEFT

Loader

Already a Registered User? Sign in now.

Subscribe For Free!
  • eNewsletters
  • Online Registration
  • Subscription Customer Service
  • eMagazine
  • Manage My Preferences

IPEX celebrates grand opening of new Florida distribution center

IPEX celebrates grand opening of new Florida distribution center

AI can boost efficiency and profitability for plumbing, HVAC contractors

AI can boost efficiency and profitability for plumbing, HVAC contractors

Bell & Gossett Illustrates Path to Net-zero at AHR Expo

Bell & Gossett Illustrates Path to Net-zero at AHR Expo

NIBCO Press Solutions

NIBCO Press Solutions

More Videos

Sponsored Content

Sponsored Content is a special paid section where industry companies provide high quality, objective, non-commercial content around topics of interest to the Plumbing & Mechanical audience. All Sponsored Content is supplied by the advertising company and any opinions expressed in this article are those of the author and not necessarily reflect the views of Plumbing & Mechanical or its parent company, BNP Media. Interested in participating in our Sponsored Content section? Contact your local rep!

close
  • J.J. Keller CMV vehicles on road
    Sponsored byJ. J. Keller & Associates, Inc.

    The dash cam game-changer for small business safety

Popular Stories

The interior of a government building.

President Trump signs executive order promoting skilled trades and apprenticeships

Figure 1 is a sketch of the flow problems of the current plumbing system.

Hydronic heating glitch solved: Why adding a circulator won't fix primary loop flow issue

Underfloor heating installation with drain sewer hole in bathroom close up on water floor heating.

Using hydronics to leverage time-of-use electrical rates

PM BEMIS June 25 Free Webinar: Optimizing Plumbing Solutions for Single-Family, Multi-Family & Public Spaces

Events

November 13, 2024

Future Proofing MEP: Navigating the 2026 High Efficiency Water Heating Standards

Join our deep dive into DOE’s new standards so you can future-proof your MEP practice.

EARN: 0.1 ASPE CEU; 1 AIA LU/HSW; 0.1 IACET CEU*; 1 PDH

View All Submit An Event

Poll

Will business be up or down in 2025?

Do you anticipate business in 2025 to be up or down in comparison to 2024?
View Results Poll Archive

Products

The Water Came To A Stop

The Water Came To A Stop

See More Products

Download the FREE Water Conservation, Quality & Safety eBook: Plumbing Trends Increasing Safe Water Availability

Related Articles

  • Ray Wohlfarth

    Learn from the mistakes of others to avoid boiler startup dangers

    See More
  • Ray Wohlfarth

    Can the boiler breathe?

    See More
  • Ray Wohlfarth

    Carbon monoxide dangers in the boiler room

    See More

Events

View AllSubmit An Event
  • April 10, 2014

    Workshop: Hydronics for High Efficiency Wood-fired and Pellet-fired Boilers

    Session added to April 9-11 Northeast Biomass Heating Expo.
View AllSubmit An Event
×

Keep your content unclogged with our newsletters!

Stay in the know on the latest plumbing & piping industry trends.

JOIN TODAY!
  • RESOURCES
    • Advertise
    • Contact Us
    • Directories
    • Store
    • Want More
    • Supply House Times
  • SIGN UP TODAY
    • Create Account
    • eMagazine
    • eNewsletter
    • Customer Service
    • Manage Preferences
  • SERVICES
    • Marketing Services
    • Reprints
    • Market Research
    • List Rental
    • Survey/Respondent Access
  • STAY CONNECTED
    • LinkedIn
    • Facebook
    • Instagram
    • YouTube
    • X (Twitter)
  • PRIVACY
    • PRIVACY POLICY
    • TERMS & CONDITIONS
    • DO NOT SELL MY PERSONAL INFORMATION
    • PRIVACY REQUEST
    • ACCESSIBILITY

Copyright ©2025. All Rights Reserved BNP Media.

Design, CMS, Hosting & Web Development :: ePublishing

search
cart
facebook instagram twitter linkedin youtube
  • Sign In
  • Create Account
  • Sign Out
  • My Account
  • NEWS
  • PRODUCTS
  • CONTRACTORS
    • BATH & KITCHEN PRO
    • BUSINESS MANAGEMENT
    • HIGH EFFICIENCY HOMES
    • TECHNOLOGY
    • WATER TREATMENT
    • PMC COLUMNS
      • Dave Yates: Contractor’s Corner
      • John Siegenthaler: Hydronics Workshop
      • Kenny Chapman: The Blue Collar Coach
      • Matt Michel: Service Plumbing Pros
      • Scott Secor: Heating Perceptions
  • ENGINEERS
    • CONTINUING EDUCATION
    • DECARBONIZATION | ELECTRIFICATION
    • FIRE PROTECTION
    • GEOTHERMAL | SOLAR THERMAL
    • PIPING | PLUMBING | PVF
    • PME COLUMNS
      • Christoph Lohr: Strategic Plumbing Insights
      • David Dexter: Plumbing Talking Points
      • James Dipping: Engineer Viewpoints
      • John Seigenthaler: Renewable Heating Design
      • Lowell Manalo: Plumbing Essentials
      • Misty Guard: Guard on Compliance
  • RADIANT & HYDRONICS
    • RADIANT COMFORT REPORT
    • THE GLITCH & THE FIX
  • INSIGHTS
    • CODES
    • GREEN PLUMBING & MECHANICAL
    • PROJECT PROFILES
    • COLUMNS
      • Codes Corner
      • Natalie Forster: Editorial Opinion
      • Guest Editorial
    • SPONSOR INSIGHTS
  • MEDIA
    • PODCASTS
    • VIDEOS
    • WEBINARS
  • RESOURCES
    • INDUSTRY CALENDAR
    • DIRECTORIES
    • EBOOKS
    • PM BOOKSTORE
    • CE CENTER
    • MARKET RESEARCH
    • CLASSIFIEDS
  • EMAGAZINE
    • EMAGAZINE
    • ARCHIVE ISSUES
    • CONTACT
    • ADVERTISE
    • PME EMAGAZINE ARCHIVES
  • SIGN UP!