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Project Log:  Sunday, June 17, 2012

Next on my agenda was to install the fresh water pump and make a number of connections for the water system inside the starboard utility space outboard of the engine room, which I'd chosen as "water central".  Since the fresh water system and diesel heating system (Webasto) were closely related in terms of hot water production and supply, I spent some time beforehand reviewing my plans and available components and preparing updated sketches (and sketches were all they were) for both systems to ensure I was prepared, which inevitably led to a round of plumbing supply ordering. 

I selected a Flojet fresh water pressure pump combined with an accumulator tank on a built-in platform.  In addition, I planned full system filtration for both pressure and manual supply sides.

To distribute the water from the three fresh water tanks, I built a manifold from off-the-shelf parts.  Because of a last-minute change in the system, as of this writing I was awaiting a 3/4" hose connector for the manifold's outlet, since the initial part of the water system (including the pump inlet) required 3/4" hose versus the 1/2" I'd used throughout.

There was good space for the pump, accumulator, and other components on the shelf I'd previously installed in the space.  Typically, as I began to consider mounting the pump I realized that I had several things I needed to do first.  Specifically, it made sense to run the hoses to and from the expansion tank for the hydronic heating system, as the only logical way in and out of this space was through a small bulkhead just aft of the proposed pump location, where I'd previously run some of the fresh water hoses. (This photo is jumping ahead a bit, but shows the red heater hoses running through the bulkhead.)

Setting aside, for now, the water pump, I prepared two holes through the bulkhead for the 3/4" heating hose required for the expansion tank.  While I was at it, I drilled a third, smaller hole further down (just above the tankage tops) for the starboard fuel tank's supply line, which would later run through there on its way to the fuel manifolds in the engine room; but I didn't run this hose now.

With the large holes ready, I ran lengths of the stiff heating hose in .  The run inside the utility space was easy enough, but leading one of the hoses around to the opposite side of the engine room to connect with the heating system's circulation pump required thought and plenty of hose.  Eventually, I led the hose around the top edge of the engine room to starboard and across the forward end, before diving the hose below the oil filter, through a system maintenance shutoff valve, and to the inlet of the pump itself. 

This valve turned out to be a challenge to install, as the hose barbs were essentially too large for the hose (despite being a 3/4" valve), and significant effort was required to force the hoses on.  I had another one of these valves on hand that I'd planned to use somewhere, but I thought I'd find something else that worked better.  After these photos, I added another line clamp on that droopy hose above the fuel filters in the lefthand photo.


Truth be told, part of the reason for this particular route was because I first mistakenly connected this hose carefully to the forward side of the heating system's engine heat exchanger, realizing afterwards that this was in error (I had it properly led on my sketch, so I don't know why I led it the way I did), so I had to work with what I'd already started since the hose was all cut and secured everywhere. 

Despite my frustration at the mistake, it was an easy-enough fix since I could connect the end of the hose to the shutoff valve as suggested in the overall plan, which allowed me to lengthen the hose as required to reach the pump.  Also, the hose required a fairly wide bend radius, and no elbows or other fittings close to the pump, so the new route worked out well in the end despite it all.

I led the second hose to the expansion tank aft to a three-way (i.e. "summer") valve that I placed just forward of the after fuel tank.  This valve, once the whole system was connected, would allow the diesel boiler to heat only the water tank during non-heating months, rather than circulating through the entire system.  I'd connect other sections of the heating hose to this area later, but for now I'd accomplished what I needed to--and besides, I'd used up most of my supply of hose.


With a small section of hose remaining, I installed the line running from the boiler to the long heat exchanger below.  Later, I'd figure out how to secure the loop of hose leading to the boiler, but I needed to keep it free for the moment to ensure I could route properly the air intake and exhaust for the boiler later.  I might shorten the loop, and I think I meant to put a shutoff valve in there, but more on that later as it happens.  Anyway, I wasn't about to use the shutoff valve I had on hand, after my experience with its counterpart earlier.


The lengthy tangent completed, I turned once more to the water pump.  Installation was easy--four screws through little rubber mounts in the platform.  Once the pump was in, I could install the lines to its outlet: a short hose leading to a tee fitting, which branched the water supply off to the cold pressure faucet at the galley sink (and later the shower), and across the boat to the water heater.


After various considerations, I mounted the water supply manifold on the forward bulkhead of the space, where it was convenient for the hose connections required.  As I mentioned earlier, I didn't have the proper fitting for the discharge end of the manifold, so I'd install that later, but now I could connect supply lines from each of the three water tanks:  two longer runs that I'd prepared earlier, plus a short hose run to the nearby starboard water tank.


Total Time Today:  6.5 hours

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